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Floor systems

Epoxy resin flooring systems

Eight systems, from primer and body coat through to the full range of topcoats — specified against the mechanical strength, chemical resistance and cleanliness the facility actually requires.

Topcoat 0.3 Body coat (structure) 1–3 mm Primer 0.1 Concrete substrate
Three-stage build-upDetail C-01
Systems

Eight systems

The first two are common to every build-up; the remaining six are selected or combined according to requirement.

Primer systemsBody coat systemsThin-build topcoat systemsSelf-levelling systemsClear topcoat systemsAnti-static systemsWater-based systemsStructural repair products
01

Primer systems

Substrate penetration and sealing An epoxy primer penetrates the concrete substrate, bonds tightly to the base layer and seals the capillary structure, raising the adhesion of the whole floor.

An epoxy primer penetrates the concrete substrate, bonds tightly to the base layer and seals the capillary structure, raising the adhesion of the whole floor. Once the substrate is prepared, the primer is roller-applied across the full area before the body coat and topcoat. Solvent-based and solvent-free grades are available according to substrate condition, with a dedicated formulation for low temperatures.

Characteristics
  • Penetrates and seals capillaries, preventing blistering in the layers above
  • Substantially improves adhesion of the system to the base
  • General and low-temperature grades available
  • High-adhesion grades suit difficult or aged substrates
Applications

All cementitious substrates; sealing prior to refurbishment of an existing floor

Reference
ApplicationRoller
PositionFirst layer, before the body coat
02

Body coat systems

Structural layer The body coat is the structural core of the floor, providing thickness, flatness, mechanical strength and impact resistance.

The body coat is the structural core of the floor, providing thickness, flatness, mechanical strength and impact resistance. It can be applied in stages to build 1–3 mm, or as a high-filler grade for greater thickness above 4 mm. It is also where overall cost is controlled — thickness is established here rather than by stacking expensive topcoat material.

Characteristics
  • Improves flatness, thickness and mechanical strength
  • Raises impact and abrasion resistance
  • Reduces overall material cost
  • Colour can be matched close to the topcoat so local wear is less visible
Applications

Factories, warehousing and car parks where loading and impact resistance matter

Reference
Thickness1–3 mm applied in stages; 4 mm and above with high-filler grades
PositionAfter the primer, before the topcoat
03

Thin-build topcoat systems

The most widely used finish Thin-build topcoats are straightforward to apply, give a smooth attractive finish, offer a wide colour choice and are reasonably priced, making them the most widely used finish.

Thin-build topcoats are straightforward to apply, give a smooth attractive finish, offer a wide colour choice and are reasonably priced, making them the most widely used finish. They effectively prevent dusting and suit facilities that want a good appearance without cleanroom standards. Normally roller-applied; on large areas, pot life and labour allocation need planning.

Characteristics
  • Easy to apply with a short programme
  • Wide colour choice; areas can be colour-coded
  • Prevents dusting and improves the working environment
  • Good abrasion resistance for frequent vehicle and foot traffic
Applications

Car parks, general factories, garages, warehousing

Reference
ApplicationRoller
CharacterThin film; the most economical in cost and programme
04

Self-levelling systems

Seamless smooth finish Self-levelling systems offer excellent adhesion and surface smoothness, high gloss and good water and chemical resistance, forming a seamless monolithic finish.

Self-levelling systems offer excellent adhesion and surface smoothness, high gloss and good water and chemical resistance, forming a seamless monolithic finish. The material must be trowelled evenly in a single operation, with strict control of pot life and labour allocation; large areas must be zoned and planned in advance.

Characteristics
  • Smooth and seamless, reducing contaminant adhesion
  • High gloss and good visual quality
  • Good water and chemical resistance
  • Easy to clean; suits facilities with high cleanliness requirements
Applications

Hospitals, pharmaceutical and electronics plants, food factories, cleanrooms, schools, offices

Reference
CoverageNot less than 0.8 kg/m²
ApplicationTrowel; requires zoning
05

Clear topcoat systems

Retains the existing appearance A clear topcoat forms a protective layer over the floor with high gloss, transparency, strength and acid and alkali resistance.

A clear topcoat forms a protective layer over the floor with high gloss, transparency, strength and acid and alkali resistance. It does not alter the appearance beneath, so it suits spaces where the existing floor character is to be retained while adding protection — commonly over terrazzo and decorative floors.

