The Opportunity

When the request came in, “Can you apply polyurea on both floors and walls for a commercial space?”, we paused.

There were no playbooks. No case studies. No YouTube rabbit holes to fall into.

This hadn’t been done before. Not at this scale. Not with this spec.

But instead of saying no, we leaned in.

We gathered our team and decided: We’re going to build the process ourselves. We’ll train. We’ll test. We’ll document everything.

Fast forward a few months, and we successfully completed the first-ever large-scale commercial polyurea install covering both floors and walls, including demo, concrete pour, full spray, topcoat, and line striping.

Here’s exactly how we did it and what we learned along the way.

It’s often used in garages, truck beds, or containment tanks.

But on commercial floors and walls? That’s a new frontier.

Most commercial spaces still rely on outdated tile + mud-bed systems. These come with headaches: water seepage, cracking, and costly repairs. Polyurea offers a seamless, waterproof, ultra-durable solution… if it’s applied correctly.

That’s the kicker: there’s no manual for vertical application at scale.

So we wrote our own.

The Full End-to-End Process (What We Actually Did)

This wasn’t a touch-up. It was a gut-and-rebuild job, with precision from start to finish.

Here’s what our process looked like:

1. Demo Phase

• Removal of all existing tile and mud-bed

• Addressed surface imperfections and cleaned thoroughly

2. Concrete Pour

• Fresh slab pour, laser-leveled to prep for coating

• Proper cure and moisture testing before moving forward

3. Polyurea Spray (Floors + Walls)

• Special rig setup to handle vertical surfaces

• Sprayed floor first, then walls in seamless transitions

  

4. Topcoat Application

• UV-stable aliphatic topcoat applied to lock in protection

• Created a smooth, non-slip finish

5. Line Striping

• Final striping applied for zones, safety, and layout clarity

From demo to stripping every layer had to work as a system, not as standalone steps.

Training Our Crew

We didn’t subcontract this out. That would’ve been easier, but also riskier.

Instead, we committed to upskilling our team.

Here’s how we trained in-house:

• Polyurea spray fundamentals: cure time, overlap, pressure balancing

• Vertical spray trials: working with sag, nozzle control, and temp control

• Safety training: PPE, ventilation, and equipment maintenance

By the time we got on-site, our team had muscle memory. They moved like they’d done this job 20 times already.

The Hardest Problems We Solved

No project worth doing is challenge-free. Here’s what tested us most:

• Vertical sag control

  • Polyurea wants to run when applied to walls. We dialed in exact temps and spray technique to combat sag.

• Fast cure = fast mistakes

  • Once sprayed, you get seconds to adjust. We had to be perfect the first time.

• Environmental control

  • Humidity, ventilation, and substrate temp all had to be in a tight window. We built a full checklist to stay dialed in.

• Line striping on polyurea

  • Paint doesn’t stick well to cured polyurea. We had to scuff surfaces and use specialty primers for adhesion.

What Made This a Success

Here’s what truly made the project bulletproof:

• Prep work: every inch of substrate was clean, leveled, and dry

• Training: our crew didn’t guess. They followed muscle memory

• Sequencing: every step flowed into the next with zero downtime

• Post-inspection: we passed the first time with no touch-ups needed

Considering Polyurea for Your Next Commercial Project?

If you're even thinking about polyurea, especially on walls or large surfaces, here’s what we recommend:

• Plan beyond just floors: Polyurea excels when it can wrap up walls and create a true containment shell

• Invest in prep: This isn’t paint. Your substrate must be perfect

• Control your environment: Get serious about temp, humidity, and substrate moisture

• Train or partner right: Don’t DIY unless your team is trained, or bring in pros who are

You don’t have to guess your way through a polyurea install.

We’ve done it. We’ll show you how.