As a leading epoxy floor paint manufacturer in China, Shanghai Danshang Technology Co., Ltd. specializes in producing high-performance industrial flooring materials for global clients. With more than two decades of technical experience, our product line includes epoxy primers, epoxy medium coatings, anti-static ultra-wear-resistant topcoats, epoxy colored sands, epoxy self-leveling systems, and polyurethane finishing coats. All materials are designed to meet the demands of heavy-duty industries and provide long-term durability, chemical resistance, and excellent surface performance.
For this real epoxy flooring project in Malaysia, the owner of an automobile workshop chose Shanghai Danshang Technology as the coating supplier. After purchasing our complete epoxy self-leveling and polyurethane ultra-wear-resistant flooring system and epoxy equipment such as concrete grinder and industrial vacuum cleaner, the client requested on-site technical support to ensure proper application of the coatings on their concrete floor.
To guarantee a successful installation, we sent a team of experienced Chinese technicians who speak both Mandarin and English to Malaysia. Our technicians provided hands-on training for the local workers and guided them through every stage of the process, including surface preparation, material mixing, flooring application, and curing. Their support ensured that the client received a high-quality epoxy floor that meets industrial standards for strength, smoothness, and long-term service life.
This article presents the full step-by-step installation process, application techniques, and the technician training workflow used in this real epoxy project for auto workshops in Malaysia.
Step 1: On-Site Floor Assessment
Upon arrival, our technicians inspect the concrete substrate, check overall floor flatness, identify cracks, and determine whether old coatings need to be ground off.
Step 2: Substrate Grinding and Old Paint Removal
Because the concrete surface had old paint, we used a YM-700 floor grinder with 16–30# diamond segments to remove all existing coatings through multiple grinding passes. After the old paint was fully removed, we switched to 80# diamond heads for fine grinding to achieve a smooth, level substrate ready for epoxy application.
We use an angle grinder to polish all corners and hard-to-reach areas that the YM-700 grinder cannot cover. Cracks are then opened into a V-shaped groove with a diamond cup wheel. This step prepares the cracks for proper repair and helps prevent future re-cracking.
After all grinding is completed, the entire floor is vacuumed and cleaned to remove dust and debris, ensuring the concrete surface is fully ready for applying the epoxy primer.
Step 4: Epoxy Primer Application (0.1–0.2 kg/m²)
Because Malaysia has high temperatures, our team mixes the primer in small batches to prevent early curing and unnecessary material waste. The recommended mixing ratio is:
- Component A: 2 kg
- Component B: 1 kg
- Epoxy thinner: 1 kg
All components are blended thoroughly and then applied evenly using a roller or trowel. This primer layer seals the substrate, improves adhesion, and prepares the floor for the upcoming epoxy coatings.
Step 5: Epoxy Mortar Middle Coat (0.3–0.45 kg/m²)
For the epoxy mortar layer, Components A and B are mixed with quartz sand to create a thick, high-strength paste. This mixture is first used to repair all cracks, holes, and damaged areas of the concrete surface. Repairs must be completed and leveled before the mortar starts to cure.
The standard mixing ratio for the full middle-coat application is:
- Component A: 2 kg
- Component B: 1 kg
- Quartz sand: 2.7 kg
- Thinner: 1 kg
After thorough mixing, the epoxy mortar is evenly spread across the entire floor using a trowel. This layer strengthens the substrate, improves surface flatness, and provides a solid base for the upcoming self-leveling coat.
Step 6: Grinding the Epoxy Middle Coat
After the mortar layer cures, we use a YM-320 dust-free grinder with 30–60# diamond cup wheels to level and smooth the surface. All edges and corners are refined using a hand grinder fitted with flap discs. Once grinding is complete, the entire floor is vacuumed and cleaned to remove dust and ensure strong adhesion for the next coating layer.
Step 7: Applying the Putty Layer (0.05–0.1 kg/m²)
To eliminate pinholes and small surface defects, we prepare an epoxy putty by blending:
- Component A: 5 kg
- Component B: 1 kg
- Thinner: appropriate amount
- Putty powder: added until smooth and creamy
This repair putty is first used to fill any small holes or imperfections that were not visible during earlier steps. After repairs, the mixture is evenly spread across the entire floor to create a smooth, uniform surface for the upcoming epoxy self-leveling coat.
Step 8: Epoxy Self-Leveling Topcoat (0.7–1 kg/m²)
For the self-leveling coat, Components A and B are mixed at:
- Component A: 5 kg
- Component B: 1 kg
The mixture is stirred thoroughly until fully uniform.
In China, experienced installers can apply epoxy self-leveling directly with a notched trowel. Since this project involved training local workers in Malaysia, we first guided them to use a 1–2 mm notched trowel to spread the material evenly. After troweling, the workers used a finishing roller to smooth the surface and ensure a consistent, level epoxy finish.
Step 9: Light Grinding After Self-Leveling Cures
Once the epoxy self-leveling layer has fully cured, we use a YM-320 dust-free grinder fitted with 50# resin pads for a light sanding. The goal is to slightly roughen the surface and create a better mechanical profile, which significantly improves adhesion for the upcoming polyurethane ultra-wear-resistant topcoat.
Step 10: Applying the Polyurethane Ultra-Wear-Resistant Topcoat (0.08–0.1 kg/m²)
For the final protective layer, the polyurethane system is mixed in the following ratio:
- Component A: 5 kg
- Component B: 2 kg
- Component C: 3 kg
All components are blended thoroughly until fully uniform. The coating is first applied using a 30 cm flat trowel to ensure even coverage, followed by a 9-inch roller to achieve a smooth, consistent finish. This PU topcoat provides excellent abrasion resistance, UV stability, and long-term durability for heavy-duty automobile workshop environments.
Step 11: Floor Line Marking and Zoning
After the polyurethane topcoat has fully cured, we mark the workshop areas according to the client’s functional needs. Using high-visibility industrial marking tape and wear-resistant coating paint, the team creates clear boundary lines for work zones, vehicle parking areas, and equipment spaces. This ensures better workflow management, safety, and organization within the automobile workshop.
Summary
This real epoxy flooring project in a Malaysian automobile workshop demonstrates the complete installation process of a high-performance flooring system supplied and supported by Shanghai Danshang Technology Co., Ltd. From substrate grinding and crack repair to epoxy mortar leveling, self-leveling topcoat application, and the final polyurethane ultra-wear-resistant finish, every step followed strict industrial standards to ensure durability, chemical resistance, and long-term performance. Our experienced Chinese technicians provided hands-on training to local workers, ensuring proper application techniques and consistent quality throughout the project.
With the combined advantages of epoxy self-leveling and polyurethane topcoats, the completed floor delivers excellent abrasion resistance, smoothness, load-bearing capacity, and enhanced visual organization through professional floor marking. This project also highlights the value of technical support and on-site guidance when installing advanced flooring systems in overseas markets.
If you need wholesale epoxy floor paints, epoxy primers, epoxy mortar materials, epoxy colored sands, polyurethane coatings, concrete grinding machines, or professional worker training services, Shanghai Danshang Technology can provide full technical support and competitive factory pricing.
Contact us today by email or WhatsApp to get your customized wholesale quote and technical guidance for your next flooring project.
