Sometimes, when planning an epoxy project, you realize you're likely to need a deeper epoxy finish than the norm. Though typical epoxy projects—such as an epoxy bar top—will require only a single comprehensive flood coating of epoxy, there are still many other situations that call for more.
In such cases, knowing the proper method for applying multiple layers of epoxy is essential to completing your project while still achieving the crystal-clear, seamless finish that premium epoxy is widely known for.
Typically, when working with epoxy on a substrate, there are two types of coating methods involved: the seal coat and the flood coat.
Knowing the Terms: Seal Coat and Flood Coat
Nearly every epoxy project involves applying two different types of coatings, one always before the other. These are the epoxy seal coat (which comes first) and the epoxy flood coat (which comes second).
Let's take a look at each.
What Is an Epoxy Seal Coat?
An epoxy seal coat is a preliminary coating of epoxy resin that is applied manually using a suitable brush (e.g., a paint brush) to "seal" a porous substrate surface.
A porous surface is one that has tiny, often imperceptible, holes in which air tends to reside. By applying a seal coat of epoxy, the air gets pushed out of these holes and released from the surface, preventing it from becoming a problem later when the more comprehensive flood coat is applied.
Because most epoxy substrates are porous, it's typically recommended that a seal coat be applied to your project as a first step. The epoxy used can be the same type as for your flood coating, such as our Primaloc Bar & Table Top Epoxy.
What Is an Epoxy Flood Coat?
A flood coat of epoxy resin is a thicker layer of epoxy applied over a surface, typically following a seal coat. Once the seal coat has partially cured and is no longer tacky, the flood coat is applied.
The flood coat is typically poured on and then spread out evenly over the entire surface, self-leveling to create a smooth, glossy finish. This coat is substantial enough to provide a durable, protective layer that encapsulates the surface beneath it, often enhancing the appearance of the material below due to the epoxy's clear, reflective qualities.
The flood coat is the most essential step in many epoxy resin projects, providing the aesthetic finish and the primary layer of protection against physical and chemical damage.
Our aim with this guide is to explain how to apply multiple flood coat layers of epoxy.
How to Apply Multiple Layers of Epoxy
Applying successive layers of epoxy flood coating is a straightforward process, needing only some basic understanding and proper timing.
First of all, once you've applied your initial flood coat of epoxy, there is a specific window of time you should wait before adding another layer. For most table top epoxy resins, you should aim to apply the next layer around 4 hours after applying the previous one but before 10 hours have passed.
The 4-hour period allows the epoxy layer to settle and start curing without becoming too hard, creating an ideal surface for the next layer to adhere to seamlessly and effectively.
If you wait longer than 10 hours, the surface of the epoxy will begin to harden more substantially., at which point a light sanding will be necessary to create a suitable texture for the new layer to bond to. The sanding helps ensure proper adhesion between the layers.
To Add a Flood Coat Layer of Epoxy Over a Previous Layer, Do the Following:
- Allow at least 4 hours to pass after the previous flood coating but no more than 10 hours. For optimal results, aim for the period between 4 to 6 hours.
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Measure and mix up a fresh batch of epoxy resin.
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Pour this fresh batch over the already applied layer.
- Use a heat gun or torch to eliminate any emerging air bubbles.
- Repeat Steps 1 to 4 as needed for additional layers. We recommend limiting your finish to 3 full flood coat layers—if possible—to reduce the risk of blemishes.
- Allow the final flood coat layer to cure undisturbed for at least 72 hours. This is the minimum recommended time for a high-quality table top epoxy to cure before using.
While this method can be adapted to your project's specific project, exceeding three layers may increase the likelihood of various imperfections. As such, it's generally recommended that users stay within this limit for ideal results.
FAQs About Epoxy Layering
In this section, we answer various questions about layering epoxy and achieving optimal bonds.
FAQ #1: Can I Apply Epoxy Multiple Times?
Absolutely! See the prior sections of this article for detailed information on how to do so.
FAQ #2: Can I Use Epoxy On Other Epoxy?
Yes. Other brands or variants of epoxy should without a doubt be cross-compatible, provided they're of decent quality and not substandard.
For fully cured finishes, this will often require a light sanding, followed by a cleaning, before any additional coatings are applied. Otherwise, the epoxy may not bond as strongly and imperfections may appear.
FAQ #3: Should I Sand Between Coats of Epoxy?
It depends. If at least 10 hours have passed since the previous coating was applied, you'll need to do a light sanding to prepare the semi-hardened (or fully hardened) epoxy surface for the next coating.
However, if less than 10 hours have passed, you may apply an additional coat as long as the previous coat has had 4 hours to partially cure (this gives additional coats something solid to grip to).
You can learn more about sanding epoxy in our guide here.
FAQ #4: Can I Apply Multiple Seal Coats of Epoxy?
Yes. Though most of the time a single seal coat is more than enough, sometimes a second seal coat is encouraged to ensure a complete seal.
This not only guarantees that most of the air will be removed from the substrate surface, but can also bring peace of mind to the epoxy user who may be concerned about persistent air bubble formulation.
Getting a Multi-Layered Finish Is Easier Than It Seems!
Achieving a multi-layered epoxy finish is not much more complicated than single-layer applications. In many cases, for your extra effort, your finish gains the benefits of enhanced protection and a greater stability. Plus, the technique for layering remains consistent across each application.
Achieving optimal results in multi-layered finishes requires a blend of expertise and the use of premium-quality epoxy resin.
Primaloc Epoxy: Premium Epoxy for Premium Results
When it comes to epoxy resin, Primaloc Epoxy gets the job done. Our epoxy resin is premium-grade, with high performance in every category, including:
- Unmatched Strength: A Primaloc finish won't buckle, even under high pressure.
- Long-Lasting Resilience: Primaloc epoxy lasts for many years with minimal care, and can endure high-traffic environments with ease.
- A Crystal-Clear Coating: With its pristine, transparent appearance, looking at a cured Primaloc coating is like peering through a window.
Epoxy resin can be beautiful, strong, and long-lasting—which is why you shouldn't compromise on quality. With Primaloc Epoxy Resin, you get the ultimate finish in durability and visual appeal.
Protect your surfaces by giving them a rock-solid epoxy finish. Choose strong. Choose reliable. Choose Primaloc.