ArmorGarage Epoxy Application Suggestions And Lessons Learned
Posted by ArmorGarage LLC on Dec 17th 2025
A Customer's Guide to Installing ArmorGarage Epoxy
Real-world lessons learned from a 1,400 sq ft garage and boat pad installation
Written by an ArmorGarage Customer
Editor's Note
The following article was written by one of our customers. It contains excellent advice and tips. A few things have changed since it was written:
Both Armor Chip & Armor Granite Garage Epoxy kits with flakes now come standard with a specialized application squeegee, TSP, and spike soles for easy spreading at the correct thickness and proper flake dispersal. We also strongly recommend reading our How to Prep & Epoxy Paint Your Garage Floor the Right Way page — it includes a flake dispersal technique sent in by a customer who did the best flake application we've ever seen.
The Project
Having recently installed the garage epoxy system from ArmorGarage to a 3+ car garage and adjacent boat pad (1,400 sq ft), I would like to share my experience and contribute my lessons learned for those who may be as concerned as I was to ensure a quality result.
While my result was awesome by any standard, had I utilized these lessons — which I learned by experience — the result would have been even better and with much less headache.
I believe ArmorGarage's product to be of superior quality to any product on the market, and their technical support staff — specifically Jim Olympios — was extraordinary and assisted my every concern.
As with any paint/epoxy application, preparation and planning is key. Do not expect imperfections to be filled in or covered up. While very thick by epoxy standards, the overall smoothness or roughness of the floor will remain. Paint chips however do cover minor imperfections and defects.
Additional Materials You'll Want on Hand
The kit contains most everything needed. If however you work in smaller batches, don't want to reuse mixing bowls, or want to be prepared for contingencies, I recommend the following — all of which can be found at a hardware store, auto paint supply, or online:
• Mixing cups — 1 gallon, 1 qt, and 1 oz sizes (if mixing small quantities)
• Disposable 16 oz "Dixie" cups — plastic or paper (for small batches)
• Min 1 qt lacquer thinner — for cleanup
• Clean-up rags — generous supply
• Paint respirator
• Box of disposable rubber gloves — one pair per batch
• Two broomstick handles — threaded ends for roller and squeegee
• Extra ¼" nap rollers
• Spike soles — a must for ease of application and best flake distribution NOW INCLUDED
• Disposable 1"+ fiber paint brushes — for cut-in work
• Paint stir sticks
• Additional drill mixing rod
• 3' wide water squeegee — if applying a second base coat
Step 1: Grinding
In my case, having had a 10-year-old epoxy finish and many imperfections in the original concrete, I elected to grind off the old epoxy with a rented cement grinder and follow up along the edges with a handheld 7" grinder with a diamond leveling wheel (available at Home Depot or Lowe's for around $50).
Walk-Behind Grinder Tips
• Rent from a reputable company — one that is very familiar with their equipment
• Ensure all stones are identical — in size, depth, and coarseness. Non-identical stones will cause the grinder to run off-level, creating deep grooves and extra work
• Rent a compatible vacuum attachment — the dust is significant. Without a vac you won't be able to see your progress, which causes over/under grinding
• Full face respirator is imperative — available at Home Depot for about $25
β οΈ Power Requirements: Many grinders require a 120V, 20-amp power source. A standard 15-amp circuit will either pop the breaker or cause the unit to auto shut down. Rent a small generator if you have inadequate power supply.
Step 2: Filling Cracks & Imperfections
If you intend to fill cracks, pits, or expansion joints, I used the ArmorGarage Epoxy Mortar. It's a very good product and I won't have to worry about a store-bought filler chipping or cracking out of the floor in the future, ruining the epoxy finish.
Large cracks should be ground slightly to a "V" shape to provide more surface area for the mortar to adhere.
• Mix in small quantities until you determine how far each batch will go
• Mix thoroughly with proper ratio — improper ratio or incomplete mixing will prevent hardening
• Add sand after 2.5 min of mixing — for vertical surfaces, peanut butter consistency; for horizontal, a lighter slurry works fine
• Pour higher than the surrounding surface so you can grind back to level
• Smaller pits can be filled with a putty knife — then smooth with a 7" hand grinder after hardening
Small Batch Tip: For small quantities, I used a dedicated one-ounce cup for Part A and one for Part B, then combined in a plastic 8 oz Dixie cup at 4:1 ratio. For even smaller amounts, a 20cc syringe ensured proper ratios. Mortar goes a long way and grows as you add sand — mix small.
Step 3: Pressure Wash & Acid Etch
If able, I highly recommend pressure washing twice. Once to remove any remaining dust from the concrete pores after grinding (or for initial cleaning) and again after acid washing and TSP.
A TSP solution is highly recommended after etching to neutralize the acid. To clean oil stains, scrub in some Liquid Tide with muriatic acid and rinse well — you may need to repeat 2–3 times until the stain is removed. Be sure to use TSP afterwards. Clean stains prior to etching the full floor.
1. Mix etch product per instructions
2. Pour solution from a 3-gallon pail onto a wet floor and brush in thoroughly
3. Wait about 5 minutes
4. Sprinkle TSP on, brush in lightly, then rinse and/or pressure wash
5. Allow floor to adequately dry
Pro Tip: Etching isn't necessary if you grind, but if you're washing the floor to remove remaining dust, you might as well scrub in the etch while the floor is wet — it's a quick, easy process. If you need a second etch (extra dirty, new concrete, or power-troweled smooth), apply the neutralizing powder before the second etch rinse.
