Systems and resins for industrial epoxy flooring
RV NEORESINS develops systems and resins for epoxy floors in factories, warehouses, workshops, car parks, laboratories and other facilities subject to professional use.
The solution is defined according to substrate condition, mechanical loads, chemical exposure, cleaning conditions, slip risk and the required finish. Before selecting a product, the floor must be considered as a complete system, from concrete preparation to the final coat.
Assessment of the concrete substrate
Floor performance depends greatly on the quality and preparation of the substrate. The concrete must have sufficient strength, be cohesive and be free from dust, laitance, oils, grease, poorly bonded paint and other contaminants.
Moisture, cracks, joints, surface flatness and possible water pressure from the ground must also be checked. Applying a resin without identifying these factors may cause loss of adhesion, blistering, cracking or finishing defects.
Mechanical preparation
Depending on floor condition, sanding, shot blasting, milling or diamond grinding may be used. The aim is to remove weak layers and create a clean surface with a suitable profile for the primer.
Epoxy primers
The primer promotes adhesion between the concrete and subsequent layers, helps consolidate the surface and reduces pores and bubbles. Its viscosity and penetration capacity must be adapted to substrate porosity and condition.
Substrates with residual moisture or difficult conditions require a specific assessment. System compatibility must be checked through measurements and tests on a representative area before covering the full surface.
Types of epoxy flooring
Thin-film epoxy coatings
Thin-film coatings protect surfaces and make cleaning easier when substrate irregularities are limited and mechanical requirements do not demand a high thickness.
They can be applied in several coats and formulated in different colours. Consumption, preparation and number of coats must be defined according to porosity, traffic and the required finish.
Self-levelling epoxy floors
Self-levelling systems create continuous, smooth and easy-to-maintain surfaces. They are used in industrial areas, warehouses, laboratories and spaces requiring a uniform finish.
Performance depends on thickness, application temperature, mixing ratio and the time between coats. Application at excessively low temperatures, incorrect mixing or moisture can affect levelling and curing.
Multilayer and anti-slip systems
Multilayer floors combine resin with broadcast aggregates to increase thickness, improve wear resistance and create different textures. They are suitable for traffic areas, ramps, workshops and places where slip risk must be reduced.
The size and quantity of aggregate, together with the number of sealing coats, determine final roughness and ease of cleaning.
Epoxy mortars for repairs and heavy loads
Epoxy mortars are used to repair spalling, level damaged areas, form coves and install floors subject to high mechanical loads. The resin-to-aggregate ratio must be adjusted to provide suitable workability, compaction and strength.
Mechanical, chemical and thermal resistance
The system must be selected according to pedestrian or vehicle traffic, impacts, abrasion and point loads. Greater thickness does not replace correct preparation and does not in itself guarantee better performance.
Where chemicals are present, the substances, concentrations, temperatures, exposure frequency and duration must be identified. Resistance can differ greatly between an occasional spill and immersion or continuous contact.
Conventional epoxy floors have limitations under certain thermal shocks and outdoor exposure. For special conditions, complementary polyurethane, polyurethane-cement or aliphatic finishes can be considered.
Finish, colour and safety
Systems can be formulated in different colours and gloss levels. Aggregates or fillers can also be added to modify texture, appearance and anti-slip performance.
The finish must balance safety with ease of cleaning. A very rough surface may improve grip, but it can also retain more dirt and require more intensive cleaning methods.
Application and curing control
The mixing ratio, homogenisation time and pot life must be respected throughout application. Once the components are combined, the reaction generates heat and the available time decreases, especially while the product remains concentrated in the container.
Air and substrate temperatures, ambient humidity and dew point affect adhesion and finish. Each coat must be applied within its recoat window and onto a clean surface.
The floor must not be put into service before it reaches the required degree of cure under the existing environmental conditions.
How to select the right system
At a minimum, the following information should be gathered when specifying an industrial floor:
- Condition, strength, age and moisture content of the concrete.
- Total area and available thickness.
- Pedestrian traffic, forklifts, vehicles and point loads.
- Chemicals and cleaning procedures.
- Working temperatures and possible thermal shocks.
- Need for a smooth, anti-slip, matt or gloss finish.
- Time available for installation and reopening the facility.
Formulations for manufacturers and applicators
RV NEORESINS can adjust viscosity, reactivity, working time, colour and application behaviour for manufacturers and professional applicators. We also study primers, self-levelling layers, mortars and finishes as parts of a compatible system.
We offer epoxy resins and solutions for construction applications that can be adapted to different manufacturing and installation processes.
Preliminary testing and technical support
Before installing a complete floor, we recommend inspecting the substrate and carrying out a trial under representative conditions. This allows adhesion, consumption, appearance and intercoat compatibility to be assessed.
If you need to develop or select a system for an industrial floor, contact RV NEORESINS and describe the substrate, service conditions and finish you require.