Characteristics
  • High gloss and transparency; original appearance unchanged
  • High strength with acid and alkali resistance
  • Protective layer for decorative floors
  • Solvent-free grades available
Applications

Hotels, residential, design studios, offices, pharmaceutical and food facilities; terrazzo and display spaces

Reference
ApplicationRoller or trowel
PositionFinal layer
06

Anti-static systems

Static charge dissipation An anti-static floor dissipates static charge accumulating at the surface, preventing sparking.

An anti-static floor dissipates static charge accumulating at the surface, preventing sparking. The system comprises a conductive primer, anti-static body coat and anti-static topcoat, installed together with an earthed copper foil grid to form a complete conductive path. The materials also provide the gloss, impact, chemical and abrasion performance of a conventional floor.

Characteristics
  • Dissipates surface static charge and prevents sparking
  • Requires an earthed copper foil grid to complete the path
  • Combines gloss, impact and chemical resistance
  • Trowel or spray grades available
Applications

Semiconductor and electronics plants, server rooms, hazardous areas, instrument facilities

Reference
SystemConductive primer + anti-static body coat + anti-static topcoat + earthed copper grid
NoteEarthing workmanship directly determines performance
07

Water-based systems

Low odour, environmentally responsible Water-based epoxy flooring is designed as an environmentally responsible option: no VOC, low odour, good appearance and sound cure characteristics.

Water-based epoxy flooring is designed as an environmentally responsible option: no VOC, low odour, good appearance and sound cure characteristics. Water-based epoxy is more sensitive to temperature and humidity, so ventilation must be confirmed; application below 10°C is not recommended as it compromises the cure. Mixing must be by powered stirrer and the material used within its pot life.

Characteristics
  • No VOC and low odour; suits facilities that cannot close for long
  • Good appearance and cure characteristics
  • Better tolerance of damp conditions
  • First choice for basements and poorly ventilated spaces
Applications

Food, electronics, pharmaceutical, cosmetics and paper plants; underground car parks and other ventilation-limited spaces

Reference
TemperatureNot recommended below 10°C
NoteConfirm adequate ventilation in the work area
08

Structural repair products

Making good and strengthening Substrate defects must be resolved before flooring is applied.

Substrate defects must be resolved before flooring is applied. This range covers repair and strengthening materials for cracks, spalling, honeycombing and areas of insufficient local strength. Applying a floor over unresolved substrate defects is one of the most common causes of failure.

Characteristics
  • Treats cracks, spalling and honeycombing
  • Strengthens areas of insufficient local strength
  • Essential preparation before the flooring system
Applications

Refurbishment works; substrate preparation before floor renewal

Reference
TimingBefore the flooring system is applied
FAQ

Frequently asked questions

What is the difference between epoxy and PU flooring?
Epoxy offers better hardness, abrasion resistance and chemical resistance, but lower flexibility and less ability to bridge substrate movement than PU. PU floors are more elastic and tolerate thermal movement better, suiting facilities with temperature variation or requiring some resilience, such as cold stores and food plant washdown areas. General factories, car parks and cleanrooms are predominantly epoxy.
What condition does the substrate need to be in?
Three factors: moisture content, flatness and strength. Epoxy is highly sensitive to moisture, and an over-wet substrate leads to blistering and delamination. Dusting surfaces, oil contamination or failed coatings must be ground off or removed. Areas of low strength, cracking or honeycombing should be made good with repair materials first. This preparation takes a significant share of the programme, and cannot be skipped.
How thick should the floor be?
It depends on loading and use. Light office use is served by a thin-build topcoat; factories with forklifts, racking or heavy vehicles need body coat thickness as the priority, built up to 1–3 mm in stages or above 4 mm with high-filler grades. Insufficient thickness leads to crushing or delamination at load points.
How long does the facility need to close?
It depends on the system and area. Thin-build systems have the shortest programme; self-levelling and anti-static systems involve more layers, each requiring cure time, so take longer. In practice work is usually phased so the facility can remain partly operational. Cure times must be built into the programme — compressing intervals to save time is a frequent cause of failure.
Our underground car park is poorly ventilated. Is there a suitable material?
Yes. Water-based epoxy systems have no VOC and low odour, making them the first choice for ventilation-limited spaces. Note that water-based epoxy is more sensitive to temperature and humidity; application below 10°C is not recommended, and ventilation should still be confirmed during installation.
Do food plants have particular requirements?
Food plants are among the most demanding environments, combining hot washdown, fats, organic acids and frequent cleaning. Thermal and chemical resistance specifications should be confirmed explicitly, and a seamless self-levelling system is preferred to reduce contaminant adhesion. Falls to drainage and detailing around gullies should be planned at the same time.

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