Seamless Epoxy Flooring Systems Explained

August 25, 2014

Epoxy.com offers many different types of seamless flooring. We offer so many kinds that sometimes it confuses people. The purpose of this article is to explain the differences, and to help you choose the right epoxy seamless flooring system for your application. In some cases the right seamless flooring system will not even be an epoxy. It may be polyurethane or Methyl Methacrylate (MMA).

Epoxy.com Epoxy Chip Flooring in VT rest area.

Epoxy.com Epoxy Chip Flooring on a VT Interstate Rest Area – Taken over 15 years after installation.


Epoxy Floor Coatings

Epoxy coatings can be effective flooring systems. Using Epoxy as a flooring system you need a 100% solids, zero voc, hard durable coating. You also want a coating that is available in multiple colors. These floor coatings can last for decades, so you want to pick a color that you like. Properly installed you will be looking at this floor coating for a very long time. This kind of flooring system is available in the following options:

  1. Epoxy.com Product #1 – www.epoxy.com/1.htm – meets all the criteria above. It has good chemical resistance, and excellent cost to benefit ratio. Great for warehouses, in areas with high traffic and only modest chemical exposure.
  2. Epoxy.com Product #1ESD – www.epoxy.com/1esd.aspx. This is the same as product #1 above but has conductive filler in it. Depending on the primer you use under this system it can be conductive (100,000 – 1,000,000) ohms of resistance or Electro-Static Dissipative (ESD) which is 1,000,000 to 1, 000,000,000 ohms. Used in plants that produce explosive materials like ammunition, fireworks, flairs, or explosive solvents, and used in areas of sensitive electronics, like computer server buildings, avionics, electronics assembly and electronic production areas.
  3. Epoxy.com Product #2 – www.epoxy.com/2.aspx. This is similar to product #1 but with a much higher chemical resistance. This major increase in chemical resistance is offset by only a small increase in the cost of the #2 over the Product #1. The product #2 is well suited for applications like garages, machine shops, sewer tank floors, battery rooms, cooling towers, grooming shops, dog kennels and all areas where an economical chemical resistant coating is required.
  4. Epoxy.com Product #633 – www.epoxy.com/633.aspx – is a highly chemically resistant epoxy floor coating and flooring system. Like Product #1 and Product #2 is extremely durable. Product #633 is typically used in areas where containment of aggressive chemical is imperative. For example Product #633 will hold up to continuous exposure of 98% Sulfuric acid for a period of at least 6 months without loss of structural integrity. Great for secondary containment for a large number of chemicals.

     

All the systems above can go over many different types of substrates with the proper surface preparation. All of the products above are available in 17 colors and can be color matched for an additional cost. The systems above can be combined with various anti-skid materials or broadcast with silica broadcast aggregate to produce a thicker floor

 

Chip Floor

Epoxy.com Chip Flooring – www.epoxy.com/chips.aspx – is the perfect blend of economy, durability, low maintenance, and gorgeous appearance. It uses a 100% solids pigmented epoxy base coat, a full broadcast of plastic chips, and two coats of chemical resistant clear glaze. The chemical resistant glaze also makes this easily the most non-yellow epoxy top coat available today. This easy to clean chip flooring system is best for high traffic areas where appearance, durability and low cost of ownership is a must. Great for commercial and residential kitchens, bathrooms, showers, grooming shops, kennels, veterinary clinics, garage floors, show rooms, rest areas, and much more. This product can be installed with an integral cove base. Epoxy.com Chip Flooring can be installed by a contractor but easy enough to be installed by a home owner. Epoxy.com Chip Flooring can be installed in a residence but is rugged enough to be used in the most demanding commercial applications.

Quartz Flooring

Quartz Flooring Product #15 – www.epoxy.com/15.aspx has a long history of being durable, attractive and non-yellowing. I personally installed this product on high school bathroom floors in the mid 70s. These floors have held up to the test of time with little or no wear, little or no loss of shine and little to no yellowing even under the urinals. This is also available with an integral cove base

Solid Colored Flooring

These solid colored floors are based around self leveling, trowelable or double broadcast application techniques. These floors are sometimes called shop floor. They are made to be thick and extra durable under extremely harsh environments. They can be top coated with any of the systems above under coatings. This kind of flooring is available in 3 speeds of cure: normal, fast, and cold cure. Solid colored flooring is also available with an integral cove base.

Methyl Methacrylate (MMA) Flooring

The big advantage of MMA is speed of curing. Each coat of MMA will cure hard to the touch in 1-2 hours. This allows the next layer to be applied quickly and traffic to be returned to it quickly. You can even build a fast setting integral cove out of MMA resin.

