All applications, from high-traffic coatings to chemical-resistant Novolac and structural heavy-duty epoxies, are governed by industrial epoxy specifications that require specialized systems, rigorous substrate preparation, and application controls.
These materials have to be 100% solids, solvent-free, and specially engineered for high standards of adherence, hardness Shore D > 75, and impact resistance for long-lasting performance under difficult conditions in industry.
Specifications for industrial epoxy floor coatings are very detailed, encompassing substrate condition, application environment, material composition, and required performance properties.
Epoxy Flooring Specification Examples (Types and Applications)
Epoxy guide specifications cover a wide range of industrial needs, including:
- High Traffic/Abrasion Resistance: Systems like the Epoxy High Build Floor Coating (Product #1) are specified for high foot traffic and light to moderate forklift traffic areas, offering abrasion resistance and protection against mild corrosion.
- Chemical Resistance: Specialized Chemical Resistant Epoxy Coatings (Product #2 or Novolac Epoxy Product #633/Product #676) are designed to protect concrete, steel, and other materials from non-oxidizing acids and alkalines.
- Specialized Functional Needs: Specifications exist for Electrostatic Dissipative (ESD) Epoxy Coatings (Product #1ESD), systems for walls (Product #1W), seamless quartz flooring (Product #15), and seamless waterproof epoxy flooring with crack isolation for mechanical rooms.
- UHV Lab Specification Example: A specific project required an Epoxy Urethane floor system for an Ultra High Voltage (UHV) laboratory. This system was designed to handle a total distributed load of 25 tons across the area, facilitate load movements on air casters, and offer resistance to absorbing water, oil, and industrial chemicals.
Industrial Epoxy Floor Coating Specifications for Concrete (Substrate Requirements)
For optimal application on concrete substrates, stringent structural and moisture conditions must be met:
| Concrete Requirement |
Specific Value/Criteria |
|
| Compressive Strength |
Must be at least 25 N/mm² |
|
| Surface Tensile Strength |
Must be at least 1.5 N/mm² (verified using a tensile tester/Pull Off Tensile Tester) |
|
| Curing Time |
At least 4 weeks should pass after pouring the concrete, although this depends on the season and ambient conditions. Concrete should be completely cured (typically 28 days). |
|
| Concrete Moisture Rate |
Must be below 4% by weight unconditionally. If this cannot be achieved, different primer and coating systems must be considered. |
|
Surface Preparation Requirements
Surface preparation is critical for adhesion and longevity, aimed at removing weak layers and ensuring a clean, porous substrate.
- Smoothing and Hardening: The reinforced concrete surface should be smoothed properly during troweling, and a smooth, level surface should be obtained. Surface hardener will not be used when pouring field concrete where epoxy is applied.
- Laitance and Abrasion: Cement laitance (weak slurry layer) must be removed using abrasive equipment to make the surfaces open porous. High places must be abraded, sanded, and cleaned.
- Cleaning Method: Surface preparation should ideally be done with a vacuum ball blasting machine (Shot Blasting-Blastrac) to achieve sufficient primer absorption. Hand spirals are allowed only where the vacuum ball blasting machine cannot enter.
- Contaminant Removal: All loose particles, oil, grease, and dirt must be removed. If oil has soaked into the floor, a burning procedure may be carried out (if required) until the floor becomes bright white to ensure good bonding.
- Repair Work: Potholes and cracks must be filled and leveled. Cracks and expansion joints require a suitable crack seal compound that has expansion and compression properties based on the surrounding temperature.
Epoxy Flooring Thickness in mm (A Detailed Example)
epoxy flooring technical specification for the UHV Laboratory mandates a robust multi-layer system with a total minimum thickness of 5mm:
| Layer |
Material Type |
Thickness (Microns) |
Thickness (mm) |
Purpose |
| Total System Thickness |
Epoxy Urethane Floor System |
5,000 microns |
5 mm |
Heavy duty industrial screen flooring. |
| Primary Coat |
Two-component full solids coating (Low viscosity, clear epoxy primer) |
200 microns |
0.2 mm |
Maximum bond potential onto the concrete surface. |
| Screed Coat (Base lining) |
Three-component solvent-free epoxy urethane urea screed |
~3,000 microns |
~3.0 mm |
Heavy duty industrial screening; fills potholes/dents and levels undulation. |
| Top Finish Coat |
Two-component epoxy urethane urea coating / Self-leveling compound |
~2,000 microns |
~2.0 mm |
Final seal and smooth surface finish. |
A general guide for self-leveling applications suggests a minimum yield of $\pm$1.55 kg/sqm/mm (pure material).
Epoxy Flooring Requirement (Material Performance & Application)
Material Composition Requirements:
- Primer: Must be a resin rich composite with low viscosity, clear epoxy primer for maximum bond potential. Consumption is typically 300–500 gr/m², applied with a roller or trowel.
- System Integrity: Must be a 100% solids system with a top coat for the final seal.
- Flexibility: Must be a flexible modified epoxy suitable for crack bridging, impact absorption, and application over substrates with high deflection or vibration.
- VOC/Solvents: Materials, including the primer and topcoat, must be solvent-free. Systems can achieve a 100% solids content and sometimes zero (0) VOC.
Application Environment Requirements:
- Temperature: Ambient and concrete surface temperature should be between +10 °C and +30 °C. A broader range of 5°C to 35°C (substrate) and 5°C to 30°C (environment) is also specified for some materials.
- Moisture: Relative humidity in the environment should be less than 80%, and below the dew point (condensation temperature).
- Curing Times (Example): After application, surfaces must be protected from moisture, dust, and air flow. Pedestrian traffic may be allowed after 24 hours, or 48 hours, with full curing taking approximately 7 days.
Performance Properties (Measured Standards):
Epoxy floor coatings are tested against various standards:
- Hardness: Shore D hardness should be greater than 75 at 7 days.
- Adherence Resistance: An example value of 3.6 MPa is achieved under UNE-EN 13892-8.
- Impact Resistance: Products are required to exhibit impact absorption. One tested system showed no damage at a 1500 mm drop (with a crater diameter of 4.2 mm), achieving an impact resistance of >14.7 Nm.
- Operational Temperature Range: The finished floor may be subject to a use temperature range of -20°C to 80°C.
- Other Properties: Material properties such as water absorption, tensile strength, compressive strength, linear shrinkage, and density must be specified as per relevant standards.
