Epoxy Stone Overlay – How Much Material Do I need

April 27, 2010

Q: How Much Epoxy.com Product #17 Do I need?

I am interested in your Epoxy  Product #17 – www.epoxy.com/17.htm – to overlay a patio and walkway.  I live in Michigan – is there a dealer or will you ship to Michigan?  My patio of 600 sq. ft. – how much epoxy #17 is required? 

You did not say what size stone you are using or how deep you are looking to install it at.

Each stone will take a different amount of resin to bond it in place, depending on the size, shape and how clean it is.  Also each stone size will have a different yield.  But here is how it is calculated (to a theoretical area and coverage).

The recommended starting point is 1.5 gallons of resin plus or minus to each 150 lbs of stone.

I measured a stone that I had that was 1/8 x 1/16,  and got about 0.6 cubic feet per 50 lbs.

So a yield of 3 gallons of #17 and 300 lbs of stone would produce about 0.6x 6 bags or 3.6 cubic feet.

600 square feet at ½ inch thick is (144/2)x600 or 43,200 cubic inches or 25 cubic feet (43,200/1728)

25 cubic feet /3.6 = 6.9 units

The unit size is 3 gallons or ( 7×3)  21 gallons.

Thank you for your interest in our products.  Please contact me with your questions.

Epoxy Systems, Inc.
Norm Lambert
President & Director of Technical Support
Available by Phone M-F 9AM-4PM Eastern Time (6 AM – 1 PM Pacific Time)
352-533-2167 (Voice)
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How to Epoxy inject Very Large Cracks – How Large a Crack can be Epoxy Injected

April 22, 2010

What is the Largest Crack that can be Repaired with Epoxy Injection

A reader writes:“What is the largest concrete crack that can be injected with an Epoxy Injection repair?”

For concrete outdoors and/or is going to see extreme temperatures, you
would typically want to limit your injection to about 1/4 inch.  If the
crack is larger than that you may experience some thermal coefficient issues, if
injected using normal epoxy concrete injection techniques. 
Thermal coefficient is the rate that materials expand and contract due to
temperature changes. Neat epoxy resin expands at a rate greater than
concrete. In small cracks this is not important, but as the mass of epoxy
gets greater, the potential for differential movement gets greater.When I have been forced to epoxy inject these cracks larger than 1/4 inch
I like to use Epoxy.com Product #301 – www.epoxy.com/301.htm.. 
Epoxy.com Product #301  is is a low mod (more “flexible”) injection
material and is less likely to create a thermal co-efficient problem than a
high modulus material.

If the crack is still bigger, I try to pack as much Epoxy.com Product
#703 – www.epoxy.com/703.htm
Low-Mod Epoxy Gel Adhesive as I can into the crack.  First I place
copper tubing as far back into the crack as I can.  Then I fill out to
the surface with the Epoxy.com Product #703.  If the crack is large
enough you can also mix up to 1 part silica sand with 1 part of mixed
Epoxy.com Product #703.  Mixing in the silica sand saves material
costs, and makes the Epoxy.com Product #703 easier to trowel. Most
importantly the thermal coefficient of the Epoxy.com Product #703 and silica
sand is much closer to that of concrete than the Epoxy.com Product # 703 alone.

After the Epoxy.com Product #703 has hardened, you can pump the Epoxy.com
Product #301 into the copper tubes that were inserted earlier.  This
results in a very effect, well designed and engineer solution for larger
cracks. When in doubt how to proceed with larger cracks, please contact me
at Epoxy.com Technical Support – 352-533-2167 or by email at

Epoxy Injection – Minimum Crack Size

April 19, 2010

How Small a Crack in Concrete Can Be Epoxy Injected?

Typically a crack that is 30 or 35 mils or larger (about 1/32 inch) can be epoxy injected. You can get into even smaller cracks under the right conditions with Epoxy.com Product #308 Ultra Low Viscosity Injection Resin for Load Bearing Applications an Ultra-Low Visocosity Epoxy Resin System for use as epoxy injection or low viscosity epoxy mortar resin. It is 100% solids and is mixed 2:1 by volume. Meets or exceeds the requirements for ASTM C881 Types I and IV, Grade 1, Classes B &C. Learn more on the Epoxy.com Website or contact Epoxy.com Technical Support by email or call 352-533-2167.

One of the most versatile, problem solving products available in epoxy systems today is Epoxy Injection Resin. Structural restoration of concrete by epoxy injection is very often the only alternative to complete replacement. It therefore results in large cost savings. Injection protects the rebar and stops water leakage.

Epoxy Injection Resin is a system for welding cracks back together. This welding restores the original strength and loading originally designed into the concrete. Epoxy injection restores the structural qualities the concrete design intended. In other words under most conditions it makes the concrete as good as new. It creates an impervious seal to air, water, chemicals, debris, and other contamination.

