repairing concrete with Epoxy

Epoxy Injection of Structures Part 2

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Infrastructure Repairs Using Epoxy

Epoxy Concrete Injection Epoxy Wood Injection, epoxy crack repair

Epoxy Structural Concrete and Wood Repair / Waterproofing

The following article is written with enough information about resin injection systems to help protect the Owner from the misuse or improper installation of an injection systems.   For more information contact me: Norm Lambert.

This is the second in a series on Infrastructure Repairs Using Epoxy. Part One was Introduction to Epoxy Injection.  If your have not read that yet you may want to go back and read it before you proceed with reading this.

Part 2: Crack Analysis Before Epoxy Injection

As with all repair and rehabilitation of concrete, the initial job analysis is by far the most important step. Epoxy Injection Resin will weld concrete cracks but, of course, will not repair the cause of the cracking.

Analyze each potential injection application to determine the exact cause or causes of the cracking. Correcting the cracking problem can be fairly simple, or may be difficult involving design changes.

Consult a structural engineer when design changes are necessary. Do this before starting the injection. Repairing cracks by Injection is effective after these design changes. Prevent future cracks by fixing the original cause of the cracking, when ever possible.

Parking garages are an example of cracking problem that require a structural engineering analysis.Epoxy.com Epoxy Inection Often inadequate design for expansion/contraction is the cause for parking garage structural cracking. Avoid weld injecting a crack if there are not enough expansion joints. Sometimes flexible overlays such as Epoxy.com System # 495 can be used to overcome this defect. This does not however encapsulate the rebar in a way that will totally stop the premature deterioration of the steel. Often times additional joints are needed, thus the analysis of cracking problems is critical.

Bridge decks and slab on grades can often be repaired with Epoxy.com Product #684LV crack healer and sealer and save some of the cost of doing epoxy injection.

Next in the Injection Series:

Part 3: Setting Epoxy Injection Ports

For more information visit our website at http://www.epoxy.com, email us at info@epoxy.com or call our technical service department at +1 (352) 533-2167.

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Epoxy Sealing a Floor Drain

Epoxy Sealing a Floor Drain

How to Seal Around an Existing Floor Drain with Epoxy.com Systems

Updated May 2025 with improved product recommendations and application tips.

The Problem

“I have a second-floor production area that has a long stainless steel trench drain around the center of the room. We hose the area down with hot water, but a crack is developing next to the drain that allows water to leak into the room below. The floor under my quarry tile is concrete.”

The Solution

Here’s how to permanently seal around a stainless steel drain using Epoxy.com Products #660, #10, #82, and #2 for industrial-grade waterproofing and chemical resistance.

Step-by-Step Instructions

1. Remove Surrounding Tile

Carefully remove the quarry tile around the perimeter of the floor drain.

2. Clean Back to Bare Concrete

Remove all grout and thinset to expose clean, sound concrete.
Surface prep guide

3. Undercut or V-Groove the Concrete Edge

  • Cut or chip a V-groove around the drain
  • Increase bonding surface for epoxy
  • Avoid cutting through the slab

4. Abrade the Drain Edge

  • Roughen stainless steel to remove shine
  • A dull surface improves bonding

5. Clean Thoroughly

  • Vacuum loose debris
  • If using air, ensure it’s oil-free

6. Prime the Drain Edge

Apply Product #660 – Aluminum Filled Primer.
Tack-free in 1–2 hours; recoat within 24 hours at 75°F.

7. Prime the Concrete

Mix and apply neat (resin + hardener only) Product #10 to all concrete and primed metal surfaces.

8. Install Epoxy Mortar

Mix Product #10 with Product #82 Mortar Aggregate.
Trowel into the cleaned drain perimeter and smooth flush. Let cure overnight.

9. Seal the Surface

Apply a squeegee coat of neat Product #10 to fully seal the repair area.

10. Allow to Cure

Let cure for 10–12 hours at 75°F.

11. Topcoat with Product #2 + Anti-Skid

Apply Product #2 – Chemical Resistant Epoxy Coating with Anti-Skid Additive.

12. Apply Second Coat

Repeat Step 11 for added durability.

