Ultimate Guide To Epoxy Flooring
Introduction to Epoxy
Epoxy is an organic compound made up of carbon chains linked by hydrogen, oxygen, or nitrogen. A covalent bond is formed when two of these elements exchange electrons to form a molecular connection. The term “epoxy” has several practical applications. It can describe an epoxide functional group, a chain of carbon and oxygen atoms. Functional groups regulate the characteristics of molecules during chemical processes, therefore molecules with the epoxide functional group can combine to create a highly hard but flexible material.
The term “epoxy” can also be used to describe the cured epoxy resins. In a curing process, an object becomes harder when exposed to air, heat, or other chemical additives. Curing epoxy often involves a catalyst or a chemical additive that speeds up the chemical reaction. Exothermic reactions during curing crosslink the polymer, providing epoxy products rigidity and
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The Origins of Epoxy
In 1936, Swiss scientist Pierre Castan invented the first epoxy resin by curing it using phthalic acid anhydride. Epoxy resins were first commercialised ten years later, in 1946, at the Swiss industrial exposition. Epoxy is currently extensively used in numerous industries, including building and construction. Epoxy is also used in food, pharmaceutical, and other industries, as well as in aircraft and aviation.
Dr. Sylvan Greenlee of the United States also developed epoxy resins in the mid-20th century by reacting epichlorohydrin with Bisphenol A. Using this process, Dr. Greenlee created one of the most widely used types of epoxy today, DGEBA or BADGE.
How Epoxy Works
Epoxy resin is the product of a chemical process known as curing. Curing is a chemical process that includes curing agents, hardeners, and epoxides. Cross-linking of polymer chains creates the hardening process. Curing produces epoxy thermoset polymers, which have exceptional resistance, durability, adaptability, and adhesion. The curing of epoxy is triggered by heat which makes epoxy a thermosetting substance. The process does not occur unless the ambient temperature is high enough to initiate it. But once the epoxy is cured, it is an irreversible process which means it cannot be undone.
It is also possible to combine multiple types of epoxy resins to get the desired result. Adding plasticisers, fillers, or other chemicals to epoxy can provide a more customised solution for a specific application. Depending on the intended usage, these additives can be employed to fine-tune certain features of the epoxy resin.
There’s so much to learn about epoxy and how it works. Speak with one of our epoxy experts if you’re interested to know more!
What is Epoxy Flooring?
One of the many uses for epoxy is as a durable, environmentally safe flooring material. Protective coatings such as epoxy are applied to residential, commercial, or industrial floors during construction as a means of safeguarding them from possible hazards for a certain period.
If you’re looking to preserve and decorate your concrete floor, then epoxy flooring is what you’re looking for. In general, epoxy coating systems are applied to a concrete base and consist of many layers of thermosetting resin that have been coated, troweled or poured. In order to preserve the substrate, the floor system’s resin layers must dry fully before they can build a strong and lasting connection.
Due to its excellent mechanical and chemical resistance, epoxy resin flooring has been extensively preferred and used in many homes, commercial establishments, and warehouses. Another advantage is that epoxy flooring can also be coloured, styled, effected, and decorated in a wide variety of ways.
Common areas that can benefit from epoxy flooring
Home Garage Epoxy Flooring
An important consideration for a garage floor is the security of the equipment you use in it. Epoxy flooring provides the right solution; its anti-slip qualities ensure that you can get to work without fear of slipping. Another benefit is that it’s very hard to damage and hence long-lasting. Epoxy flooring can therefore be used as a platform for equipment, which can be moved about without fear of damaging it.
The epoxy garage floor is also incredibly simple to maintain. Any oil or paint spills can be cleaned with a mop in a matter of minutes! Not to mention, the epoxy coating will look fantastic in your garage.
Commercial Building Epoxy Flooring
Epoxy has several benefits, but even for just one particular feature alone, it makes this kind of flooring ideal for commercial buildings. This epoxy flooring feature is its resistance to chemicals.
Epoxy flooring is also incredibly sturdy and durable so your machinery and equipment will not easily damage it. The commercial use of epoxy flooring differs from other flooring options that easily peel and tear—epoxy can take a beating and still look great!
