Specification Guide
Specification Guide to Selection, Preparation, Application & Maintenance of Epoxy Composition Surfacing Systems
System Overview
This section contains sample performance profiles for three different types of epoxy coating and topping systems:
Flexible Epoxy
For crack bridging, impact absorption, and application over substrates with high deflection or vibration.
Semi-Rigid Epoxy
For general purpose floor topping and coating.
Rigid Epoxy
For applications under more severe chemical exposure or higher temperature.
The above three basic types provide the tools required for achieving most flooring objectives. In cases involving special requirements, the designer should consult with a technical specialist.
System Selection Factors
Aesthetics
(Check One)
- Color granule pattern
- Solid color coating
- Clear finish
Texture / Safety Flooring System
- Light anti-slip finish in pedestrian traffic areas
- Decorative anti-slip finish
- Coarse finish for pneumatic tire vehicular traffic in wet areas
- Surfaces subject to extreme heavy traffic and abrasion
- Untextured (Dry areas)
Flexibility
High flexibility is required in some areas, especially around drains and at coved bases so movements, temperature changes and impacts won't crack or chip the surface. Flexibility is also required to reduce tendency for subsurface cracks to transmit to the surface, causing it to crack. In addition, some structures undergo high vibration or deflection and require a more flexible system to prevent cracking.
If the floor develops surface cracks or chips, contamination can be drawn into the matrix or into the subsurface causing further deterioration and an unsanitary environment.
Rigid systems are required for higher chemical resistance, higher scratch resistance, and to efficiently transmit loads to the rest of the structure in situations where the system has a structural role, such as in repair of columns, structural slabs and piers.
Chemical Resistance
The ability of the floor system to withstand exposure to cleaning compounds, water, or other materials being handled in the particular subject environment.
Knowledge of the particular chemicals to which the floor system will potentially be exposed, as well as their concentrations and temperatures is a critical factor in proper floor system design.
Pitch
A slope given to the floor toward drains, so that cleaning and rinsing water doesn't stand and allow bacteria to breed, will help determine whether a trowel-grade mortar must be installed as part of the flooring system.
Sloping with concrete is less expensive than sloping with epoxy mortar, and is preferred when under new construction, but in restoration work the time delay for concrete curing (28 days) may not be possible.
Coved Bases
These are given to wall/floor joints, and are required in sanitary areas such as food processing plants or laboratory animal rooms so that contamination doesn't stand in corners of floor.
Structural
Maximum expected service load must be calculated, and flooring system design capacity should be at least three times this anticipated maximum or as otherwise required by State and local building codes. This includes evaluation of not only the type of traffic (heavy vs. light) expected, but also subfloor strength, its structural supports, all static and dynamic loads, as well as the strength of the epoxy composition floor system itself.
In renovation or restoration projects, the condition of the substrate and the need for any structural repairs must be considered.
Heat
Most standard epoxies soften at 80°C. Service exposures in excess of this range require the use of harder, higher temperature resistant epoxies.
Thermal Shock
Rapid temperature change creates stresses which must be considered in a number of applications, including:
- Coolers and freezers
- Floors which will be hot water washed or steam cleaned regularly
- Floors near heat-releasing equipment which operates intermittently
- Exterior applications subject to wide temperature swings
Sanitation / Permeability
While surface texture also impacts on ease of cleaning, permeability is the single most important factor affecting both sanitation and rates of deterioration of surfacing systems and concrete subsurfaces.
The ratio of the polymer to aggregate/filler is the most important factor in achieving a non-porous, impenetrable surfacing system.
V.O.C.
Environmental Requirements — Volatile Organic Compounds content (V.O.C.) is regulated in many areas by law. Therefore 100% solids coatings should be preferred.
Thickness / Film Build
The number and types of coatings used will determine overall system build or thickness. Some common types include: