Industrial Epoxy – Boston Concrete Floor Coatings

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Industrial epoxy coatings are widely used to resurface concrete and steel. They can transform a drab, dusty concrete floor to one with light reflection with easy maintenance. Epoxies are a liquid flooring. Liquids consist of a harder and a resin. When mixed together the chemicals cross link becoming very durable.

They cure quickly and adhere to concrete provided the concrete surface has been prepared with mechanical grinding or shot blasting. These surface prep methods remove potential bond breakers such as grease, oil, glue and paint. Shot blasting and floor grinding also increases the surface area for epoxies to bond. Imagine the difference between a surface with coarseness of fine versus rough sandpaper.

Industrial epoxy is not a simple coating like paint. Manufacturers use scientists to engineer epoxy coatings for specific uses. For example, aircraft carriers require a specific coating able to withstand the elements as well as heat from jets as they take off as well as petroleum.

Other epoxies include Novoloac systems engineered to withstand chemical s. They serve as a secondary containment system in case of a leak from chemicals or hazardous waste.

Uses of Industrial Epoxy                                                                       

• Aviation – used in Hangars, Assembly areas, maintenance areas and warehouses
• Breweries – Used in tasting rooms and commercial kitchens.
• Electronic – ESD or Electrostatic dissemination. This is used in clean rooms, warehousing and chemical areas to eliminate shock and combustion of chemicals.
• Healthcare – flooring in corridors, kitchen and cafeterias, operating rooms and reception areas.
• Chemical – Chemical storage, processing areas and secondary containment.
• Retail – popular choices for shops, cafeterias, shopping malls and supermarkets.
• Food and Beverage – bakeries, dairy processing, freezer and cold storage, meat and fish processing, snack foods processing and fruit and vegetables processing.
• Pharmaceutical – Clean rooms and laboratories, production, assembly areas and solvent storage.

Reasons why industrial epoxy is chosen more often:

• Resistant to mild acids, strong alkaline and other chemicals
• Slip resistant especially during wet conditions
• Stain resistant
• Easy to clean, including walls and ceilings
• Insect proof and rodent proof
• High-traffic durability
• Can withstand heavy impact
• Limitless choice for colors and textures
• Seamless

There is a stark difference between a garage floor epoxy paint sold in home improvement stores and the professional grades installed by experienced professionals.

Most professional grade epoxy coatings cost $1.00 per square foot  and quickly jumps to $2.00 PSF or more depending on the application of colored chips, quartz or sand. Each finish coat added increases cost of material and labor.

There are various finish coats such as urethanes and polyaspartics and anti slip additives that will increase the total coat of a project.

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Industrial Epoxy

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Boston Concrete Floor Coatings - Types of Concrete Floor Coatings

Epoxy Kits are widely used by the do it yourself home owner. While inexpensive and easy to apply, they do lack performance characteristics of high performance epoxy coatings installed by professionals. 

Epoxy floor paints are thin coatings.Thickness of epoxy systems is measured in mils which are 1/1000th inch thick. Most DIY epoxy concrete floor coating kits dry to 1.5 – 3.0 mils. 

 

Compare to a most entry level professional grade coatings which apply at 10-20 mils with some thicknesses at 60 mils or more. Epoxy coatings come in many forms and combinations of coatings depending on the use. 

For example, an aircraft carrier decking is coated with a coating which will endure the heat from engines in a fighter jet plus the salt air and harsh conditions of the sea. In the epoxy family are also urethanes and polyureas. 

Urethanes are great coatings with tremendous hardness that will endure uV rays without discolorization. Metallic epoxy flooring, another type of concrete flooring, has experienced tremendous demand due to being an outstanding alternative to self leveling concrete and overlays. They can look like acid stain concrete or a marble looking finish. 

Self Leveling Concrete coatings have evolved with new systems in recent years. They can be applied at ¼ - 3/8th inch thick. They can exceed ½ inch thickness if needed. Some of the new self leveling concrete systems are excellent for applications of decorative dyes and can be polished and honed to a beautiful durable floor. 

Many self leveling concrete coatings are used as underlayments for tile, hardwood and carpet. The self leveling systems and be applied at a measured thickness to accommodate floor vents, stairs and transitions to other rooms. Self leving systems are also an integral part of a moisture vapor flooring system for new concrete. 

Concrete takes a few years to work moisture out of a new slab. For new construction, especially in medical facilities and hospitals where bacteria poses a risk, a moisture vapor system is the solution. Mositure vapor concrete floor coatings start with shotblasting to prep the surface. The next step is application of a penetrating epoxy that anchors in the pores of the concrete. 

 Once the epoxy cures, it is permanenetly anchored into the concrete. Then a primer is applied followed by ¼ - 3/8th inch thick self leveling concrete. Finally a seal coat is applied. Now carpet, tile or hardwood can be installed. From Boston Concrete Floor Coatings Smaller boutique manufacturers have also emerged with specialized floor coating systems.

Technology Is Changing the Options for Industrial Flooring

The internet has provided visibility to industrial flooring that once was available to contractors and manufacturers and those customers who had specific requirements. Now everyone, with just a few clicks, has access to unlimited videos, data sheets, photos, research, manufacturers and contractors.
This visibility has opened up the options to consumers. Simultaneously, contractors, manufacturers of products and equipment companies are developing new products and techniques based on what customers want.

Epoxy Flooring – Epoxy products have been around for decades. They have been used to protect concrete floors from dirt and water with a bright, reflective surface. They are easy to clean provided the top coat is preserved.

