Flake floors look simple on YouTube, but the first time you try it yourself, you’ll realize there’s a lot more to getting a professional finish than just tossing flakes in the air. The prep work, timing, and broadcast technique all matter more than most beginners expect.
Here’s the full process broken down the way I wish someone had explained it to me before my first install.
The 7 Steps to Installing an Epoxy Flake Floor
1. Surface Preparation
This is where most DIY jobs fail. You need to diamond grind or shot blast the concrete to open the pores. A quick acid etch won’t cut it for a commercial-grade bond. The surface should feel like 80-grit sandpaper when you’re done.
2. Crack and Joint Repair
Fill any cracks with epoxy crack filler or flexible polyurea. Control joints need to be routed out and filled properly, or they’ll telegraph through your coating within six months.
3. Prime the Surface
Apply a thin primer coat of epoxy. This seals the concrete and gives the base coat something to grip. Skip this step and you’ll get pinholes and bubbles you can’t fix later.
4. Apply the Base Coat
Roll on your pigmented epoxy base coat at the manufacturer’s recommended thickness—usually 10-15 mils. Work in sections and maintain a wet edge. You’ve got about 20-30 minutes of working time depending on temperature.
5. Broadcast the Flakes
This is the fun part and the hardest to get right. Toss flakes up in the air so they fall evenly across the wet epoxy. Most jobs use a full broadcast (100% coverage) or a heavy broadcast (70-80% coverage). Throw too hard and they bounce off. Too soft and they clump.
6. Scrape the Surface
After the base coat cures (usually 12-24 hours), scrape off any loose or proud flakes with a razor scraper. Then lightly sand with a buffer and 100-grit screen to knock down sharp edges.
7. Apply Clear Topcoat
Roll on two coats of clear polyurethane or polyaspartic topcoat. This seals the flakes, adds UV resistance, and gives you the glossy finish. Wait for the first coat to tack up before applying the second.
Common Mistakes Beginners Make
I’ve seen hundreds of failed flake floors, and the mistakes are almost always the same:
- Skipping proper grinding — acid etching alone doesn’t open the concrete enough for a commercial bond
- Waiting too long to broadcast flakes — if the base coat starts to gel, flakes won’t stick and you’ll have bare spots
- Not backrolling the base coat — you need to backroll immediately after pouring to ensure even thickness and remove trapped air
- Using the wrong topcoat — cheap epoxy topcoats yellow under UV and scratch easily; use polyurethane or polyaspartic
- Rushing the cure time between coats — epoxy needs to fully cure before you scrape or topcoat, or you’ll pull up the flakes
The biggest issue I see is people trying to learn this from videos alone. Watching someone broadcast flakes doesn’t teach you what the epoxy should feel like when it’s ready, or how to read the concrete and adjust your prep.
How Long Does a Flake Floor Installation Take?
For a standard two-car garage (400-500 sqft), expect three days if you’re doing it right:
- Day 1: Grind, repair cracks, prime (6-8 hours of work)
- Day 2: Base coat and flake broadcast (4-5 hours of work, then 12-24 hours cure time)
- Day 3: Scrape, sand, and apply two topcoats (6-8 hours total)
Experienced crews can do smaller jobs in two days by working longer hours and using faster-curing products, but don’t rush your first few installs.
Should You Learn This on Your Own or Take a Class?
Here’s my honest take: if you’re just doing your own garage and never plan to do another floor, watch some videos, buy good materials, and give it a shot. You’ll probably make mistakes, but it’s your garage.
If you want to do this professionally or start a business, don’t waste time learning by trial and error. I burned through $3,000 in materials on my first few jobs fixing mistakes I didn’t even know I was making. A hands-on epoxy training course would’ve saved me six months of frustration and a lot of money in redos.
You need to see what proper prep looks like on real concrete, feel when the epoxy is ready for flakes, and learn how to fix problems in real time.
Frequently Asked Questions
How much does it cost to install a flake floor yourself?
Materials for a two-car garage run $600-$1,200 depending on flake coverage and topcoat quality. Equipment rental adds another $200-$400 if you don’t own it. Professional installation typically costs $5-$10 per square foot.
Can I install flake flooring over old epoxy?
Sometimes, but it’s risky. You need to sand the old epoxy heavily to create a mechanical bond. If the old coating is failing, it all has to come off.
What’s the difference between epoxy flakes and vinyl chips?
They’re the same thing just different names. Some manufacturers call them flakes, some call them chips or color flakes. They’re all made from colored vinyl.
Ready to get started in Salt Lake City?
Epoxy Classes Utah is here to help with epoxy flake floor installation in Salt Lake City. Reach out today and we’ll walk you through your options, answer your questions, and book a time that works for you.
Call +1 385-483-5154 or visit Epoxy Classes Utah to schedule your Salt Lake City appointment.
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