Every once in a while, just like in any other industry, a tried-and-true epoxy resin installation method will become outdated. For example, acid etching has been a traditional go-to for surface preparation. But, recent advancements have highlighted the superiority of mechanical surface preparation methods like shot blasting and diamond grinding. These techniques offer a safer, more efficient, and environmentally friendly alternative that has rapidly become the industry standard.
In this article, we’ll dive into why mechanical surface prep is taking the lead and why epoxy resin flooring contractors should consider making the switch.
Should You Acid Etch to Prepare Concrete Surfaces?
The answer, according to industry experience and veteran contractors, is no. Although acid etching has been a top solution in epoxy resin surface preparation, it still doesn't hold a candle to tried-and-true mechanical preparation methods.
The process involves using acid solutions to create a rough profile on the concrete, which helps the epoxy adhere better. All epoxy resin flooring projects must start with efficient and thorough surface preparation, and acid etching aims to achieve that. But, is it the best method to prepare a surface?
While acid etching has its merits (it is certainly effective), it falls short in several critical areas. Here are just the top 3:
Inconsistent Surface Profiles Compared to Mechanical Methods
The success of any epoxy project depends heavily on the concrete surface profile (CSP). Acid etching, however, often results in inconsistent surface textures, making it difficult to achieve the desired CSP. This inconsistency can lead to uneven results, weakened flooring, and potentially costly rework.
Now, obviously, that's a worst case scenario. Most acid etching projects won't end up in a costly repair. But when you have the dependability of mechanical solutions right there, why take the risk?
Safety Hazards in Acid Etching
Using acid-based solutions on the job site introduces significant safety risks. Even with stringent safety protocols, contractors face the danger of chemical burns, toxic fumes, and other hazards.
The unpredictability of acid reactions further compounds these risks, making it a less-than-ideal choice for modern flooring projects. Especially if you're working on a large flooring space! Your specific project may require something as specialized as acid etching, but chances are you would be better off avoiding the risks.
Environmental Concerns of Acid-Based Preparation Solutions
The environmental impact of acid etching cannot be ignored. Our flooring industry is rapidly advancing towards a greener future. Sustainable solutions are front and center, and acid etching comes with quite a few sustainability & environmental concerns.
Muriatic acid, commonly used in this process, poses a serious threat to the environment. Improper disposal will lead to soil contamination and possibly harm local ecosystems. With growing awareness of sustainable practices, many contractors are seeking out greener alternatives.
While epoxy resin's VOC emissions themselves are an environmental concern, there are ways to mitigate it. And just because epoxy may present some environmental harm, even if it is less than alternatives, that doesn't mean we have to double down!
Are Mechanical Surface Preparation Methods Superior to Acid Etching?
Acid etching, as we just outlined, comes with some flaws. But, you may say, so will any solution designed to prepare a concrete surface for epoxy resin. That doesn't have to be the case! With mechanical surface preparation, the hazards & possible downsides are not only easier to mitigate, but there are less of them than acid etching!
Here are just a few advantages of mechanical surface preparation:
Mechanical Preparation is More Precise
Mechanical surface preparation methods, such as shot blasting and diamond grinding, offer unparalleled control over the concrete surface profile. These techniques allow contractors to adjust the intensity and pattern of the treatment to achieve a consistent, customized finish that is perfect for epoxy application. And with the high-quality diamond tooling that Xtreme Polishing Systems offers, you'll have cleaner, more efficient results in no time!
The versatility of mechanical methods means you can tailor the surface preparation to meet the specific needs of your project. Whether you need a deeper profile or a smoother finish, both shot blasting and diamond grinding offer more precision towards your goals.
Mechanical Preparation is Safer
Compared to acid etching, mechanical surface preparation is significantly safer. While proper safety gear—like industrial-grade dust vacuums, protective footwear, and masks—should always be used, the risks associated with mechanical prep are far easier to manage. Any handling of acidic solutions will always be less safe than a mechanical solution.
Training your team to operate heavy equipment like floor grinders safely is key, but the overall safety profile is much higher than that of acid-based methods.
Mechanical Preparation is More Efficent
Mechanical surface preparation is not only safer, but also faster! High-quality grinders and shot blasters can significantly reduce project timelines, a
The ability to prepare a surface quickly and efficiently means more time can be spent on the actual installation. That means quicker turnaround time on projects, and more profit for you! It's important that you invest in the grinder you need for your jobs.
For example, a grinder rated for industrial settings won't necessarily be the most efficient for a garage job like XPS' Concrete Genie would. So, do your research and get the solution that fits your projects!
Conclusion
Don't get stuck hanging on to outdated practices. Embrace the most efficient surface preparation methods in shot blasting and diamond grinding and find new success today! Acid etching isn't just comparatively inefficient, it's also less safe, and a possible environmental hazard. Get informed on your options with XPS, and get the right products for your job!
Xtreme Polishing Systems (XPS) will give you the knowledge & resources you need to succeed. Our veteran technicians at (877) 958-5264 are on call to help with any issues. Check out our online store for the best prices on the highest quality products on the market!