Wear and tear makes floors scratch allowing for dirt buildup. Fortunately, epoxy can be lightly sanded and recoated. Floor wax can be applied and buffed with a high speed burnished. This will create a glossy light reflective finish.

As demand increased and technology improved, epoxy coatings have been formulated for specific uses. High performance systems are widely used in commercial kitchens and food processing facilities with characteristics enabling performance near refrigeration and hot ovens. Today’s epoxy coatings will withstand these excessive temperatures.

There are numerous products used for industrial flooring in addition to epoxy such as polyureas, polyurethanes and polyaspartics. 

Each system can be mixed with sand in between coatings as well as adding colored quartz and decorative chips to enhance curb appeal and durability.

 

Polished Concrete – A cost effective solution to epoxy coatings is polished concrete. Concrete floors can be grinded and honed to a matte or glossy finish. They can also be stained for a decorative appearance. Techniques, equipment and products have improved in recent years to meet the growing demand.

Though, an industrial finish, due to the popularity of the industrial look, many retail stores, restaurants, breweries and conversions of industrial buildings to residential loft use are choosing stained concrete polishing.

Self-Leveling Concrete and Overlays

 
In cases where polished concrete is not appropriate due to the condition of concrete, self-leveling concrete overlays can be polished with a predictable decorative concrete result. These systems are then sealed with an epoxy, urethanes solvent or water based sealer. 

This system combines the look and durability of polished concrete with the protection of an epoxy floor coating.

Best Epoxy - Metallic Epoxy Is For Restaurants and Retail Stores

Metallic epoxy coatings are sensational for restaurants and retail stores due their unique combination of function and design.

The process combines a combination of colors creating a unique marbleized appearance with tremendous depth. They are one of the Best Epoxy and most unique flooring choices available.

Non Slip and Seamless

Metallic epoxy is a 2 part liquid system combining a resin and hardener. When combined and mixed together, the chemicals cross link like a chain. Cross linking results with a hard, durable surface with tremendous adhesion to existing concrete floors.

When applied to the surface similar to painting a concrete floor, your new metallic epoxy is 100% seamless. This is a tremendous advantage over tile and hardwood flooring.

Cleaning and maintenance is minimized with long term durability. There are no grout lines or seams where dust, dirt and bacteria can settle.

Metallic epoxy coatings also are non-slip and skid resistant.

Simple Application

The process takes a few days from start to finish. The most important first step of application for any decorative resinous flooring is surface preparation.

Any potential bond breakers such as grease, oil, old paint or carpet glue needs to be removed. Removal is best achieved with use of a floor grinder or shot blaster.

Floor grinders are heavy walk behind machines with course diamond blades. Imagine a push type lawn mower ranging from 300 – 1,000 lbs. The epoxy pro will push the grinding machine over the concrete surface grinding the top layer of the hard cement and any impurities. A high performance vacuum is attached eliminating dust particles.

A shot blaster is an alternative but can also be used along with a grinder depending on condition or hardness of the floor.

The ultimate goal is not only to remove bond breakers, but also to open up the pores of the cement. This enables the primer to soak into the surface. Once cured it is anchored in the concrete.

The next step is application of the metallic epoxy system.

Once the hardner and resin are mixed, colors are added and poured on the floor. Squeegees are used to spread over the surface. Colors are added during this process to achieve the marbleized appearance and “Wow” factor.

 

Where Metallic Epoxy Flooring is Used.

Restaurants and retail stores are popular users due to the unique cub appeal. Many retail store and restaurant owners find that their customers associate their brand with “those amazing floors”. It’s the Best Epoxy that enable consumers to be interested with and only way to be more elegant in your business stores.

Other users are car dealers for use in their showrooms, salons, offices, residential garages and basements.

Concrete Floor Epoxy: Benefits for Garage Flooring Designs

The typical garage floor made of plain gray concrete absorbs stains and attracts dirt from car tires and other activities. As property owners use their garages, the flooring becomes hard to clean. Fortunately, concretegarage floor limitations are easily overcome by applying garage floor epoxy coatings to its surface. 

Transforming new or existing floor installations is made easy through correction application of concrete floor epoxy. A variety of designer flooring options are now available for those homeowners that seek to extend their home's living space into their garage.  

Concrete Floor Epoxy Design Options

Simple design options, such as plain gray, are available for the individual seeking a subtle approach to sealing the garage floor. Color-based epoxies can be enhanced with multicolor flecks that offer an appearance similar to terrazzo or granite. The newest trend of metallic epoxy floor coatings really adds an upscale design to any flooring it covers whether garages, showrooms or entryways. Some contractors also create a grid with concrete epoxies to offer the more formal look of a tile floor. Diagonal designs remove the boxy appearance in large garage spaces.

Another consideration for long-lasting floors is impact resistance. Color flakes, various textures and even plain epoxy design create hard epoxy surfaces ideal for use in garages, commercial kitchens, warehouses and more - really anywhere that floors need to stand up to tough working conditions and traffic. Quartz floors are another option and are created through the use of multicolored aggregates combined with 100-percent solids epoxy. Quartz provides higher impact resistance for floors that incur a great deal of use.

Design for the garage floor epoxy coatings might simply match the color of the house exterior. Another approach might be to use textures and flecks in the epoxy that will hide imperfections in the floor surface. Sealants will allow all imperfections to show through, but textured epoxy creates a new surface. 

Close evaluation of the existing floor will enable the owners along with their concrete epoxy professional to determine the best design approach. Design variations provide different levels of coverage. To learn more about concrete floor epoxy for your garage, home or business, contact Smith and Company flooring professionals today.