The Idea:
#300/21 epoxy is very waterproof, and it is
an excellent adhesive- that's why it is a favorite with boat and
aircraft builders. But an all-epoxy deck coating would show every
flaw in the concrete, and would be very slippery. By adding a lot
of small stones to the AeroMarine 300/21 we get a nice thick nonskid coating that
hides all the flaws beneath it.
The Process:
Sweep the area well. Mix the #300 resin and #21 hardener together in the
prescribed 2:1 ratio. Don't mix more than a half gallon at a time until
you get used to how the epoxy reacts.
Most applicators brush or roll a thin prime coat of the mixed epoxy onto the
substrate (usually concrete). Then mix another small batch and immediately blend the stones into the epoxy. Commercial applicators use a
cement mixer to blend the stones and AeroMarine 300/21. You can also use a bucket, or
better yet a concrete mixing tray. Try to make as dry a mix as possible,
while still completely coating the stones with epoxy. Spread immediately
with a trowel.
Coverage (New installation):
New Installation 300/21 Pebble/rock Paving Epoxy Coverage Chart (Square feet) |
| Kit Size |
Square feet |
Pounds of pebbles |
| 1 1/2 Gallon |
75 |
150# |
| 3 Gallon |
150 |
300# |
| 6 gallon |
300 |
600# |
| 15 Gallon |
750 |
1500# |
One gallon of mixed epoxy covers approximately 50 square feet when used with 100 pounds of pebbles.
Recoating
Occasional overcoating may be necessary
depending on degree of wear and the intensity of sunlight. No
stones are usually added, but a thin layer of AeroMarine 300/21 can be brushed or
rolled over the existing installation. If your installtion has been neglected for a long time, you might want to use a thick roller or even an acoustic ceiling roller to get more epoxy down into the surface. Coverage will be significantly less if you use a thicker roller. We do not recommend spraying this epoxy.
Coverage: (Resurfacing existing pebble surface):
Recoating 300/21 Pebble/rock Paving Epoxy Coverage Chart (Square feet) |
| Kit Size |
Square feet |
| 1 1/2 Gallon |
300 |
| 3 Gallon |
600 |
| 6 gallon |
1200 |
| 15 Gallon |
3000 |
If you are recoating an existing installation,
expect to get about 200 square feet per gallon.
Cleanup:
Clean tools with acetone or lacquer thinner.
Hints:
AeroMarine 300/21 cures by generating heat. Bigger batches
generate more heat, reducing cure time. Warm weather also speeds
up the cure. We normally want plenty of time to work with the
epoxy- that's why it is best to mix small batches until you understand
how the AeroMarine 300/21 cures.
1/4" is a good pebble size- Anything less than 1/8" is too small, and anything over 3/8" is probably too large.
In the San Diego area you can find pebbles at Southwest Boulder.
If you need an installation in SoCal, AZ,and Southern Nevada, we have a customer called Pebble Stone Flooring Systems that will do the work. Their phone number is 1(480)600-2130.
Pebble Paving FAQ's
Where do I find pebbles?
Search in the yellow pages or online for a local brick, paving or stone supplier.
What is the work life?
30 minutes for the mixed epoxy. Adding pebbles to the epoxy increases the work life to approx 1 hour.
How do I clean and prep the surface prior to application?
This epoxy is an extremely tenacious adhesive and will bond to almost any substrate, so you don’t need to take any extreme measures. Sweep the area to remove any dirt or debris, and remove or repair any broken concrete. If you wash it, allow time to dry completely. It will not bond to greasy or oily areas.
Do I clean and prep the pebbles?
Only if they are really dirty. Rinse them with water and let them dry completely.
Should I prime the deck?
Professional applicators that guarantee their work generally prime the substrate with a thin coating of mixed epoxy. Most homeowners generally just trowel the mixture directly onto the substrate. Both are acceptable practices.
Does the surface need to be dry before application?
Yes.
If new construction, the concrete slab should be what minimum thickness?
It should meet the building codes in your community as if it were a standalone concrete slab. The epoxy and pebble layer should not be considered a structural component.
What is the recommended thickness of the pebble and epoxy layer?
The thickness of one to two pebbles – generally ¼” to ½”.
How is it applied?
With a trowel, similar to how you would smooth concrete or apply stucco.
What’s the best way to mix epoxy and pebbles?
First, thoroughly mix the resin and hardner, then add that mixture to the pebbles. If it’s a small application, you can mix it by hand in a concrete mixing trough. Disposable plastic troughs are commonly available at hardware stores. If it’s a large application, use an electric cement mixer. The goal is to completely wet each pebble with epoxy, but just barely. Excess epoxy will just drip down between the pebbles to the substrate. The objective is to create a mixture resembling a Rice Krispy treat.
How long does it take to reach full cure?
Generally it will cure in 24 hours, however if you plan to drive on this surface let it cure for 48 hours. Winter weather conditions may lengthen the time required to cure.
What happens if it rains before the epoxy cures?
Try to apply the epoxy when you are certain it will not rain in 24 hours. If the epoxy is exposed to rain or water, which includes your sprinklers, it may turn a whitish color which can not be changed.
How do I repair an existing pebble paved surface?
For small repairs, mix epoxy in a coffee can or other disposable container. Using disposable gloves, add pebbles as needed to create enough material to complete the repair. Apply with a trowel, or with gloved hands. Larger repairs are similar to a new applications. Mix the resin and hardner, add the pebbles in a mixing trough or wheel barrow, and apply with a trowel.
How often should I re-coat the pebbles with epoxy?
We recommend recoating residential applications every 4 years, commercial applications every 2 years. It can be applied just like paint using paint rollers. For light re-coats a regular nap paint roller works well. We frequently receive phone calls about installations that haven’t been recoated for 12 to 15 years. At the point, it’s best to apply a thick coating to refresh the installation. The best way to apply a thick coat is with a thick nap roller or an acoustic ceiling roller. When purchasing the product, consider the reduced coverage achieved when applying a thick coat.
What temperature and weather conditions are required?
Application must be done during dry conditions, at temperatures above 40 °F. Applications at temperatures over 100 °F tend to cure much faster than applications made in the 70 °F range. Cure time is affected by ambient temperature and size of the batch. In extreme heat, mix smaller batches.
How do I apply it to a vertical surface?
Application onto a vertical surface can be very tricky and is not recommended. The epoxy has the look and feel of clear 30 weight motor oil, and tends to drain rapidly off vertical surfaces. The best way to apply the epoxy and pebble mixture onto a vertical surface is to wait until it has started to gel before application with a trowel. If the mixture slides off the surface or pebbles fall out, then the epoxy is still too green. Keep working it on to the surface until it stays. Also keep in mind that the work life is now shorter so plan to complete smaller areas in each batch.
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You have seen it around the pools,
decks and entries of some of the world's finest hotels and corporate
headquarters. There's no real agreement on what to call it, but it
is a system where small pebbles are mixed with epoxy resin to create a
beautiful and durable nonskid coating.