A safe working environment is perhaps the major reason why epoxy flooring is so vital and a preferred choice for many commercial establishments. Its non-slip features make working on this surface a lot safer. Also, it is relatively simple to clean and maintain compared to other flooring options.
Warehouse Epoxy Flooring
Warehouses built some years ago are mostly with plain concrete sealed floors which has been the most cost-effective flooring option at that time. However, the option to use plain concrete flooring in warehouses has over time grown more expensive for a variety of reasons. So this is where epoxy flooring comes in to provide better benefits than plain concrete at a better cost when considering the long term.
Epoxy flooring can provide a non-slip surface for your warehouse, among other perks. Even in less-than-ideal situations, the textured surface of an epoxy flooring gives exceptional grip and thus, additional safety for all your workers.
Epoxy flooring will also be resistant to chemical damage, which may be crucial in a warehouse scenario. It can withstand impact and skid shearing from machinery and equipment being used and moved around.
Outdoor Spaces / Verandah / Balcony / Patio Epoxy Flooring
If you have an outdoor space like a veranda, balcony, or patio, you also know that its flooring is exposed to several natural, harmful elements. For this reason, it is critical to have durable flooring for these spaces for a feeling of security when enjoying the great outdoors. Epoxy flooring can not only make your veranda, balcony, or patio safer but also more beautiful and simpler to maintain.
Epoxy is a great option for your outdoor floor. Outdoor epoxy flooring is noted for its extended life and it can transform a plain veranda, balcony, or patio into a beautiful yet useful outdoor space.
Outdoor spaces such as verandas, balconies, or patios need a floor that can withstand a variety of weather conditions. Whatever the weather, your flooring should be weather-resistant. You can use epoxy flooring to protect your floors from heat and moisture, among other benefits that you will appreciate for your outdoor floors.
So many rooms and spaces in your property can benefit from epoxy flooring. Call us today for your FREE quote!
Benefits of Epoxy Flooring
Toughness / Impact Resistance
Epoxy flooring coatings are a popular choice in residential, commercial, and industrial sectors because of their ability to resist direct mechanical impacts and the high volume and intensity of foot and vehicle traffic. This is just another proof that epoxy flooring is more resilient and tougher than any other kind of flooring.
The fact that epoxy flooring is less likely to crack or chip than concrete makes it a better choice in the long run. You will not have to worry about damaging your flooring if you accidentally drop a tool or anything else heavy on it because of its toughness. Floors with epoxy coating are resistant to the vast majority of materials and substances that might create dents or stains.
Durability
Durability is what defines epoxy flooring and what made it the preferred choice in the first place for most applications. There is very little room for discussion about the fact that epoxy flooring is far more long-lasting than any concrete sealer. And if you haven’t previously known or heard of this, you should know it now—epoxy flooring is durable.
Epoxy floor coatings can withstand significant foot and vehicle traffic, as well as typical warehouse equipment such as forklifts, without showing any signs of wear and tear. These coatings are hard-wearing and robust! Epoxy flooring solutions can save homes and businesses like yours a significant amount of money that you otherwise would have spent on frequent floor repairs. In addition to its well-known durability and long service life, epoxy flooring is also known for its excellent resistance against liquid damage and even chemicals.
Versatility / Customisability
You do not have to settle with boring plain concrete for your floors whether it’s in your garage, outdoors, business, or warehouse. Epoxy flooring will breathe new life into your floors and in turn, your property.
Epoxy’s broad choice of shapes and colours allows you to capture any design you like. But the options aren’t all cosmetic, there are functional options as well. If you are worried about slipping and falling, your flooring may be made slip-resistant. You can also have a polyurethane or urethane coating to protect your floors from the sun’s damaging UV rays. Floors can also be made to glow in the dark to resemble stars in the night sky.
You can also choose a design that matches or complements the design of the building’s interiors or architecture. Needless to say, whatever style you want, it can be done on epoxy flooring!
Aesthetics
Epoxy-coated flooring is more sophisticated and upmarket than a plain concrete one. The high-gloss coating raises the floor’s brightness by up to three times, improving illumination and safety in the process.
