How to Repair and Rebuild Rotted Wood Before Epoxy Consolidation

May 20, 2025

Introduction

Not all wood can be saved. When decay has gone too far—when it crumbles under light pressure or smells of rot—it’s time to cut out the bad and rebuild the structure. This blog walks you through how to safely remove rotted wood, rebuild missing areas, and prepare the surface for long-term durability using Epoxy.com Products #12, #899, and #2005.

When Consolidation Isn’t Enough

Epoxy consolidants are designed for structurally sound but weakened wood.
If the wood is:

  • Soft and spongy to the touch
  • Darkened or blackened from fungal rot
  • Easily gouged with a screwdriver

What You’ll Need

  • Chisel or oscillating tool (for clean removal)
  • Wire brush or coarse sandpaper
  • Product #12 (for dry wood) or #899 (for slightly damp wood) – consolidating primer
  • Product #2005 – 100% solids epoxy binder for mortar repairs
  • Product #10 Mortar – Trowel-grade epoxy patching material
  • Optional: Clean, dry silica aggregate for custom mortar blends

Step-by-Step Repair Process

1. Remove All Rotted Material

Use hand tools or saws to remove all visibly rotted, spongy, or moldy wood. Cut back to firm, dry material. Do not attempt to epoxy over active wet rot or dry rot.

2. Clean and Shape the Repair Area

Use a wire brush or coarse sandpaper to clean and roughen the surface. Square or undercut edges provide better bonding than shallow bevels.

3. Prime With Consolidating Epoxy

Before patching, consolidate and prime the exposed wood using:

  • Product #12 for dry surfaces
  • Product #899 for slightly damp or moisture-prone wood

Let it soak in and cure as directed.

4. Rebuild With Epoxy Mortar

Once the primer has cured:

For shallow surface fills, apply Product #2005 directly without any filler.
For deeper voids or structural cavities, blend Product #2005 with clean, dry silica aggregate to create a strong, custom epoxy mortar.
By blending the 2005 with silica sand it makes it still thicker. It makes it more economical and helps with thermal coefficient improvements needed for large patching.
Product #10 combined with silica sand can be used in areas where a form is in place, or where the shape of the cavity naturally contains the material—such as recessed or enclosed voids.

Tool flush or slightly proud of the surface. Epoxy mortars are difficult to sand once fully cured.

5. Finish and Coat (Optional)

Example Applications

After the patch cures, you may apply an additional coat of #12 or #899 for sealing, or topcoat with paint, stain, or other finishing systems.

Rotted window sill:

Cut back to solid wood, prime with Product #12, then fill with Product #2005 or Product #12 and silica sand Mortar.

Decorative trim with soft spot:

Excavate the damaged area, consolidate with Product #12, and rebuild using a custom mortar mix made with Product #2005.

Dock board edge with water damage:

Trim back the affected edge, prime with Product #899, and patch with Product #10 Mortar.

Column base or porch post:

Remove all rot, consolidate with #12 or #899 as appropriate, then form and pour an epoxy mortar patch using Product #2005.

Tips & Warnings

  • Never apply epoxy over saturated, rotting, or fungal-infected wood
  • Always consolidate first with #12 or #899 before patching
  • Epoxy is permanent—shape and tool before full cure
  • Confirm compatibility if you’re topcoating with a different system
  • You can also add a replacement wood member:
    Use Product #2005 between the original wood and the new section to create a flat, high-strength bearing surface.
    While mechanical fastening is still recommended, the epoxy bond ensures the new piece acts as though it were part of the original structure.

Conclusion

When wood is too far gone to consolidate, you can cut it, rebuild it, and seal it—permanently. With Product #12 or #899 for priming and Product #2005 or #10 Mortar for patching, Epoxy.com provides everything you need for professional-grade restoration.

