by John Russell Davis on July 8, 2011
I have been in the industrial floor coatings manufacturing, and application business for over 24 years. Over the past two decades we have specialized in formulating floor coatings using a 100% solids resin based epoxy to be used in resurfacing industrial, commercial and residential concrete floors with our advanced “work time” epoxy formula that can be applied just like “Floor Paint”. Our business is to protect concrete flooring from contamination and wear and tear with our industrial grade epoxy floor coating system.
Epoxy PRO is based just north of Detroit Michigan, home of the automotive capital of the world and many of its subsidiaries. Epoxy PRO’s methods of concrete floor protection, using 100% solids resin based “floor paint”, have been a proven standard in the industrial floor market for all concrete floor coating needs from heavy manufacturing, commercial, institutional, and now for the first time ever as a “Residential” floor coating system for use in garage floors in your neighborhood.
Floor Paint & Floor Coating-An Image Rich Technical Analysis for Concrete Floor Protection
Since the inception of Epoxy Resin in 1936 by Dr. Pierre Castan of Switzerland and Dr. S.O. Greenlee of the United States, there have been thousands of combinations of Epoxy formulations for many different industries. Here are some of the leading industries that currently use Epoxy: Floor Paints and coatings, adhesives, industrial tooling and composites, electrical systems and electronics, consumer and marine applications, aerospace applications, art, and wind and energy applications. This article will be focusing on the floor paints and coatings industry, and what the best product is for its application.
Although there are many choices one can make when deciding which type of Epoxy to apply, one must understand that there is a clear and definite technical hierarchy. Below is a chart that ranks Epoxy for effectiveness.
|#1||100% Solids Resin based Epoxy||1 to 20 mils Dry Film Thickness (D.F.T.)||No solvents/no V.O.C.||2 Component with a 2 to 1 mix Ratio|
|#2||Solvent Base Epoxy||High Build 2 to 4 mils Dry Film Thickness (D.F.T.)||40 to 55% vol. solids with 45 to 60% Solvents Shrinkage and Evaporation||2 Component with a 1 to 1 ratio|
|#3||Solvent Base Epoxy||Low Build 1 to 2 Dry Film Thickness (D.F.T.)||30 to 40% volume solids with 60 to 70% Solvents Shrinkage and Evaporation||2 Component with a 1 to 1 ratio mix ratio|
|#4||Water Base Epoxy||1 to 1.5 mils Dry Film Thickness (D.F.T.)||30 to 40% vs. with 60 to 70% Shrinkage and Evaporation||2 component with a 1 to 1 mix ratio and or 1 component|
|#5||Water borne Epoxy||Same as #4||Same as #4||Same as #4|
|#6||Modified Epoxy sealer||1 to 2 mils Dry Film Thickness (D.F.T.)||5% Epoxy additive with approx. 30% of other active ingredients and fillers. 30 to 40% vs. with 60 to 70% Shrinkage and Evaporation||1 component moisture cured product|
|#7||Oil Base Acrylic Enamel (Porch and Deck Paint)||1 to 1.5 mils Dry Film Thickness (D.F.T.)||30 to 40% vs. with 60 to 70% Solvents Shrinkage and Evaporation||1 component moisture cured product|
|#8||Moisture cured Polyurethane Sealers||Same as # 6||Same as #6||1 component moisture cured product|
|#9||Acid Stains||No mil rating of thickness||Penetrating Sealer with concrete to chemical color reaction properties upon contact||1 component moisture cured product|
|#10||Water Base Stain||No mil rating of thickness||Penetrating water based stain sealer||1 component moisture cured product|
|#11||Standard Sealers:Applications for concrete patio’s, sidewalks, driveways, brick pavers and stampings.||NA||NA||1 Component|
100% Solids Epoxy (Resin base, Industrial Grade) epoxy floor paint floor coating is far superior to all other concrete floor paints, floor sealers and floor stains available today. 100% Solids Epoxy was developed as a “High performance protective floor coating” to protect concrete floor surfaces from high traffic volume of hilos (tires/steel forks )constant wear and tear to the concrete floors surface.
