A Disciplined Sequence, Not an Improvised Application
Forty-five years of specification-grade epoxy practice in Ghana’s institutional sector has produced one consistent truth: the quality of the finished floor is determined before the first gram of resin is mixed. Epoxy GH’s 7-Step Project Method is the formalised expression of that truth — a calibrated sequence that removes ambiguity from the process and installs rigour at every phase.
This guide documents the method and provides the QA checklist used on every institutional engagement.
Step 1 — Site Survey and Substrate Assessment
Every project begins with a structured site survey. Our specialists assess slab age, moisture vapour emission rate (MVER), surface pH, existing coatings, and point-load conditions. No specification is issued without this data. Assumptions at this stage produce failures at month six.
QA Checkpoint: Substrate pH within 7.0–9.0. MVER below 5 lbs per 1,000 sq ft per 24 hours (or client-approved mitigation specified in writing).
Step 2 — System Selection and Specification Writing
Based on survey findings, our specialists select the correct system — broadcast, self-levelling, mortar, or anti-static — matched to the facility’s operational demands: chemical exposure class, trafficked load type, hygienic grade, and thermal cycling risk.
The specification document is issued to the client as a controlled document before any mobilisation.
QA Checkpoint: Written specification signed and acknowledged by the facility manager or commissioning agent prior to mobilisation.
Step 3 — Surface Preparation
Surface preparation accounts for the majority of epoxy coating failures reported across the industry. Epoxy GH operatives use diamond-head shot blasting and mechanical grinding calibrated to achieve the correct concrete surface profile (CSP) for the selected system — typically CSP 3 to CSP 5 for institutional applications.
Contamination is removed. Cracks and voids are repaired with appropriate filler systems before any primer coat is applied.
QA Checkpoint: CSP verified against ICRI standard guidelines. Crack repairs cured and mechanically tested before priming proceeds.
Step 4 — Priming
The primer phase establishes chemical and mechanical adhesion between the substrate and the system build coat. Epoxy GH applies specification-grade penetrating primers, dwell-timed precisely for the recorded substrate temperature and porosity profile. Rushing the primer phase creates delamination risk that no topcoat can correct.
QA Checkpoint: Primer application log completed per bay. No build coat applied until minimum primer cure time has elapsed, confirmed by dry-touch and pull-off test where specified.
Step 5 — System Build and Broadcast
The selected system is applied in controlled lift thicknesses. For broadcast systems, aggregate is seeded uniformly at the correct rate per square metre and back-rolled to embed evenly. For self-levelling systems, gauge rakes and spiked rollers are deployed immediately after pour to maintain consistent mil thickness.
Ambient temperature, relative humidity, and substrate temperature are logged at every pour.
QA Checkpoint: Wet film thickness readings recorded per pour section. No adjacent section poured until current section is within the cure window that prevents contamination.
Step 6 — Topcoat and Seal
The topcoat phase delivers the finish specification: gloss level, slip resistance rating (where applicable), chemical resistance grade, and UV stability class. Epoxy GH applies topcoats in two passes where institutional specification requires, with adequate inter-coat windows observed.
QA Checkpoint: Gloss meter reading documented. Slip resistance verified against specified PTV or R-rating. Final dry film thickness (DFT) confirmed per approved specification.
Step 7 — Cure, Inspection, and Handover
The completed system is protected during the full cure period. No trafficked access is permitted until the system has achieved the hardness index specified. At handover, Epoxy GH issues a project completion document that includes all QA logs, the as-installed specification, cure period records, and maintenance guidance.
QA Checkpoint: Full QA log presented at handover meeting. Facility manager sign-off obtained on the completed works. Defect notification period formally initiated in writing.
Why the Method Holds
Institutional facilities — pharmaceutical manufacturing halls, food-production environments, Tier-1 bank operations floors, clinical laboratories — cannot absorb remedial downtime. The 7-Step Project Method exists to make remedial work unnecessary. Every step is documented. Every checkpoint is signed. Every system installed by Epoxy GH carries the discipline of 45 years of practice behind it.
To commission a site survey or request a system specification, contact the Epoxy GH project team at info@epoxygh.com or +233 27 000 0844.