Contact:

For more detailed information
Contact Us Today:
📞 Call: 321-206-1833 (orders)
📞 Technical Support: 352-533-2167
📧 Email: sales@epoxy.com
🌐 Visit: www.epoxy.com

Leave a Comment » | Bonding systems, Epoxy, Epoxy wood repair, Restoration & Repair | Tagged: , , , , , , | Permalink
Posted by Norm Lambert

Protect Your High Traffic Areas

February 3, 2025

High-traffic areas like warehouses, garages, kitchens, and retail spaces demand surfaces that can withstand constant use without showing signs of wear. Traditional flooring options often struggle to hold up, leading to cracks, stains, and frequent maintenance. That’s why Epoxy.com’s high-performance coatings are the ideal solution for these demanding spaces. In this post, we’ll explore the benefits of epoxy for high-traffic areas and why it’s the best choice for durability and style.

The Challenges of High-Traffic Areas

Heavy foot traffic, vehicles, and equipment place significant stress on flooring. Common problems in high-traffic areas include:

        •        Cracks and Chips: Repeated use weakens the surface, causing visible damage.

        •        Stains and Spills: Grease, chemicals, and dirt can penetrate unprotected surfaces, leaving permanent stains.

        •        Frequent Repairs: Traditional materials like bare concrete or tile often require costly and time-consuming repairs.

        •        Safety Concerns: Slippery surfaces increase the risk of accidents, especially in busy environments.

Epoxy coatings address these challenges with superior performance and versatility.

Why Epoxy Coatings Are Ideal for High-Traffic Spaces

        1.        Durability to Withstand Heavy Use

Epoxy.com coatings are designed to handle the toughest conditions:

        •        Resist wear and tear from foot traffic, vehicles, and machinery.

        •        Maintain their integrity even under heavy loads, such as forklifts or pallet jacks in warehouses.

        2.        Chemical and Stain Resistance

        •        Prevent damage from grease, oil, cleaning agents, and other chemicals.

        •        Keep your surfaces looking pristine with minimal effort.

        3.        Seamless and Easy to Clean

        •        Epoxy creates a seamless, non-porous surface that won’t trap dirt or debris.

        •        Makes cleaning quick and easy, reducing downtime in busy environments.

        4.        Enhanced Safety Features

        •        Optional anti-slip finishes improve traction, reducing the risk of accidents.

        •        High-gloss finishes enhance visibility, especially in low-light areas.

        5.        Aesthetic Appeal

        •        Available in a variety of colors and finishes, from sleek metallics to decorative flakes, epoxy coatings elevate the look of any space.

        •        Combine style with function for a polished, professional appearance.

Best Applications for Epoxy in High-Traffic Areas

Epoxy.com coatings are versatile and work well in:

        •        Warehouses: Protect floors from heavy equipment, forklifts, and constant foot traffic.

        •        Garages: Withstand the weight of vehicles while resisting oil spills and stains.

        •        Kitchens: Create a seamless, hygienic surface that’s easy to clean and maintain.

        •        Retail Spaces: Enhance the aesthetic of your shop while standing up to customer foot traffic.

        •        Hospitals and Labs: Provide durable, chemical-resistant surfaces for high-demand environments.

How to Apply Epoxy in High-Traffic Spaces

To get the most out of your epoxy coating, proper application is essential:

        1.        Prepare the Surface:

        •        Clean thoroughly to remove grease, dirt, and dust.

        •        Repair any cracks or damage using a patching compound.

        2.        Apply a Primer:

        •        Use a primer to ensure strong adhesion and enhance durability.

        3.        Mix and Apply the Epoxy:

        •        Combine the resin and hardener and mix thoroughly.

        •        Apply evenly using a roller or squeegee, working in sections.

        4.        Add a Topcoat (Optional):

        •        For added protection and specific features like anti-slip or UV resistance, apply a topcoat.

        5.        Allow for Curing:

        •        Let the coating cure fully before heavy use (typically 48–72 hours).

Why Choose Epoxy.com for High-Traffic Areas?

At Epoxy.com, we offer coatings specifically designed to withstand the demands of high-traffic environments. Our products are:

        •        Industry-tested for durability and chemical resistance.

        •        Easy to apply with step-by-step guides for DIYers and professionals.

        •        Customizable with various colors and finishes to suit your style and functional needs.

Upgrade Your High-Traffic Space Today

Don’t let wear and tear compromise your workspace. With Epoxy.com’s coatings, you can protect your surfaces while enhancing their look and functionality. Whether it’s a busy warehouse, bustling retail shop, or family garage, epoxy coatings are the perfect solution for high-traffic areas.