A crack, obviously, is a sign of failure caused by stresses, inadequate design, improper curing, etc. One of the dangers of a structural crack is the effect that it has on the reinforcing bar. The reinforcing represents one of the main structural values of the concrete.

Cracks left unprepared allow moisture, road salts and other contaminants to penetrate and attack the rebar. The rebar deteriorates, losing the structuEpoxy Injection of concreteral value. Loosing the entire structure is often the result.

Epoxy injection resin has two purposes. First, it effectively seals the crack to prevent the damaging moisture entry. Secondly, it monolithically welds the structure together. Most people assume that this welding of the structure is the most important result of the repair. Actually what is most important is the sealing.

The sealing properties of the injection prevents premature deterioration of the reinforcing. This can be of equal, or in some cases greater importance than the structural welding. It would theoretically always be desirable to get this welding effect.

Crack Analysis

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. 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 # 485 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. more…

Epoxy.com Announces New Conductive Novolac Chemical Resistant Epoxy Flooring System

April 9, 2010

Epoxy.com a division of Epoxy Systems, Inc. announces that it has added  Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating to the Epoxy.com line of Conductive Resins.  Epoxy.com Product #676 is a 100% solids – Zero (0) VOC epoxy Novolac Chemical resistant conductive (anti-sparking) epoxy flooring and floor coating system ideal for severe chemical and solvent storage requiring a chemically resistant conductive and spark resistant surface.

 Applied at a nominal 1/16”, Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating offers the superior chemical resistance of an Epoxy.com  Novolac Epoxy Resin System while maintaining a conductive surface.


  • Low viscosity for improved handling during application.
  • Exhibits excellent resistance to strong acids, alkalis and most industrial chemicals and solvents.
  • 100% Solids—low odor application and cure (0-VOC).
  • Bonds well to cool, damp substrates.
  •  Conductive & non sparking, 25,000 to 1,000,000 ohms resistance.


  • Substrate  to receive Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating temperature must be a minimum of 50°F.
  • Substrate must be free of dirt, waxes, curing agents and other foreign materials.
  • Steel surfaces to receive Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating must be free of grease and oils.  Abrasive blast to SSPC-SP-3.
  • Refer to Epoxy.com Surface Preparation Guidelines for  substrate requirements.


100% Solids, modified polyamine, cured epoxy novolac resin and fillers



Surface Preparation is the most critical portion of any successful resinous flooring system application.  All substrates must be properly prepared as outlined in Epoxy.com Surface Preparation Guidelines.  Contact epoxy.com  technical service department is pleased to answer any questions.


Installation of Epoxy.com Product #676 Novolac Novolac Epoxy Chemical Resistant Conductive Floor Coating will vary with application.  Normally spread with a trowel or squeegee and lightly back-rolled with a medium or short nap roller.  Care should be taken to minimize the entrapment of air caused by over rolling. For complete instructions, consult installation guide or Epoxy.com Technical Support Department


Clean skin with soap and water.  Tools and equipment should be cleaned with xylene or lacquer thinner.


Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating will yield approximately 32 mils when spread at 50 ft2 per gallon.  Two coats required.


Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating is available in Standard Colors and Custom Colors as approved.


Viscosity @ 75°F 1,000-1,500 cps
Mixing Ratio by volume 2 Part A to 1 Part B by Volume
Solids Content by volume     100% by volume
Volatile Organic Content 0
Weight per gallon, mixed 11.0-11.5 lbs. per gallon mixed


Pot Life 20-25 min. @75°F
Dry to Touch 6-7 hours @ 75°F
Re-Coat 8-12 hours @ 75°F
Light Service 24 hours @ 75°F
Full Cure & Maximum Resistance     5 days




Acetic Acid-10%, 30% R
Acetone L
Ammonia Hydroxide-38% R
Beer R
Bleach L
Brake Fluid R
Citric Acid-30% R
Citric Acid-40% R
Crude Oil R
Diesel Fuel R
Ethylene Glycol R
Fatty Acids R
Gasoline R
Hydrochloric Acid-37% R
Lactic Acid-50% R
Lactic Acid-80% R
Methyl Ethyl Ketone R
Methylene Chloride L
Nitric Acid-10% R
Peroxide-35% R
Phosphoric Acid R
Skydrol R
Sodium Hydroxide-50% R
Sulfuric Acid-98% R
Toluene R
Urea R
Vinegar R
Xylene R
R-Recommended for continuous service
L-Limited Recommendation, occasional spills
*-May cause slight stain or discoloration


After completing the application of Epoxy.com Product #676 Novolac Epoxy Chemical Resistant Conductive Floor Coating, the installer should provide the owner with maintenance instructions. Epoxy.com Product #676 Conductive Chemically Resistant Novolac Floor Coating is easily cleaned with neutral soaps or detergents.

For more information please contact Epoxy.com Technical Support at: 352-533-2167 or email them at info@epoxy.com

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