What is an epoxy floor?
An epoxy floor is made from a two-component material: the resin is mixed with a hardener, and the chemical reaction produces a hard, dense, liquid-tight layer with good adhesion to concrete. This is the most widespread type of industrial resin floor: it is laid in warehouses and production halls, laboratories, clean rooms, hospitals, garages, dry areas of food plants, and retail and exhibition halls.
The strengths of epoxies are hardness, resistance to abrasion and to many chemicals, a smooth, easy-to-clean surface and a wide range of colours. Their weaknesses are rigidity, which means the coating copes poorly with impact, vibration and movement at cracks in the substrate; yellowing and chalking in sunlight; and limited resistance to heat and thermal shock. Where these weaknesses are critical, polyurethane or polyurethane cement systems are chosen.
Types
Thin-film coatings
Paint systems a fraction of a millimetre thick: for the materials in the catalogue, the consumption by roller is about 0.2–0.3 kg/m² per coat, while high-build solvent-free products give 200–400 µm per coat. They dustproof the concrete, make cleaning easier and provide colour and line marking. Water-based epoxies have almost no odour and are convenient in premises that remain in operation; solvent-free products give a thicker, more wear-resistant layer. They are suitable for foot traffic and light trolleys, but not for intensive forklift traffic.
Self-levelling systems
A solvent-free resin is mixed with quartz filler and poured onto the primed substrate in a layer several millimetres thick — 1.5 to 5 mm for the materials in the catalogue; it flows out into a level, smooth surface, and air is released with a spiked roller. Such a floor withstands trolleys and forklifts with polyurethane wheels, is easy to clean and suits workshops with dust-free requirements.
Quartz-filled broadcast systems
Resin is applied as a layer, quartz sand is broadcast into the fresh layer to excess, and after curing the surplus is swept off and the surface is sealed with a topcoat. The resulting multi-layer system is rough-textured, slip-resistant and strong, and its texture is adjusted through the sand grading and the thickness of the sealing coat. This is the choice for wet areas, ramps and heavily loaded zones.
Mortar (trowelled) systems
Resin with a high filler content forms a stiff mortar, which is laid and trowelled by hand or with a power trowel in a layer several millimetres thick. Mortars are used under heavy loads and impact, for repairing potholes and for forming coving at walls.
Primers and barrier coats
Low-viscosity epoxy primers penetrate the pores of the concrete and provide adhesion for the system; mixed with quartz sand, they are used to make levelling fillers. A separate group are epoxy-cement compounds, which manufacturers recommend as a temporary barrier against moisture from young or damp concrete under a subsequent polymer coating; the conditions for their use are set out in the technical data sheet.
How to choose an epoxy system
By load
Foot traffic and light trolleys — a thin-film coating. Trolleys, stackers, forklifts with polyurethane wheels — a self-levelling layer. Wet areas and ramps — a quartz-filled broadcast system. Impact, steel wheels, heavy pallets — a mortar system or a switch to polyurethane cement floors.
By chemical exposure
Epoxies resist many salt solutions, alkalis, oils and fuels, but organic acids, certain solvents and oxidisers can attack them or stain the surface. For laboratories, battery rooms and electroplating areas, choose products whose technical data sheets explicitly state their chemical resistance. Resistance to the specific medium is confirmed by our questionnaire: substance, concentration, temperature and regime. For strong acids and oxidisers, see the vinyl ester systems in the “Chemical protection” section.
By substrate moisture
Epoxy systems are sensitive to moisture in the concrete: where there is too much, blisters and delamination appear under the coating. Moisture is measured before application and compared with the limit in the data sheet; if the concrete is young or moisture is rising from below, a barrier coat or a different system is used.
By lighting and colour
In sunlight, and even under the UV light of some lamps, epoxy yellows; light and bright colours change more noticeably. Near loading doors and windows, and in halls where appearance matters, the epoxy layer is overcoated with a UV-resistant polyurethane topcoat.
By dust-free requirements
Where the floor is subject to strict requirements on dust release, the Uzbek code ShNK 2.03.13-24 “Floors” provides for “low-dust” finishes with an abrasion loss of no more than 0.4 g/cm² and “dust-free” finishes with no more than 0.2 g/cm². Seamless resin floors are the standard solution for such rooms, including clean rooms.