Why This Works

  • Prevents water migration into lower levels
  • Resists chemical cleaning agents
  • Withstands high-temp washdowns
  • Bonds to both stainless steel and concrete

Need Help?

Contact Epoxy.com Technical Support:
📞 Call: 352-533-2167
📧 Email: info@epoxy.com
🌐 Visit: www.epoxy.com

Illustration

Cross-section of floor drain sealed with epoxy mortar and primer

Blog Details

  • Excerpt: Learn how to seal around stainless floor drains in food processing plants using epoxy systems from Epoxy.com.
  • Tags: epoxy floor drain, trench drain seal, epoxy patching, product #10, food plant waterproofing
  • Category: Floor & Drain Repairs
  • Slug: epoxy-floor-drain-repair

Patching Vinyl Ester Floors With Novolac

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A customer writes:

“We have a dairy processing and packaging facility that was built circa 1994.  At the time of construction we chose to install a flooring system which was vinyl ester based with fiberglass mat.  The floor has held up quite well in areas where it had a good bond.  The failures we have seen are in areas that covered either an expansion joint or control joint in the concrete.  In these areas the flooring has delaminated from the concrete.  Where possible we have made a clean cut through the flooring to an area where we had a good bond and left the concrete exposed.  Other failure areas are around floor drains.  We have made repairs with quick curing epoxies in the past but these don’t seem to bond well to the existing vinyl ester flooring. 

“Having a manufacturing facility with only one down day limits our ability to make substantive repairs.  During a search for low or no VOC  flooring systems I you folks.”

I have personally made many thousands of square feet of floor repairs that sounds exactly like the issues and conditions that you are describing.

Here is what I did to permanently resolve the issue, at least in the patched areas.

  1. Cut back the edges of the delaminated areas back to a point where the vinyl ester is well attached.
  2. Prep the concrete under the failed area and the edges of the old material – epoxy.com/surfaceprep.aspx.
  3. Prime with Epoxy.com Product #12 – epoxy.com/12.aspx
  4. Install a trowel coat of Epoxy.com Product #630 – epoxy.com/633.aspx and
    1. Epoxy Mortar Blend aggregate #82 Mortar Blend Aggregate
    2. Allow to cure hard to the touch and cool.
  5. Glaze with a neat coat of Epoxy.com Product #633 with optional Anti-skid – http://epoxy.com/non-skid-additive-polycarbonate-aggregate.aspx

Please email your additional questions to norm@epoxy.com or visit http://www.epoxy.com .

Epoxy Oil Stop Primer

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Epoxy_oil_stop_primer
Oil Saturated Concrete

 

Oily contaminated concrete is very difficult to bond to, but it can be done with special care and Epoxy.com Product #201 Oil Stop Primer.  Plant floors, warehouse floors, commercial, and residential garage floors can all have this problem.  Here is a typical question that I get about oil contaminated floors:

“We were looking at your product because we have a floor in a maintenance garage that is pretty well soaked with oil.  A new tenant is going into that space so we know that there needs to be something to allow the new floor to stick and to stop the odors.”

Here is my typical response:

Is the oil saturation petroleum oil? If so you need to:

  1. Degrease the floor
  2. Mechanically clean the floor – www.epoxy.com/surfaceprep.aspx.
  3. Apply 1 coat of Epoxy.com Product #201 – www.epoxy.com/201.aspx – at a rate of 200-320 SF per gallon.
  4. Inspect for bond the next day. If bond fails remove the loose #201 and go back to step one.
  5. If bond is good check for oil on top of the primer.  If there is oil on top of the #201 and it is well bonded remove the oil with xylene or other effective degreaser.
  6. Coat with 2 coats of Epoxy.com Product #2 – www.epoxy.com/2.aspx.

I like the Product #2 for these applications because it is very resistant to petroleum oils. Depending on your specific application the material you use over the #201 can be a number of different flooring, coating systems or chemical resistant epoxy floor systems.

For more information, please visit our website at www.Epoxy.com, contact our technical support department at 352-533-2167 or email me at norm@epoxy.com for a specific recommendation.