How to Install Aggregate Flooring

Field Stone Aggregate

Aggregate flooring is a floor finishing system that features an epoxy resin mixed with small field stones or pebbles. The stones give the floor a unique look and texture and are available in a large variety of colors. Floors made from epoxy are among the most durable and long-lasting materials available to homeowners. Because they are stain-resistant and waterproof, aggregate flooring is especially popular in kitchens, bathrooms, garages, and outdoor applications.

Things You'll Need

• Epoxy flooring primer and sealer
• Aggregate
• Epoxy mortar
• Trowel
• Epoxy filler
• Caulk gun
• Broom and vacuum
• Drill with paddle bit
• Bucket
• Paint roller

Instructions

1. Purchase the epoxy flooring materials, including primer and seal coat. These items can be purchased from home improvement stores or from a specialty retailer. Plan to use about a half a gallon of primer and 1.25 gallons of sealer for every 100 feet of floor space. Keep in mind that you will likely want to install multiple coats of sealer.

2. Choose an aggregate flooring product. Aggregate is available in dozens of blends of colors and sizes. Generally, smaller stones are used for indoor applications, while larger ones are used outdoors. Plan to use about one pound of aggregate per square foot of flooring.

3. Seal floor joints or major voids in the subfloor using an epoxy mortar mix. This product can be purchased from most home improvement stores, or from an epoxy dealer. The resin and hardener components should be mixed just before they are applied. Epoxy mortar can be installed using a trowel or putty knife, and all excess material should be wiped away before it dries.

4. Fill smaller cracks in the floor using an epoxy injection filler. This process should be completed using a caulk gun or integral applicator. Excess material should be wiped away immediately before it can harden.

5. Clean the floor thoroughly. For best results, use a broom or vacuum.

6. Combine the resin and hardener for the primer. Use the ratios indicated in the product's instruction sheets. Use a drill with a paddle bit to mix the materials at a slow speed. Immediately apply the primer to the floor using a large paint roller. Wait one hour for the primer to dry, then repeat this process again to apply the base coat. Use a new, clean roller cover for this step.

7. Apply the aggregate to the floor immediately after applying the base coat. This step is done by hand, and aggregate should be applied as evenly as possible. Allow the surface to dry overnight, then sweep away any loose stones. Follow up with a vacuum cleaner to ensure all loose stones are removed.

8. Mix the seal coat components in the ratios indicated in the product instructions. Blend the materials using a paddle bit, then use a paint roller to apply them on top of the aggregate. Allow this seal coat to dry before proceeding.

9. Repeat step eight until the floor has the desired texture and finish. Often, one coat of sealer will allow the texture of the rocks to project properly. Adding a second or third coat may leave the floor smooth.

References

• Installing Epoxy Chip Floors
• The Flooring Lady

Resources

• Epoxy Flooring Materials
• Everstone
• Pebble Rock Flooring