Projects · Floor preparation & LVP

Wire Crafters

Self-leveling over epoxy · Strawberry Lane, Louisville

Freshly poured self-leveling underlayment reflecting the ceiling fixtures, capping an existing epoxy floor
The job

An existing epoxy coating is one of the harder substrates to put plank over. It is non-absorbent and it is rigid, so underlayment poured straight onto it has nothing to key into and can delaminate. The usual answer is to remove it, which means demolition and a space that cannot be used.

At Wire Crafters we left the epoxy in place and capped it. The surface was mechanically abraded to give the primer something to bite, then primed with a bonding primer rated for dense, non-absorbent substrates. Once that had dried we skimmed roughly an eighth to a quarter inch of self-leveling underlayment over about 8,000 square feet of offices and breakroom.

A cap that thin only works when the underlayment is rated to run at that depth and the bond underneath it is right. Luxury vinyl plank and cove base went down over the cured underlayment.

Bid a similar project

The
work

Abrade, prime, cap, plank
Wire Crafters breakroom before renovation, with tables and chairs on the existing grey epoxy floor
The breakroom before we started, still in service on the original epoxy coating.
Existing epoxy coating over concrete with slab control joints showing through the surface
Epoxy over concrete, with the slab’s control joints telegraphing through.
Three-man crew in Trademark Development Group shirts beginning to roll primer over the abraded epoxy floor
Primer going down over the abraded epoxy, working away from the far wall.
Installer rolling bonding primer, with abraded dark epoxy on one side and white primed floor on the other
The dark field is abraded epoxy. The white is primed and ready to take underlayment.
Two installers rolling primer out toward the wall line across the office floor
Carrying the primer tight to the wall line so nothing is left unbonded at the perimeter.
Low angle view of the boundary between abraded epoxy and freshly rolled white primer
Close on the boundary — abraded epoxy in the foreground, primer beyond it.
Installer working self-leveling underlayment out to depth with a gauge rake in a room with a maroon accent wall
Underlayment worked out to depth with a gauge rake. Working time is short once it is down.
Self-leveling underlayment flowing out across an office floor with the perimeter dammed at the wall base
The underlayment finding its own plane. The perimeter is dammed so it stays where it belongs.
Ceiling light fixtures reflecting cleanly off the surface of freshly poured self-leveling underlayment
Ceiling fixtures reflecting clean off the surface — that reflection is the flatness check.
Capped and flattened floor in the Wire Crafters breakroom, ready to receive luxury vinyl plank
The same breakroom, capped and flat, ready for plank.
General contractor on this project

Trademark Development Group — the renovation

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LVP over SLU
Material
Epoxy-coated concrete
Substrate
~8,000 sq ft
Area
Complete
Project status

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