Not every floor is ready for a thin decorative coating. Slabs that are badly spalled, pitted, gouged, or worn down to exposed aggregate need to be rebuilt before they can be finished. An epoxy mortar system does exactly that, creating a new high-strength wearing surface bonded directly to the old concrete.
Katy Floors Epoxy installs epoxy mortar and trowel-down systems for damaged residential and commercial floors throughout Katy and Greater Houston. These heavy-duty systems are how we save slabs that other contractors would tell you to tear out and repour.
What an Epoxy Mortar Actually Is
An epoxy mortar is a blend of epoxy resin and graded aggregate, troweled onto the slab at significant thickness, often a quarter inch or more. Unlike a thin roller-applied coating, it's a structural wearing course. The aggregate gives it compressive strength rivaling or exceeding the original concrete, and the epoxy binds it into a dense, monolithic surface that won't dust, crack, or wear like tired old concrete.
When You Need One
We specify epoxy mortar systems for floors with surface spalling and scaling, where the top layer of concrete has flaked away; deep pitting and pop-outs that a flood coat can't fill; heavily worn slabs in shops and warehouses; ramps and transitions that need to be rebuilt to grade; and floors that need to be leveled or sloped to a drain. If a slab has lost its surface integrity but the underlying concrete is still sound, a mortar rebuilds the wear layer without the cost and downtime of demolition.
Mortar vs. Self-Leveling Epoxy
An epoxy mortar is troweled and is ideal for rebuilding heavily damaged or sloped surfaces and ramps. A self-leveling epoxy flows out to a smooth, flat finish and is better for filling minor undulations on an otherwise sound slab. We choose between them, or combine them, based on the condition and the finished look you want. Both deliver far more strength and thickness than a standard coating.
Aggressive Prep Comes First
An epoxy mortar is only as good as its bond to the slab. We mechanically prepare the concrete, often with shot blasting for heavily damaged floors, to reach a clean, sound, sharply profiled surface. Loose and deteriorated concrete is removed, cracks are routed and filled, and the slab is opened to an aggressive ICRI profile so the mortar locks in. We never trowel a mortar over a contaminated or laitance-covered slab.
A Finish on Top
The mortar rebuilds the surface; a decorative or industrial topcoat finishes it. Once the mortar cures we can broadcast flake or quartz, apply a solid-color or metallic finish, and seal it all with a UV-stable urethane or polyaspartic. You end up with a floor that's not just repaired but actually better than the original, both stronger and better looking.
Built for Katy Conditions
Spalling on Katy slabs is often moisture-driven, so we test for moisture vapor and address it with mitigation primers as part of the rebuild. Fixing the surface without addressing the cause just invites the damage back, and we build the system to last.
Get a Free Floor Assessment
Damaged, spalled, or pitted concrete rebuilt with heavy-duty epoxy mortar systems.
Get a Free Quote (832) 939-9841