How to Apply a Three Coat Epoxy Flooring System

If your floors have seen better days, a three-coat epoxy flooring system can completely transform them. Whether it’s a residential garage, a busy warehouse, or a commercial retail space, this system offers a durable, glossy, and chemical-resistant surface that can handle heavy foot traffic and daily wear and tear.

Many people wonder if this is a job you can tackle yourself. The answer is yes—especially if you’re a confident DIYer. With proper preparation, the right tools, and a clear plan, you can achieve a professional-looking finish. However, if your concrete has high moisture levels, or if you’d simply prefer complete peace of mind, hiring a professional installer is a safe choice.

For the best results, having a small team helps. One person can focus on mixing the epoxy and cutting in edges, another can roll or squeegee the coating, and a third can broadcast anti-slip media or assist with back-rolling. This setup keeps the process smooth and efficient.

Step 1 – Surface Preparation: Cleaning, Repairing, and Grinding Your Concrete

The first step in achieving a long-lasting epoxy floor is surface preparation. This is where the magic begins. Start by thoroughly cleaning and degreasing the concrete. Any dirt, oil, or debris can prevent the epoxy from bonding properly. Next, repair cracks using a suitable filler, like Concrete Bog or Sikadur 33. For the best adhesion, mechanically abrade the surface or diamond grind it to a CSP 2–3 profile. Finally, vacuum and mop the floor until it is completely dust-free.

If you’re in Sydney, we can even help you out by delivering or renting a concrete grinder with a dust extractor at competitive rates—making prep easier than ever.

Step 2 – Applying the Epoxy Primer

Once the surface is ready, it’s time to lay down the Ultra Primer. This penetrating epoxy primer helps the topcoats adhere better and ensures a uniform base. Mix Part A and Part B thoroughly for 2–3 minutes (mix ratio 2:1 by volume), then cut in the edges with a brush. Use a roller or squeegee to spread the primer evenly, back-rolling for consistency. Coverage generally runs between 6–8 m²/L, depending on the porosity of the concrete. Allow 10–12 hours for the primer to dry before applying the next coat.

A tip for perfection: you can tint the primer to create a uniform base color, making your topcoat look even more vibrant. Just remember, never leave mixed epoxy sitting in a bucket, as it will drastically reduce the pot life.

Optional Moisture Barrier

If your concrete has moisture above 5% or you’re working on ground slabs and damp areas, adding a two-pack moisture barrier like Ultrabarrier can make a big difference. This involves applying two coats perpendicular to each other, allowing 8–10 hours between coats and 12–18 hours before applying the topcoat.

Step 3 – Applying the Base Coat

Next comes the Ultrashield Base Coat. Mix the components at a 3:1 ratio by volume, using a mixing paddle and drill, and add a bit of thinner if needed—especially in colder conditions. Spread the coating evenly with a squeegee or roller, then back-roll to ensure uniform coverage. For added safety, lightly broadcast anti-slip media while the coating is still wet. Allow 12–18 hours for the base coat to cure.

Step 4 – Applying the Top Coat

Finally, the Ultrashield Top Coat finishes the floor with both style and functionality. Mix the parts at a 3:1 ratio, add anti-slip media as required, and roll the top coat evenly. Coverage is typically 5–6 m²/L. After application, light foot traffic can resume after 24 hours, with full curing in 5–7 days.

Tools and Materials You’ll Need for a DIY Three-Coat Epoxy Floor

For a standard double garage (around 40m²), here’s a handy list:

• Ultra Primer (8L kit)
• Ultrabarrier (8L kit, optional)
• Ultrashield Base and Top Coat (2 × 8L kits)
• Anti-slip media (1 tub per 8L kit)
• Magic Squeegee, Spike Shoes, Paint Trays & Rollers
• Concrete filler for cracks
• Solvent for clean-up

Tips for Success

The key to a flawless epoxy floor isn’t just following the steps—it’s paying attention to the conditions. Ideally, work in temperatures between 15–25°C, store your products in a cool place, and avoid applying epoxy if rain or high humidity is expected. Stick closely to the recommended recoat windows to prevent adhesion issues.

A three-coat epoxy floor isn’t just a coating—it’s a transformation. Durable, glossy, chemical-resistant, and customizable with anti-slip additives, it’s perfect for garages, workshops, and commercial spaces. And if you’re unsure at any stage, testing a small section or consulting a professional can save time and ensure the best results.

Pick up materials from our Rydalmere store, order online 24/7, or get delivery Australia-wide. Your dream floor is just a few steps away.