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Epoxy Technical Hierarchy

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Epoxy Technical Hierarchy

by John R. Davis on March 17, 2015

I have been in the industrial floor coatings manufacturing, and application business for nearly 30 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.

EpoxyPRO is now based at the 'Tip of the MITT' near the beautiful Lake Huron in Cheboygan, Michigan. We originated down state near the home of the automotive capital of the world and many of its subsidiaries. EpoxyPRO’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.

Epoxy’s Technical Hierarchy

#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

Advantages

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:

  • Surface restoration and repair
  • Increased light reflectivity
  • Resists hot tire marks
  • Chemical resistant
  • Abrasion resistant
  • Industrial grade
  • Easy to clean
  • Slip resistant
  • Salt resistant
  • Oil resistant
  • Self leveling
  • High gloss
  • Aesthetics

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:

  1. Oil soaked, dirty, greasy, spalled, or cracked concrete floors must be degreased cleaned by a heavy concentrated degreaser followed by rinse bath. Repeat until satisfied.
  2. Fill all cracks with recommended cementitious cracker filler and/or any non-silicone base epoxy, polyurethane joint sealant that is paintable.
  3. Profile surface by recommended Mechanical method or chemical etch method.
  4. Purchase EpoxyPRO Oil Block Patch to cover oil saturated floors
  5. Some substrates may require additional product to attain full coverage due to being overly porous.

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.

EpoxyPRO– 2 PARTS EPOXY PRODUCT DESCRIPTION

TECHNICAL

EpoxyPRO 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.

BASIC USES

EpoxyPRO is recommended for several basic applications:

  • As a base resin used as a coating, to encapsulate wear resistant aggregates and as a lock coat.
  • As an overlay with aggregate, to provide traction and wear resistance to concrete floors. Filled with silica sand, aluminum oxide or other suitable wear resistant filler.

LIMITATIONS

  • EpoxyPRO should be installed above 40°F.

PACKAGING

  • Available in 3 Gallon, and 5 Gallon (Kit / units).

STANDARD COLORS

  • Light Gray
  • Tan
  • Dark Gray

INSTALLATION

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 EpoxyPRO Resin to a dry surface.

Coating System:

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.

PropertyTest MethodTest 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
% Yield   99.00%
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.  

Concrete Overlay:

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.

EpoxyPRO APPLICATION PROCESS

After completing the pre surface cleaning it’s as easy as 1, 2, 3.

MIXING

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.

APPLICATION

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.

DECORATIVE FLECK