Typical system
- mechanical preparation of the substrate: removal of laitance and contamination, repair of potholes and cracks, dust removal;
- primer — one or two coats depending on the absorbency of the concrete, with a sand broadcast where necessary;
- a levelling coat of filled resin — over a rough or uneven substrate;
- main layer — self-levelling, quartz-filled broadcast or mortar;
- topcoat: a clear or coloured seal coat and, where necessary, a UV-resistant polyurethane one;
- details: coving, junctions with columns, drains and channels, carrying movement joints through the coating.
Application: what to watch
- Substrate and air temperature, air humidity and the margin above the dew point — strictly as per the data sheet: for the epoxy materials in the catalogue, the minimum temperature is +8…+10 °C, and the substrate must be at least 3 °C above the dew point. On a cold substrate, the resin thickens, flows less readily and cures slowly; with condensation, the surface becomes tacky and whitish.
- The components are mixed as complete kits with a mechanical mixer, decanting into a clean container; splitting a kit “by eye” is not allowed.
- The pot life of the mix drops sharply in hot weather — mix only as much as can be poured in time.
- Overcoating intervals are observed as per the data sheet: after the maximum interval, the surface is sanded, otherwise the next coat may delaminate.
- Foot traffic, vehicle traffic and wet cleaning are allowed only after the curing times given in the data sheet for the actual temperature.
Common mistakes
- A self-levelling layer over laitance or dusty concrete — delamination in sheets.
- Application to damp concrete without measuring the moisture — bubbles and blisters.
- A thin paint coating on forklift routes — worn down to the concrete within months.
- Light-coloured epoxy near loading doors and windows without a polyurethane topcoat — yellowing in streaks.
- Working in an unheated building in winter — incomplete curing, tackiness, staining.
- Pouring over movement joints without carrying them through — cracks along the joint line.
- Epoxy in an area with hot spills and steam cleaning — cracking and delamination.
See also: resin flooring — overview, polyurethane floors, anti-static and conductive floors.
Materials in the catalogue
- Sikafloor-264 — Sika — two-part coloured epoxy roller coat and seal coat for concrete floors.
- Sikafloor-263 SL — Sika — coloured epoxy resin for 1.5–3 mm self-smoothing and broadcast industrial floors.
- Sikafloor-161 — Sika — low-viscosity epoxy primer, binder for levelling mortars and screeds, intermediate layer.
- Sikafloor-2540 W — Sika — low-emission water-based semi-gloss epoxy floor coating for interior use.
- Sikafloor-81 EpoCem — Sika — epoxy-cement temporary moisture barrier and self-smoothing screed for damp or green concrete.
- Jotafloor EP SL — Jotun — solvent-free self-levelling epoxy floor coating, 1.5–5 mm, for industrial areas.
- Jotafloor Coating — Jotun — solvent-free epoxy floor coating, 200–400 µm per coat, for warehouses and workshops.
- Fosroc Nitoflor SL2000 — Fosroc — 2 mm flow-applied epoxy floor topping for clean rooms, laboratories and kitchens.
- Mapefloor I 300 SL — Mapei — epoxy resin for 2–4 mm self-levelling and quartz-broadcast slip-resistant floors, Bfl-s1.
- Resuflor HB — Sherwin-Williams — high-build epoxy floor coating, 0.2–0.3 kg/m² per coat, Skydrol resistant.
- PPG NU-KLAD SL — PPG — solvent-free self-levelling epoxy floor, 2 mm layer, resistant to hot tyres.
- Mapecoat EPN 24 — Mapei — chemical-resistant epoxy-novolac coating for floors and concrete at chemical plants.
This list is not exhaustive. The final choice is made on the basis of the manufacturer’s documents and the project requirements.
Frequently asked questions
How does a self-levelling floor differ from epoxy floor paint?
In thickness and purpose. Paint is a thin layer for dustproofing and colour under light loads; a self-levelling floor is a layer several millimetres thick that carries the load itself and evens out minor defects in the substrate.
Can an epoxy floor be made slip-resistant?
Yes: by broadcasting quartz sand into the fresh layer and then applying a sealing coat, or by adding additives to the finishing seal coat. The coarser the grading and the thinner the sealing coat, the higher the slip resistance and the harder the cleaning.
Why has my epoxy floor turned yellow?
Aromatic epoxies change colour under UV light — this is a property of the material, not a defect. For areas exposed to sunlight, a UV-resistant polyurethane topcoat is used.
How many days before the floor can be used?
The times for foot traffic, light traffic and full cure are given in the technical data sheet for several temperatures; in a cold room they can be several times longer.
We will select an epoxy floor system to suit the loads, substrate and schedule of your project — call us or message us on WhatsApp/Telegram: +998 94 094 52 27.