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Repairing Epoxy/Stone Deck/Patio Surfaces
When the Stones Break Loose

or

Doing the Stone/Epoxy Surfaces Yourself (click here)

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WITH OUR SLOWER THICKER SUMMER CURING AGENT (NEEDED IF TEMPS ARE OVER ABOUT 85 DEGREES) COVERAGE IS PROBABLY CLOSER TO 180-200 SF PER KIT. PRICE IS THE SAME. SO, IF WORKING IN SUMMER CONDITIONS ORDER THE SLOW SUMMER CURING BASIC NO BLUSH.

7/12/01

Packaged under a lot of different names, there are many flavors of epoxy and stone slurries that are applied over concrete surfaces to form an attractive and uniform new surface. These systems are generally used on patios, porches, around swimming pools (visit our swimming pool repair page for products/notes in and around pools), and along walkways. After a period of time (a few years) the epoxy ‘glue' begins to breakdown, primarily due to sun (UV) exposure and the stones break loose. The standard fix is a new coating of epoxy over the surface every few years.

The problem will always exist because of UV damage to any/all epoxies, however it is probably made worse by the methods and products used by the original installer/applicator. The ideal application would consist of a high quality epoxy (with little or no solvents), and smallish stones (more surface contact/glue points). After the slurry is applied and allowed to cure (harden) - an additional top coating of epoxy should be applied because much of the epoxy in the original slurry would have flowed away from the surface grains and pooled uselessly along the bottom of the slurry mixture. Next a UV resistant coating should be applied on top of everything to help protect the epoxy from UV sun damage. I doubt few, if any, installer do all these things because of the extra cost. (our 2 part acyrlic poly UV plus is sometimes put over the epoxy coatings to keep them from yellowing. - (epoxies yellow in UV - More on UV blockers)

).

In any event, when the stones break loose, it is time to ‘reseal' or ‘reglue' them. In many cases the original installer will return and recoat the surface with more epoxy, often for about one dollar per square foot. Even assuming more low quality epoxy will be used, this fix is probably well worth your consideration.

If the repair has become your job:

Use our least expensive epoxy (Basic No Blush) and our special slit-foam roller ($6.50) to apply a new topcoat of epoxy to the stones. Find it in our catalog - click here

COVERAGE

Coverage rates will very greatly depending upon stone size, condition of the surface and personal technique, never-the-less we estimate 200-225 square feet of recoat coverage per 1.5 gallon kit of epoxy based upon user feedback. Note that this is a very common number but we also get folks saying they only got 150 sf per kit, and others insisting they got over 300 sf. Still, 80% of people seem to like the 200-225 sf figure.

WARNINGS:

The epoxy will yellow in sunlight (starts out clear). Your stones are probably golden in color - this is most likely actually white stones covered with sun yellowed epoxy.

Pool chemical contamination on your stonescan sometimes turn the epoxy a bright yellow or white. Even hosing/washing etc. of the stones always seems to miss places, so yellow/white splotches around your swimming pool is a real posibility.

Also and more commonly, rain, water splashes, bird pee, or dew on still liquid or tacky epoxy can result in a white 'stain' that will not go away. It is either a waxy white film that forms on the surface (blush - but being a no blush epoxy this is rare) or more commonly little water caused indents on the smooth epoxy surface that now reflects the light making it appear white. Try a bit of clear nail polish over these white spots. Very likely it will fill in the 'dents' and the surface will (maybe) return to clear. (I have no way to test this). If so, the fix is a bit more epoxy over those spots.

NOTE POTLIFE ABOUT 60 MIN FOR 6 OZ MIX AT ABOUT 65 DEGEES F - BUT MUCH SHORTER FOR BIGGER BATCHES (DON'T MIX ALL 1.5 GAL AT ONCE!).

This is a very popular 'fix' with our customers.

Customer feedback (7/31/02)

Basic No Blush/epoxy pebble stone surface around swimming pool/recoat

"Job went well for a do-it-yourselfer. Coverage was much higher than directions - covered 600 square feet with a little less than 3 gallons. Mixed 1.5 gallons per batch. First batch exothermed adn cured in the paint pan in about 30 minutes. Air temperature was 74 degrees F and in the shade." - John K.

"Just finished using your NoBlush Epoxy on our stone/pepple pool deck. Used four 1.5 gallon kits for about 800 sq. feet. The rollers you sell for this are the way to go. I used 3 for this job and should have ordered a 4th to be safe. Power mixed 1.5 gallons at a time and used an oversized paint roller an(1gallon) and a standard size one. With 2 people we were done in 11/2 hours. The weather was overcast and 62 degrees and had not trouble at all. Looks great and hope to get 3 or 4 years out of it here in Ohio. The stone was laid 3 years ago and am interested to see the comparison. Great product."
Kevin D

ALL COMMENTS ABOVE REFER TO BASIC EPOXY WITH THE STANDARD CURING AGENT

TEMPERATURE WARNING - Now available in three versions (standard, 'cold weather-winter' (fast), and 'hot weather-summer (slow)) - same low price for each! Our hot weather curing agent is extra thick to 'fix' the normal thinning of the epoxy resin as temperatures increase. So, may be too thick if stored/used at temperatures below about 85 degrees. Unlike the standard curing agent, which is clear in color, the Summer version is amber colored (not that noticable when applied but certainly amber in the bucket). The winter version is just slightly yellowish in color.

Creating - Making Your Own Epoxy - Stone Deck/Surface

It's not that difficult to make your own epoxy - stone surface. The most difficult part is finding the small pebble stone. Having to purchase 3 tons of stone and shipping it across the country will probably nix the entire project. If you can get around 'stone availability' issue, you're home free.

STONE SOURCE: TRY ARKANSAS DECORATIVE STONE (www.arkansasdecorativestonellc.com). Pls tell them you found them via Progressive Epoxy Polymers!

Usually the epoxy-stone surface is applied as a thin topcoat over a poured concrete surface. It is generally applied as thin as possible. You want to cover the surface with a uniform layer of pebble stone, but not much thicker. The smaller the stones the, easier and more attractive the end result will be.

OK - heres how to do it:

Mix up epoxy and have the stone ready. Working time will be about 30-45 minutes per batch of expoxy. Use our Basic No Blush epoxy. Roll on a coat of epoxy on the concrete (1.5 oz of epoxy per square foot).

Immediately begin applying the stone - epoxy slurry over the epoxy primer coat. The slurry will consist of 2.5 oz of epoxy and approx. 1.85 pounds of pebbles per square foot.

Evenly spread the epoxy - smooth using a trowel. Wiping down the trowel with our Trowel Aid cleaner will keep the epoxy-stone slurry from sticking to the trowel (the Trowel Aid product is a helpful, but not necessary, product).

Let the epoxy-stone surface harden overnight or longer.

It is strongly suggested you apply a topcoat of more epoxy to prolong the life of the surface. Follow the directions above for 'repair'. You will use approx. 1.5 oz of epoxy per square foot and we suggest you use our extra thick, slotted foam roller.

Almost no one puts a UV blocker over the epoxy to keep it from UV yellowing, but if you wanted to we do have a 2 part clear polyurethane with lots of UV blockers in it (very hard to find clearcoats with UV blockers) called Acrylic Poly UV Plus. This will keep the surface shiny much longer and will, to a small degree, protect the epoxy and provide additional 'gluing' between the pebbles. Figure on about 2.5 oz of clear acrylic per square foot, applied with an ordinary paint roller (this is an approx. figure, not based on user feedback).

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