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Epoxy Aggregate Systems
for Decorative Toppings

These seamless systems work well in lobbies, hallways, kitchen areas, showrooms and similar environments. There are two basic variations: clear resin with colored aggregate or pigmented epoxy with aggregate.

To install, the prepared substrate is primed and the mortar troweled to the desired thickness — usually 3⁄16 to 1⁄4 of an inch. Troweling can be done by hand or by machine. Hand troweling can be tricky and heavy power trowels need a drier mortar to support their weight (and can leave swirl and chatter marks), so a lightweight power trowel might be considered. The surface gets a light sanding to take off imperfections, but not enough to take the color off the aggregate. Leveling is done by trowel, not grinding, in these systems. An epoxy grout coat fills any voids and a topcoat — frequently a urethane — is applied as a sealer.

Howard Sinclair, vice president of sales at Rez Solutions L.L.C. in Lakewood, N.J., says these systems can be “functional or decorative” and are usually low maintenance. “The standard recommendation is to sweep daily and mop with a mild detergent. No resealing is required, except in extreme wear conditions.”

Broadcast systems are often used for restrooms and las because they are durable, easy to clean, seamless and require no wax.

Broadcast systems
The use of these seamless systems is frequent in industrial and commercial applications, such as research labs, locker rooms and restrooms, but is growing in residential applications, particularly garages.

To install, the prepared substrate is primed and a base coat of epoxy is rolled on. While the epoxy is wet, the aggregate — typically fine quartz — is broadcast to full saturation and allowed to bond over night. Excess aggregate is then cleaned away, and another coat of epoxy and aggregate is applied. Sinclair explains, “Each broadcast gives you about 1⁄16 of an inch. You reapply multiple times to build up to the desired thickness.”

Gwynn Stegen, chief operations officer for Excellent Coatings Inc. in Vista, Calif., cautions that broadcast systems “will telegraph imperfections in the substrate. The system you put on is only as good as the substrate you put it on.” But she says these systems are a very creative medium to use. “You can do borders, logos, checkerboard patterns and [you can use] different colors, resins and aggregate. You have the flexibility to let your imagination go wild; limited only by budget.”

The last step is the sealer. Grout with epoxy to flatten the surface or use a different topcoat, such as urethane, to help maintain the surface profile, advises Murphy. Decide on the skid-resistance desired and have your customer agree to this before the project starts. Do sample boards with different topcoats.

Cleaning is a simple affair, only complicated by the amount of texture. Resealing is generally not needed unless there is heavy traffic.
How do they stack up?

Installation prices vary around the country, but McKinnon estimates that epoxy-pebble systems can run from $3.50 to $14 a square foot. Koury strongly advises that contractors base their warranty on reliable maintenance to avoid problems caused by sunlight.

Of the systems which are used mostly on interiors, terrazzo is the most expensive up front, which can cause sticker shock. Murphy recommends having a basic price for simple floors and pricing out logos and detailed patterns separately.

Troweled epoxy mortar systems fall in line next, followed by broadcast systems, which are comparable in cost to other decorative finishes such as stamped toppings, according to Stegen.

While there is growing demand for epoxy-aggregate systems, there is a learning curve. If you’re interested, talk to experienced contractors. Most system manufacturers offer training, too. And start with small jobs. Cain observes, “These things are in high demand, but it takes a specialty contractor to do a good job.”