Different Types of Industrial Concrete Floor Coatings

Types of Industrial Concrete Floor Epoxy Coatings

There are various types of concrete floor coatings. The most popular coating used in industrial settings is epoxy. The durable coating is available in various colors and comes with a polished, smooth finish. Moreover, cementitious urethane finish provides a unique antimicrobial solution for health facilities, restaurants, and food processing facilities. A methyl methacrylate (MMA) coat of acrylic gives a smooth floor that requires minimal maintenance. Polyaspartic finishes stand out due to their speedy application.

The concrete floor installation requires a great deal of preparation. This includes deciding the most appropriate concrete mix to make solid, level surfaces and constructing the forms and allowing the concrete to cure properly, etc.

When you step into your branded new commercial concrete flooring, you could think that you are done thinking about the floor and get towards other areas of your building. There is another aspect to pay particular attention to the flooring coating.

What are the reasons to apply a floor coating?

Concrete floor coatings aren’t solely for show although they may be quite attractive. They protect concrete from staining, moisture as well as general wear and tear.

While concrete may appear to be totally solid, it is actually a network of tiny pores. When water gets inside these tiny spaces in the concrete, it may make the concrete expand or shrink. The result is cracking inside the concrete or causing pieces of concrete to fall off the surface, in a process known as spalling.

That’s right, everyday exposure to water can damage the strength of the concrete you have invested many hours, energy, and labor to construct. The protection of your investment by the use of floor coatings is logical.

Floor coatings act as a shield against stains and moisture and can provide other benefits based on the substance. While their primary function is to seal concrete and prolong its lifespan flooring coatings be attractive to your flooring.

The various options of epoxy floor coatings

The most popular flooring coating used for concrete floors in industrial settings is epoxy. The durable coating is available in various colors and comes with a polished, smooth finish.

Like concrete flooring, you can find a variety of floors coated with epoxy available to select from, each having slight differences in characteristics.

Self-leveling epoxy can be described as one of the simplest to apply and even, which allows a smooth and seamless surface to be made without much effort. Mortar epoxy coating is thought to be one of the strongest coatings that are available.

It can also be used as a repair material for concrete that has cracked. Self-dispersing epoxy floor coatings are extremely durable and can withstand constant use by heavy equipment like forklifts. It also has anti-slip characteristics.

Vapor-barrier epoxy coats can be utilized when the concrete is used as a foundation for flooring materials like carpet or hardwood. This is why it’s not the most popular option to use for concrete flooring in industrial settings however, it can be utilized in commercial spaces.

Anti-static epoxy coatings are used in areas that have large amounts of electrical equipment that could be susceptible to shocks from static. This kind of coating is utilized in static-sensitive settings, such as electronic manufacturing plants, hospitals, and laboratories, where maintaining a static-free atmosphere is critical.

Additionally, there are decorative elements to be considered:

Metallic epoxy coatings give the appearance of metals such as bronze, silver, or copper. The graveled epoxy floor coatings create the look of gravel or stonework. Epoxy terrazzo floors are known to be the most intricate design and can have extensive options. They are typically found on concrete floors that are industrial in reception areas for clients.

The liquid that is used to carry the epoxy coat must also be considered.

Solvent-based epoxy coatings are able to be spread thinly however, they should be installed in an area that is well ventilated. Water-based coatings can’t be considered to be extremely durable, however, they provide waterproof protection from stains.100 percent pure epoxy comes with no carry solution and is hard to put in and is better left to experts.

Other materials used to protect concrete floors in industrial environments

While epoxy is a well-known chemical used to protect concrete floors, it’s not the only choice:

While epoxy is a well-known chemical used to protect concrete floors, it’s not the only choice:

A methyl methacrylate (MMA) coat of acrylic gives a smooth floor that requires minimal maintenance. A cementitious urethane finish provides a unique antimicrobial solution for health facilities, restaurants, and food processing facilities.

Polyaspartic finishes stand out due to their speedy application. This is the ideal solution for industrial buildings which do not have the funds for regular maintenance on floors.

Additionally, it does not possess any odor, making it ideal for places that have poor ventilation. Thin-film urethane coatings offer excellent stain resistance even to the most abrasive chemicals and solvents. It is usually a clear topcoat that can enhance other floor coatings and decorative elements.

You are now aware of the many varieties of floor coatings for protection that is available, let us pick and install the best one to meet your needs in the industrial sector.

Key Takeaways

Epoxy, methyl methacrylate (MMA), polyurethane, polyurea, and polyaspartic are the most popular resins used in industrial floor coatings.

They’re employed in various designs to attain certain performance requirements. Typically, they are applied at a thickness of 8 to 10 mil to 1/4′′ depending on the project needs.

Concrete flooring’s porous surface allows water and soluble pollutants to infiltrate a structure, causing premature disintegration. Efflorescence, laitance, and physical defects such as cracking and spalling are all signs of concrete flooring degradation. Abrasion, stain, chemical, and freeze/thaw protection are among the features that concrete floor coatings can provide.

Acrylics, epoxies, polyurethanes, polyaspartic polyurea, and specialized elastomeric coatings are examples of coatings that can be effectively specified and utilized for concrete floors. Alkyd-based coatings should never be recommended for use on concrete because the alkyd resin may chemically react with alkaline concrete components and moisture, resulting in saponification. This reaction turns the resin into a soft substance that serves little purpose as a covering and offers no protection to the concrete substrate.

Acrylic sealers are often several millimeters thick and applied in two or three coats. They are either solvent or water-based chemicals. In most cases, solvent-based acrylic sealers are utilized on the exterior, while water-based acrylic sealers are employed on the interior. Concrete can be coated with a number of epoxy coatings. Epoxies are multi-component polymers that cure with a polyamide or amine. Polyamide epoxies are known for their greater flexibility and resilience to water, whereas amine-cured epoxies are noted for their superior chemical resistance. Epoxy systems are typically applied in one to three layers, with each coat having a thickness of a few mils. Concrete is also coated with thicker-film epoxy coatings, such as those based on epoxy phenol novalac resins. More frequently than not, Novolac epoxies are utilized to provide chemical resistance. Because epoxy coatings chalk/amber in sunlight, they should be top-coated with a finish coat of different resin chemistry. Polyurethanes are commonly used to cover them.

Because of their better abrasion and UV resistance, polyurethane coatings are commonly employed as topcoats over acrylics or epoxies. They can be combined with a cement-sand matrix to create extremely long-lasting polyurethane concrete flooring systems. The speedy return to service features of PU Concrete is well-known.

Elastomeric coatings are an excellent solution if exterior concrete needs further protection, especially against water infiltration such as wind-driven rain. Because elastomeric can tolerate some substrate movement and may be able to cover or “bridge” tiny cracks, they are a good match for concrete. Elastomeric coatings are flexible, thick (10 to 100 mils DFT), and have a low water permeability. They are most commonly used for outside concrete applications like building exteriors, roofing systems, and parking decks, but they can also be used for inside concrete applications like showers and spas. The many types of elastomeric coatings, such as acrylic, silicone, polyurethane, and polyurethane/polyurea hybrid, are based on a variety of resin chemistry.

Before applying any coatings on concrete surfaces, they must be thoroughly prepared. Mechanical abrasion or pressurized water cleaning are examples of preparation processes. Testing for moisture in the concrete may also be necessary, especially if there have been any previous issues. Concrete coatings can enhance the useful life of concrete in a variety of applications. Successful application necessitates the use of the proper surface preparation procedure and the selection of the suitable coating type based on performance requirements and service conditions.

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