Step 4: Primer Coat
I decided to use a primer both due to the age of my floor and the type of work I do on it. The primer is a two-part epoxy mixed at a 1:1 ratio. As with all multi-part systems, mix 2.5 minutes per batch.
Stir individual cans of Parts A and B for one minute with stir sticks. Do NOT combine mixing rods. I found I could mix Part B (Clear) with a paint stick but purchased an additional drill mixing rod for Part A to prevent cross-contamination.
Roll on with a standard 9" roller. Goes a long way and is easy to apply. Use a small disposable fiber paint brush to cut in areas inaccessible with the roller.
β οΈ Fiber-Reinforced Concrete: If you have reinforced concrete with fibers and used a grinder, the fibers will become visible and look like thousands of hairs in the dried primer. A light sanding with the 7" grinder after the primer is completely dry will knock them off quickly. A small butane or propane torch works just as well.
Step 5: First Base Coat (Optional Skim Coat)
While not necessary, should you desire a second base coat to fill imperfections, the first coat should be applied as follows:
1. Mask off any protected areas
2. Cut in edges with a disposable fiber paint brush
3. Pour mixed epoxy along the surface
4. Spread with a 3' wide flat water squeegee, forcing into cracks and imperfections
5. Smooth out any lines with a ¼" nap roller
Determine a plan of attack so you work in a predetermined pattern that ends at an exit. If you're using spike soles, this isn't an issue — you can walk freely over the wet surface.
Mix Size: Using the 2:1 ratio, the recommended ¾ gallon mix (½ gallon : 1 qt) works well with one person, gives plenty of working time, and is an easy quantity to manage.
Step 6: Final Base Coat & Paint Flake Application
Master the Flake Technique First
If you're applying flakes, I cannot emphasize the value of practice. Practice before you ever begin — flakes can be swept up and reused if you practice on a clean surface.
The best results came from throwing smaller quantities into the air with a quick flick of the wrist, giving them time to separate and create a random pattern. If you try to throw too much at once or don't get a good snap, the flecks will drop in clumps.
With spike soles, you can walk out onto the wet surface and throw from above — creating a much more random, natural pattern. Without them, you'll have to throw outward from your position, which makes even distribution harder.
Easier Method: Use a plastic-handle jug with 3/8" holes drilled in the bottom. While walking in the wet epoxy with spike soles, shake the jug — the flakes will come out in a random but even pattern. Apply to each section as you go. This method is detailed on ArmorGarage's How to Prep & Paint page.
Vertical Surfaces
Vertical surfaces create a unique challenge — you can't throw flakes at the surface or they'll clump at the base. Do vertical surfaces first:
1. Apply epoxy to the vertical surface with a roller or brush, leaving an inch unpainted at the base
2. Stand several feet away and hold small quantities of flakes in your palm
3. Use a hair dryer or air source to blow the flakes out of your hand and onto the surface — or spread flakes on the floor and puff them onto the curb with a leaf blower
4. Sweep up any flakes that accumulate at the base for reuse
Applying the Final Base Coat
Mix all Parts A (color) together before beginning to ensure the color mix is uniform.
Apply the same way as the skim coat, using the notched squeegee on a threaded handle to spread evenly. After application, lightly roll over the material with a ¼" nap roller to eliminate squeegee lines.
β οΈ Key Tips for Base Coat + Flakes:
• You don't have to spread all poured material before applying flakes — spread as you go
• Without spike soles, spread in 4' wide sections max so you stay within flake-throwing range
• Always leave about 2' clear of flakes at the edge of the wet surface — don't flake all the way to the edge, or you'll have to roll over an already-flaked surface
• With spike soles, you can spread farther before flaking — makes the whole process much easier
Coverage Note: Material coverage was not a problem — I found the product actually covered more square footage than advertised.
Step 7: Top Coat
The top coat is both the easiest and the hardest part. It's easy because there is no mixing required if using the red-labeled xylene-based top coat. It's difficult because the material is nearly invisible when applied — it's almost impossible to see where you've been.
You must determine a method of sectionalizing and roll the material in two directions to ensure you don't miss any areas.
Critical — Do NOT Go Back Over Drying Areas:
Once the material begins to dry, do NOT try to go back over missed areas — it will clump up and require sanding and recoating. If you notice a missed spot right away, simply fill it in. Look at the floor from different angles to spot misses. Having a second person watching is very helpful.
Next-Day Fix: If you see a missed spot the next day, simply sand the spot and a bit of the surrounding topcoat lightly with 120 grit, then brush on some topcoat. It should blend in nicely. Don't use a roller for touch-ups.
Non-Slip: The surface will be incredibly bright and slippery when wet. Use the non-slip additive that is provided.
Bonus: Adding Custom Decals
Personalizing your floor with decals requires planning and possibly some experimentation. I decided to have several images enlarged to between 42" and 60".
You'll need to find or develop a digital file capable of expansion without losing quality — a standard .jpg won't work due to limited pixel count. Once you have the file, any sign company can modify and print to your specifications.
Decal Application Tips:
• Tell your decal supplier you'll be applying a urethane epoxy over it — most decals are fine, but better safe than sorry
• Decals must be applied over a very smooth surface
• Mark the decal location before applying epoxy — try to keep that area free of flecks
• Sand any flecks in the decal area smooth before applying — they will show through
• Once decal is applied and any water has dried, roll on the topcoat
While applying a personalized decal can be difficult and tedious, it creates an even more unique and impressive result.
Ready to get started on your garage floor?
Our kits come complete with everything you need — including the squeegee, TSP, and spike soles mentioned in this article.
Shop Garage Epoxy Kits · 2026 Complete Guide
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