Along with wear and tear to concrete floor surfaces, mechanical machines and equipment also leak oils and fluids. Without proper concrete floor protection, such as the recommended 100% Solids Epoxy, these oils and fluids will be absorbed through the concrete and into the soil beneath, resulting in contamination and potential deterioration to the floor surface. Consequently, these oils and fluids in the soil can potentially lead to environmental concerns in the future.
Concrete surfaces are very porous and soft compared to the 100% Solids Epoxy floor paint. That being said, imagine the concrete surface acting as a big “sponge” that holds and retains water, fluids, dirt, oil, grease, dust, mold and other substances that absorb into a porous surface. Unprotected concrete floor surfaces will yield a decreased life span. 100% Solids Epoxy is a permanent solution to the problems listed above.
The following are other very important advantages when using 100% Solids Epoxy floor paint:
CONCRETE SURFACE PREPARATION
Concrete Floor surface preparation For New or Old Concrete Floor surfaces must be clean contaminate free and profiled (etched) for proper bonding/adhesion of 100% solids epoxy floor paint & floor coating.
NEW CONCRETE FLOORS:
Contaminate free concrete floors must be mechanically surface profiled by either a diamond grinder or a shot blaster or chemically etched with a recommended 4 to 1 part ratio acid base or “Inorganic Acid” concrete cleaner and etcher.
OLD CONCRETE FLOORS:
100% Solids Epoxy Resin Base Industrial Grade is the only choice for concrete floor protection to paint your garage, shop, and basement or for any indoor concrete floor surface that you desire.
See below: List of all other products available for concrete floors in today’s market, starting with the best product at the top of the list which is (100% Solids Epoxy) followed by their rating of performance levels from wear and tear to mil thickness and chemical resistance.
Epoxy PRO Floor Coating is a two-component epoxy resin, containing no solvents or coal tar. EpoxyPRO Epoxy Resin is designed for use in both interior and exterior (if top coated) applications.
Epoxy PRO is recommended for several basic applications:
Available in 3 Gallon, and 5 Gallon (Kit / units).
Diamond grinding must be employed to provide a sound, clean substrate. In areas where shot blasting is not feasible, consult the manufacturer for other methods of surface preparation such as concrete acid etching / cleaning.
Apply Epoxy PRO Resin to a dry surface.
Parts A and B should be mixed separately before combining. When combined mix thoroughly with a low speed motor and “Jiffy” paddle, always scrape the container sides and paddle blades. Do not aerate the mix.
Mix ratio: 2 Part A to 1 Part B by Volume.
|Property||Test Method||Test Results|
|Weight per Gallon||10.1 lbs/gal.|
|Hardness (Shore D)||ASTM D2240||70-80|
|Viscosity @ 77°F(24°C)||ASTM D2196||2000-5000 cps|
|Cure Time @ 75°F(24°C)||ASTM C920||12-24 hours|
|Abrasion Resistance||ASTM D4060
Tabor 1000 rev
CS17 Wheel, 1000 g
|Loss 0.08 grams|
|Weathering Resistance||ASTM G53-83||Yellowing|
|Tensile Strength||ASTM D412||5800 psi|
|Ultimate Elongation||ASTM D412||15.00%|
|Tear Resistance||ASTM D1004||180 pli|
|Port Life @||ASTM C603||45 minutes|
|Shelf Life @ 77°F(25°C)||(2 years in sealed containers)|
|Chemical Resistance||Unaffected by gasoline, oils, and coolants.|
Use as a slurry coat to add strength and wear resistance. Mix Parts A & B, then add fine silica sand, aluminum oxide or other suitable filler. The amount added will dictate the resulting density and surface texture.
EpoxyPRO Resin can be left as cured, or it can be top coated with a urethane to enhance the color and wear resistance.
EPOXY PRO APPLICATION PROCESS
After completing the pre surface cleaning it’s as easy as 1, 2, 3.
Pre-mix the Part A resin thoroughly. Pour Part A and then Part B into the 6-gallon bucket (Ratio:2 parts A to 1 part B by volume). Begin mixing for no less than 3 minutes using a drill motor and the included mixing wand.
Trim all the edges using the included 2 inch trim brush. Squeegee and back roll 3 to 5 foot sections until the surface area is complete.