Ready to upgrade your surfaces?

Ready to start your garage transformation?

For more detailed information Contact Us Today.

Call:

321-206-1833 (orders)

352-533-2167 (technical support)

Email: sales@epoxy.com

Visit: www.epoxy.com

Leave a Comment » | Chemical Resistance, Chemical Resistant Epoxy, Epoxy, Epoxy and Urethane Material Calculators, flexible Epoxy Membrane, Garage Flooring, Waterproofing | Tagged: , , , , , , , , , , , , , , | Permalink
Posted by Norm Lambert

Epoxy Mortar Installation

June 19, 2019

Epoxy.com Mortar Systems can be used to make permanent repairs that no other kind of product can make. The purpose of this blog is to give you an overview of what you can use and how to use it.

  1. Product Selection –  The following are a list of Epoxy.com Products that make excellent epoxy mortars  All the products listed below are zero (0) VOC, so it meets even the strictest low VOC requirements, and meets Indoor Environmental Quality/Air Quality (LEED IEQ 4.2 Indoor Emitting Materials Credit). See the individual product component technical data sheets and MSDS for further information.
  2. INSTALLATION:
    • First and foremost is good surface preparation.  Good surface preparation is necessary for most if not all patches to have long term success: www.epoxy.com/surfaceprep.aspx.
    • Prime the bottom of the whole with some of the neat mortar resin. Neat mortar resin is the liquid (A&B) mixed at the proper mix ratio and stirring in a way to insure a completely mixed product.  This will typically take about 3 minutes.
    • Mix some of the neat epoxy into the Epoxy.com Mortar Blend Aggregate #82 or other appropriate dry clean silica sand gradation.
    • The amount of sand aggregate depends on the aggregate used. 
      • Typically, the Epoxy.com Product #82 Mortar aggregate can be added at a rate of 18 to 27 lbs. of #82 per 1.5 Qt of mixed resin (1Quart of A to ½ Quart of B).
      • You will need to recalculate the sand above when using a different sized batch. This is doubly true if using one of or 4:1 mix ratio material.
      • Shallow patches tend to be a smaller amount of sand filler.
      • Deeper patches tend to be on the higher side.
      • If you get a lot of resin to the surface your mix is too wet.  If your mixture after it hardens is porous, or weak then you have added too much aggregate.
      • For a better finish in very deep pours do it in 2 lifts. 
        • Fill all but the last ¼ inch plus or minus with your dryer mix. Allow to cure hard (typically overnight).Fill with a wetter mix on top of that after the first one has cured.
        • To ensure proper adhesion between layers never wait more than 24 hours between layers.
      • It is always better to have your patch slightly higher rather than to low.  If you are slightly high you can grind the patch back to level. If to low you will need to fill again. 
    • For very shallow fills (1/32 or so) where the sand particles are to large you can use any of the following:

As always, when in doubt contact me at Epoxy.com Technical Support with your questions.

norm@epoxy.com
1-352-533-2167

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Posted by Norm Lambert

Existing Epoxy Seamless Floor Repair

June 29, 2017

Epoxy.com Materials have nearly 40 years of history with their seamless flooring products.  These high quality products seldom have to be repaired.  There have been a few times with Epoxy.com Products where the floor has been damaged in a fire, or a piece of equipment has been moved exposing an area that had not been done before.

IMG_1895

Picture of a Terrazzo Floor patched with an accent color.

The most difficult thing to do in repairing existing seamless floor is matching the color. The solution to this problem is a simple one: don’t try to match it, try to accent it.  Do this in a way that it looks like it is part of a design. This adds aesthetic appeal while creating an easy solution to the color matching issue.

Are you going to add additional seamless flooring next to the flooring to be patched?  If so use the accent color for the new area of flooring. That helps to tie all the colors back together.

For a complete list of seamless flooring epoxies please visit – www.epoxy.com. You can also email us, or call Epoxy.com  Technical Support Department at 352-533-2167.

Leave a Comment » | Chemical Resistant Epoxy, Epoxy | Tagged: , , , , , , , , | Permalink
Posted by Norm Lambert

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