Project Highlight – 17,000 Sq Ft Epoxy Floor Transformation

When it comes to commercial and industrial flooring, appearance is only part of the equation. Durability, safety, and proper installation matter just as much—especially in high-traffic environments where floors take daily wear and tear.

That was exactly the case for a recent 17,000-square-foot epoxy flooring project completed by Dragon Scale Construction for the Aviation Institute of Maintenance in Manassas.

The facility’s existing floor coating had completely failed, leaving behind a worn, damaged surface that needed far more than a quick cosmetic fix. Our team stepped in to completely restore the flooring system from the ground up and delivered a durable, slip-resistant finish built to handle the demands of an aviation training environment.

The Challenge: Failed Floor Coatings

Before any new coating could be applied, we had to address the biggest issue: the original flooring system had failed.

Peeling coatings, uneven surfaces, and compromised adhesion can create serious safety concerns in commercial facilities. In a training environment where students and staff are constantly moving equipment and working in active spaces, the floor needed to be both functional and reliable.

Rather than covering up the problem, our team removed the damaged materials completely to ensure the new system would perform properly long-term.

 

Step 1: Removing the Existing Coating

Proper preparation is one of the most important steps in any epoxy flooring installation.

To remove the failed coating, our team used PCD diamond grinding, which effectively stripped away damaged material and brought the floor back to a stable surface.

After that, we completed a second pass using a diamond grinder to properly prepare the concrete for the new system.

This two-step preparation process helped ensure:

• Better adhesion
• A smoother finished surface
• Longer-lasting performance
• Reduced risk of future coating failure

Skipping this step often leads to premature flooring issues, which is why proper prep is always a priority.

 

Step 2: Building a Strong Foundation

Once the surface was fully prepped, we began rebuilding the flooring system with high-performance materials designed for durability.

Sikafloor 161 Primer

We applied Sikafloor 161 primer to create strong adhesion between the concrete substrate and the new coating system.

This step helps prevent peeling, bubbling, and early wear.

Sikafloor 264 Base Coat

Next, we installed a pigmented Sikafloor 264 base coat, which provided both durability and a clean, polished appearance.

This layer helps create a uniform finish while protecting the underlying concrete.

Step 3: Adding Durability and Slip Resistance

In commercial environments, safety is very important.

To improve traction and durability, we finished the floor with:

• Sikafloor 340 topcoat
• Aluminum oxide additive for slip resistance

This combination created a high-performance surface that can withstand heavy daily use while helping reduce slip hazards for employees and students.

 

Step 4: Precision Line Striping for Organization

To complete the project, our team added precision line striping using Sherwin-Williams Macropoxy 646.

These clearly marked walkways help improve:

• Workplace organization
• Traffic flow
• Safety compliance
• Visibility throughout the facility

In active training facilities like the Aviation Institute of Maintenance, clearly defined pathways make a major difference.

 

Completed in Just 4.5 Days

Despite the scale of the project, our experienced crew completed the full transformation in just 4.5 days.

The final result?

A clean, durable, slip-resistant flooring system built to perform in a demanding environment.