You’ve seen the photos: flawless, mirror-shine epoxy floors transforming Sydney garages, showrooms, and commercial spaces. You invested in self-levelling compound, expecting a perfect base. But now, you’re looking at a map of cracks, a hollow drum-like sound when you tap it, and a crumbling, dusty mess. That dream of a perfect epoxy finish just hit a major snag. So, what went wrong? And more importantly, can you just "pour over it"? Applying expensive epoxy resin over a failed, unstable leveller isn't just a bad idea—it's a guarantee of total project failure. The new epoxy will delaminate, crack, and peel, taking the faulty leveller up with it. You won't just be back at square one; you'll be out thousands of dollars with an even bigger problem. As Sydney's experts in high-performance flooring, we at Elyment Group have seen this exact scenario countless times across NSW. Here’s the professional breakdown of why your leveller failed and the exact, non-negotiable steps to redeem your floor for a lasting epoxy finish. Why Did My Self-Leveller Fail? Understanding the Root Cause Before you can fix the problem, you must understand it. A failed levelling compound is almost always a symptom of a deeper issue. Simply pouring more on top is like putting a bandage on a broken leg. Here are the most common culprits we find in Sydney properties: No (or Incorrect) Primer: The primer is the "glue." It bonds the concrete to the leveller and prevents the porous concrete from sucking the moisture out of the mix too quickly. No primer means no bond. Contamination: The original concrete slab was dusty, oily, or damp. Self-leveller, like epoxy, needs a pristine, porous surface to adhere to. Poor Mixing: Too much or too little water, or improper mixing, compromises the chemical structure of the compound, leading to weak spots, crumbling, and shrinkage cracks. Underlying Slab Issues: Is there moisture rising from the concrete slab (hydrostatic pressure)? Is the slab itself cracked and moving? A leveller can't fix a structurally unsound foundation. Incorrect Curing: Applying the leveller in the extreme Sydney heat or in damp, cold conditions can cause it to cure too fast or not at all, leading to a weak, powdery finish. Redemption: The Professional 5-Step Process to Fix a Failed Surface Can this floor be saved? Absolutely. But it requires a methodical approach that starts from the bottom up. This is not a simple DIY weekend fix; it's a professional remediation project. Step 1: Complete Removal of the Failed Compound There is no "patching" a delaminated surface. The entire failed layer must be removed. Our teams use heavy-duty floor scrapers and, in most cases, proceed directly to diamond grinding. This is the only way to get back to a solid, uncontaminated foundation. Step 2: Aggressive Concrete Grinding This is the most critical step. We use powerful, HEPA-filtered diamond grinders to achieve two essential goals: Remove All Contaminants: This strips away every last trace of the failed leveller, old glues, oils, and the weak top layer of the concrete (laitance). Create a "Mechanical Profile": The grinders open the pores of the concrete, creating a rough, textured surface. This "profile" gives the new primer and epoxy system a massive surface area to grip onto, creating an unbreakable mechanical bond. Note: Acid etching, a common DIY alternative, cannot achieve this. It's inconsistent, hazardous, and often fails to remove sealed contaminants, leading to new bond failures. For a high-performance floor in NSW, professional grinding is the only answer. Step 3: Detailed Crack and Damage Repair With the slab fully exposed, we meticulously inspect and repair all underlying damage. This isn't just filler—we use high-strength, fast-curing epoxy mortars and polyurea fillers to structurally mend cracks and spalls, ensuring the slab is monolithic and stable. Step 4: Application of a Moisture-Mitigating Primer Given the history of failure, we don't take chances. We apply a specialised, moisture-mitigating epoxy primer. This penetrates deep into the freshly ground concrete, locks down any residual dust, and creates a powerful chemical bond. Crucially, it also acts as a vapour barrier, stopping any underlying moisture from affecting the new floor system. Step 5: Re-Levelling (If Necessary) or Direct Epoxy Application Only now, on top of a fully prepared and primed slab, can we re-level. In many cases, a high-build epoxy system can be applied directly, smoothing minor imperfections. If significant levelling is still required, we apply a high-strength, primer-compatible compound, now 100% confident it will bond permanently. Key Takeaways: Don't Risk a Second Failure Your floor’s success is decided before a single drop of coloured epoxy is poured. The preparation is everything. Never pour new material over a failed, cracked, or crumbling leveller. Failure is a symptom: You must diagnose the root cause (moisture, contamination, no primer). Diamond grinding is the non-negotiable standard for professional floor preparation in Sydney. Professional repair of the underlying concrete slab is essential for a long-lasting finish. Your Flawless Sydney Floor Starts Here A failed leveller is frustrating, but it's not the end of the road. It's an opportunity to do it right and build a floor that truly lasts a lifetime. Don't gamble on a second failure. Get a professional assessment from the team that specialises in complex remediation. For expert advice on concrete preparation and premium epoxy flooring in Sydney and across NSW, trust the specialists. Contact us at Elyment Group for a comprehensive on-site consultation. .elyment-cta-btn { background: linear-gradient(135deg, #022b5f, #16443e); /* Gradient for depth */ color: #fff; border: none; padding: 14px 36px; border-radius: 50px; /* Pill shape */ cursor: pointer; text-align: center; display: inline-block; margin-top: 20px; text-decoration: none; font-family: 'Helvetica Neue', Helvetica, Arial, sans-serif; font-weight: bold; font-size: 17px; letter-spacing: 0.5px; transition: all 0.35s ease; box-shadow: 0 6px 15px rgba(2, 43, 95, 0.4); position: relative; overflow: hidden; } .elyment-cta-btn::before { content: ""; position: absolute; top: 0; left: -100%; width: 100%; height: 100%; background: rgba(255, 255, 255, 0.2); transition: all 0.4s ease; } .elyment-cta-btn:hover { transform: scale(1.05); /* Slight zoom */ box-shadow: 0 10px 25px rgba(2, 43, 95, 0.6); } .elyment-cta-btn:hover::before { left: 100%; /* Shimmer effect */ } Start Your Flawless Floor Journey