How to apply an epoxy coating over an existing vinyl floor

Many of our customers ask about applying an epoxy floor coating over existing vinyl flooring, both in sheet form and tiles. As many have experienced, as vinyl flooring gets old and/or well-used, the heat-welded seams often burst open, allowing contamination to seep through and under the flooring. It also becomes porous and difficult to keep clean.

Yes, you can apply epoxy over vinyl flooring—as long as you have the right knowledge, materials, and follow the proper steps. While vinyl presents some challenges for epoxy application, a well-prepared surface and the correct approach can result in a durable, high-performance floor.

The key to success is ensuring the vinyl is properly adhered to the subfloor, thoroughly cleaned, and sufficiently abraded to create a strong bond. Contaminants, moisture, and existing coatings (such as wax or polish) must be removed to prevent adhesion issues.

By following the steps outlined in this guide, you can achieve a long-lasting epoxy coating over your vinyl floor. Read on for expert advice on preparation, surface treatment, and choosing the best epoxy system. And if you need further guidance, our team is always available to help!

Removing vinyl flooring can be a real headache for several reasons:

Residual Adhesive

Vinyl flooring is often securely adhered to the subfloor, making removal difficult. When you do manage to lift it, you’ll find either hard glue or soft glue underneath… and both can cause problems!

• Soft glue: Soft adhesives are problematic as they gum up diamond grinders and wire brushes. Chemical removal can turn them into a sticky mess. The best removal method is using an STR Machine with PCD Shoes… otherwise, you’re relying on hand scrapers I’m afraid!
• Hard glue: Hard adhesives can be even more difficult to remove. The best approach depends on the amount left on the surface, requiring tools like a Handheld Diamond Grinder, High-Speed Diamond Grinder, or a Scabbler. We’d always recommend a discussion before setting out to remove hard glue.

Poor-Quality Substrate

The next issue is not just what is left on the surface by way of the glue, but what gets pulled up when removing the vinyl.

Many businesses opt for vinyl flooring due to issues with the underlying subfloor, so when pulling up the vinyl, MOST people also end up pulling any latex or self-levelling screeds previously used to level out the surface. This creates two problems: glue residue on the surface and holes or loose screeds. Both of these needs addressing before applying epoxy.

Vinyl floors are commonly used in areas prone to grease, moisture, and contaminants, such as kitchens, bathrooms, food processing areas, factories, garages, and laboratories. People have laid these floors because they’re portrayed as totally impervious and non-slip, but they are often in greasy or wet areas that can cause havoc with any coating that hopes to stick to the vinyl. It is therefore vitally important that a suitable biodegradable degreaser is used.

To ensure a clean surface:

• Use a biodegradable degreaser – see Polycote Degrease IT.
• Then remove and re-lay any loose vinyl and repair any holes.
• Once the surface is clean and dry, perform a final abrasion to create a key for the epoxy to adhere properly.

If you choose to apply epoxy over vinyl, keying the surface is crucial. This involves thoroughly abrading the flooring to promote adhesion.

• Small areas: Use an orbital sander with something like 60-grit sandpaper.
• Larger areas: An STR Machine is strongly recommended.

It’s important to note that if the vinyl flooring has been polished and/or waxed (especially in schools and colleges, hospitals and hotels) a simple abrasion of the surface is NOT good enough. It is vitally important that the surface layers of wax/polish are sufficiently ‘cut’ through to ensure the coating can adhere to the tile itself. The STR Machine could still work for this, although you may need something slightly more aggressive such as a Vacuum Assisted Grinder.

After preparation, any holes, gaps, or damaged areas should be repaired before applying epoxy. The best repair material would be very much dependent on your own specific needs of course, but the most popular repair products include:

• Polycote Easi-fil
• Polycote Cretex EP

Once repairs are complete and cured, the surface is ready for coating.

There are many factors to take into consideration when choosing a coating for your vinyl flooring. Selecting the best epoxy coating depends on:

• The type of vinyl flooring
• The intended use of space
• The level of wear and tear expected

If the existing vinyl flooring consists of multiple colours (e.g., alternating light and dark tiles), the colour variation will most likely show through a standard epoxy coating. In such cases, additional coats may be required for full coverage.

For a durable, high-wear, and easy-to-clean finish, we recommend the following system:

• One coat of Polycote WD Primer
• One coat of Polycote Flortex Professional

Proven nationwide (even worldwide!), this system is excellent for the coating of vinyl floors and can save a whole lot of headaches caused by the many other coatings that would require the full removal of a vinyl floor.

The time required to install an epoxy coating over vinyl flooring depends on several factors, including the size of the area, the extent of surface preparation needed, and environmental conditions. As a general guide:

• Surface Preparation & Priming: This involves cleaning, degreasing, and keying the surface, all of which can be completed on Day 1. We recommend priming first, as it helps identify areas that need repairs. Our team can advise on the best primer based on the substrate, potential oil contamination, or the need for a DPM (damp-proof membrane).
• Repairing Imperfections: Once the primer is applied on Day 1, any surface imperfections—such as holes or loose vinyl—can be repaired. If conditions are suitable, Easi-Fil can be used and will cure in just 20 minutes.
• Applying the Epoxy Coating or Topcoat: This should be done on Day 2. If using our most popular epoxy coating, Flortex professional, it will cure in approximately 24 hours, allowing for foot traffic. After 48 hours, it will be ready for vehicular traffic and will reach full chemical cure in 7 days.
• For larger projects or areas with significant repairs, the entire process may take longer from start to finish but our expert team will be able to advise.

When properly applied, an epoxy coating over vinyl can last 5 to 10 years or more, depending on the level of foot traffic and maintenance. Factors that influence longevity include:

• The quality of the surface preparation: A well-prepared vinyl surface ensures better adhesion and durability.
• The environment: Areas with heavy machinery, high footfall, or chemical exposure may wear faster.
• Regular maintenance: Cleaning with non-abrasive, non-corrosive products extends the lifespan of the coating.

For schools, factories, or commercial spaces with high traffic, applying a protective topcoat or anti-slip additive can further enhance durability and performance. Talk to us for more information as it really does depend on your situation.

After reading all this, you may be wondering whether you’d be better off simply replacing the vinyl altogether. We know cost is a big factor in this sort of decision, so here’s a quick cost comparison for you:

• Epoxy over vinyl really is typically much cheaper, since it eliminates the cost of vinyl removal and subfloor repairs. The main expenses include surface preparation, epoxy materials, and labor.
• Vinyl replacement is usually more expensive, as it involves removal costs, subfloor leveling, and purchasing new vinyl flooring and is not as durable or long lasting as epoxy flooring.

In many cases, properly applied epoxy provides a more durable and cost-effective alternative. However, if the existing vinyl is in extremely poor condition (loose, damaged, or poorly adhered), replacing it might be the better long-term investment. Think of it like fixing up an old car – sometimes a repair job keeps it going strong, but if the whole thing really is falling apart, it might be time for an upgrade!

We believe in providing honest advice to help you achieve the best possible flooring solution. With the right preparation and products, epoxy over vinyl can be a great option. We recommend following the steps outlined here or reaching out to our team for expert guidance. It is always good to know of problems that could arise before they happen. As the old saying goes, forewarned is forearmed!

If you need more information or are unsure about the best solution for your flooring needs, please don’t hesitate to ring our technical helpline on 01234 846400. We have a fully qualified team ready to give practical advice and help you figure out what to do next with your vinyl flooring.