I personally installed MMA on one kitchen floor with a very tight schedule. The restaurant was only closed for breakfast. The project started with rotten plywood floors. At 10 PM the carpenters came in to work. They removed rotten floor and floor joists. They replaced the floor joists and the plywood. At 5 AM I went in with my crew and we primed the floor and sealed up the joints in the wood and the screw holes. At 6:30 AM we laid the floor. At 8 we put a glaze coating on the floor and by 10:30 the restaurant workers were on the floor prepping for lunch. The floor installation from start to traffic took just 5.5 hours.

Polyurethane Decking Systems

Polyurethane Decking – http://www.epoxy.com/elastomeric.aspx – is the system best used in areas where maximum flexibility is necessary. This is typically outdoors, waterproof applications like balconies.

Specialized Flooring

We have a number of systems that are specialized flooring like conductive and ESD (Electrostatic Dissipative) flooring – www.epoxy.com/conductive.aspx – and various hybrid systems. If your project does not seem to fit in the categories above email me at norm@epoxy.com or call us at 352-533-2167.

 

In conclusion we offer many types of seamless flooring systems, they can be used for commercial and residential applications. These systems are durable, economical, and easy to install even by homeowners. These seamless flooring systems may be made out of epoxy, polyurethane, or methyl Methacrylate (MMA). Seamless flooring systems are available in multicolored or solid colored. They range in chemical resistance from very good to resistant to aggressive chemicals. When in doubt what is right for your project send me an email at norm@epoxy.com or give me a call at 352-533-2167.


Repairing Floors with Epoxy Mortar Resin

August 8, 2014
epoxy-Deck-after-2

Epoxy Patching Mortar #10 for patching. Coated with Urethane Decking System #495.

Epoxy.com Product #10 is a versatile resin for use in epoxy floor patching. Product #10 comes in standard cure, fast cure and cold cure. It can be used with 3 different aggregates: self leveling, mortar blend, and broadcast aggregate. Product #10 is available in 15 colors plus black and white making a total of 17 colors available. Custom colors are available at a small additional cost.

The Epoxy Cures

Normal Cure at 77 degrees F. has a pot-life (the usable time after mixing) of about 30-40 minutes. It hardens to the touch in about 10-12 hours. Normal Cure should never be used below 50 degrees F.

Fast Cure at 77 degrees has a pot life about 15-20 minutes. It hardens to the touch in about 5-6 hours. At 50 degrees F the Fast Cure hardens to the touch in 10-12 hours. In other words the Fast Cure at 50 degrees will cure as fast as normal cure at 77 degrees F.

Cold Cure at 77 degrees F. has a pot-life of about 8-10 minutes. It sets hard to the touch in about 2.5 to 3 hours. At 50 degrees F the cold cure will typically cure in 5-6 hours. It is able to cure at temperatures as low as 35°F.

The Aggregates

The aggregates come separately from the Product #10 resin and hardener. That allows you to be able to use a unit of resin with multiple aggregates making the system even more versatile.

Mortar Blend Aggregate Product #82 is the work horse of floor patching. You can get up to 50 lbs or more of Product #82 into a mixed gallon of #10 epoxy mortar. This is ideal for deep patching.

Self Leveling Filler Aggregate Product #78 is used for self leveling applications, typically in thicknesses of 1/16 inch plus or minus. This is ideal where a thinner flat overlay is required. A typical use would be where a floor needs to be leveled. Another typical use would be for a “scratch coat” which is where you are trying to cover large amounts of chips and divots in the floor.

Broadcast Aggregate Product #77 is broadcast into wet #10 in order to produce an anti-skid surface. It can be broadcast into a neat coat (just the resin and hardener mix without the aggregate) of #10 or into the Mortar Blend Aggregate or Self Leveling filler systems above.

In addition to being able to mix the #10 with the fillers above, you can also mix it with Product #71 Fumed Silica to make a paste for cracks and other small imperfections.

 

In summary the Epoxy Mortar Resin Product #10 is a versatile epoxy mortar system available in many colors, several cures and different fillers for different purposes. This makes Product #10 an important part of your floor repair tool chest.

 

Additional Information:

Product #10 Lo-Mod Epoxy Adhesive and Mortar Epoxy Binder is a 100% solids epoxy has a low modulus of elasticity (flexibility) and is Low Viscosity. An adhesive used as a binder for epoxy mortar systems in patching and grouting applications, as a seal coat for non-skid surfaces outside, and as a primer to insure high bond strength for coatings and patches.

System #495 Elastomeric Polyurethane Traffic Membrane System– is an Elastomeric Urethane Membrane System, that is liquid applied. System #495 Elastomeric Polyurethane Traffic Membrane System is seamless, elastomeric (flexible), and UV. Thee qualities make it an excellent choice for outside applications in direct sun and weather, where water tightness, durability, and excellent appearance is required. Its elastomeric properties will allow horizontal movements up to 1/8 inch without breaking. System #495 Elastomeric Polyurethane Traffic Membrane System has excellent abrasion and chemical resistance. The surface of System #495 Elastomeric Polyurethane Traffic Membrane System can be varied to achieve the required anti-skid and decorative look.


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