You may want start by contacting the epoxy manufacturer. They may have some additional surface prep information for dealing with expansion joints. I have no personal experience with epoxy coatings so I can’t comment on them. I have however installed many stone and tile floors over concrete slabs that had expansion joints and the client didn’t want to see them either. Instead of trying to eliminate the joint I will treat it as if it were a big crack with a anti-fracture isolation type materials. Ultra set is one I like to use even though the data sheet says not to use it on expansion joints. The method and manner varies slightly from job to job but it’s not rocket science. I can provide you with a step by step walk-thru with pictures if needed. If your epoxy is compatible with isolation materials, this may be an option. Regardless I would get them to sign a waiver or walk away.  

 

 

 

I would not fill any isolation or relief joints in the floor.  The “V” grove or relief joint is designed to "attract" cracking, allowing the remainder of the slab to be relatively crack free. The expansion or isolation joints are used to separate or isolate the slab from other parts of the structure such as walls, footings, driveways, ect. Isolation joints permit the slab to move and help minimize cracking caused when movement is restrained. Both techniques are required by code unless other methods are used. The house is only 6 months old and will continue to settle for a long time. Is the home still under the builders warranty? What happens if the slab cracks, who is going to answer? The expansion or isolation joints could be filled with a self leveling Polyurethane designed for flexibility to improve appearance. For the “V” grove or relief joints, sell him a throw rug.

 

 

I have a customer who wants us to grind his garage floor and place an epoxy coating on top of it.  He also wants us to fill in the seams of the garage floor to make it look like a single slab.  The garage was only installed January of 2009.  We explained that the seams are there to allow flexibility but he still insists on having it filled.  Should we use concrete to fill it or is there another product that will fill it nicely and smooth to make it look like a single slab?  One other person told me thin set.  Does that make sense?

Thanks all!
Georgia

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