Epoxy flooring not only improves safety but it can also be used to decorate your floor to whatever design you fancy. Epoxy flooring is available in a variety of colours and has options for satin matte or a lovely glossy finish. You can also have your own custom pattern and design embedded in epoxy flooring to promote your company brand or logo. Given its versatility, epoxy can be used to adorn your garage, home, office, or even a warehouse.
Ease of Maintenance
Epoxy flooring systems, whether they are installed inside or outdoors, do not need a significant amount of time to clean or maintain after they have been put in place. Because of the resin that it contains and the brilliant sheen that it has, epoxy flooring is very simple and quick to clean up if any liquid is spilt on it. And it is also resistant to stains. So, if you have epoxy flooring, then you don’t need to be too concerned or anxious about the possibility of floor stains.
The non-porous, smooth, stain-resistant surface of epoxy flooring can be easily cleaned of dust, dirt, and debris. It’s a nice feature that you don’t have to worry about any germs or bacteria lurking in the pores of the concrete. Clean, germ-free epoxy flooring can be achieved with a simple antibacterial solution mopped over the top.
Surface Protection / Abrasion Resistance
The floor in your outdoor space, garage, business, or warehouse will look better and last longer if you apply an epoxy coating. Epoxy coating not only provides surface protection and abrasion resistance, but it also adds aesthetic appeal to your floors
Epoxy coating protects your floors against mechanical impacts, liquid stains, chipping, chemicals and abrasion while also being very resilient. This means your floor will not be vulnerable to being damaged by nicks and scratches.
For additional protection, you can use a thicker epoxy coating to protect your concrete floor. Any cracks and other defects in concrete can be concealed by applying a thick layer of this coating. It shields your floor from heavy foot traffic, moving vehicles, and mechanical equipment being moved across it.
Chemical Resistance
Without a protective coating on the floor, any solvents, acids, alkalis, and other liquid spills can be absorbed by the concrete surface, causing it to deteriorate. In order to build a durable and impermeable surface, a chemical-resistant epoxy coating must be applied to penetrate and seal the concrete.
Epoxy floor coating has good chemical resistance and high acid and alkali resistance, in addition to a number of other advantages such as durability, resistance to impact load, wear and tear, crack bridging, and low permeability. Epoxy floor coating protects concrete from corrosive chemicals and excessive pH compounds that might otherwise damage other kinds of floor coatings. It can be applied as a thin coating or blended with aggregates to produce thicker layers for better protection and durability.
Liquid & Moisture Resistance
Another benefit of epoxy flooring is its moisture resistance. Epoxy flooring has been used successfully in wet and cold environments, and during the winter, this coating allows you to simply wipe ice brines and road salts off the floor.
Epoxy flooring is also resistant to grease stains and water droplets. It’s also quite easy to clean with just a little soap and water. And when the floor is dry, use a mop or a soft brush to remove dust and road dirt.
Dust collection on the epoxy floor is also minimised. Unlike typical concrete floors, epoxy floors do not accumulate dust from cement floor powder or normal foot traffic. A dust-free epoxy floor looks clean and allows you to operate without fear of breathing dust.
If you’re unsure whether epoxy flooring can meet your needs, call our expert team today!
Bacterial & Germ Resistance
In commercial kitchens, food processing plants, and medical institutions, there are some strict health and safety rules that need to be observed. Due to the demand in meeting these high standards, epoxy flooring has grown in popularity.
Epoxy floors outperform other flooring materials in terms of health and sanitation requirements due to their resistance to chemicals and other corrosive factors. This implies the floor has no seams, cracks, or fractures where germs and bacteria can thrive.
Epoxy flooring is an ideal antimicrobial solution for businesses with strict hygiene rules due to its high resistance to pathogens including bacteria, mould, and dirt. Epoxy is also a good option for hypersensitive materials since it does not accumulate dust.
Skid & Slip Resistance
As a precautionary measure, every business in the commercial and industrial sectors should consider installing non-slip epoxy coating on its floors in order to avoid any potential accidents. Epoxy flooring can improve the safety and overall efficiency of your business, no matter whether you run a busy restaurant or a warehouse where trucks come and go all day.
When working in a busy place where workers’ safety is a top priority, epoxy flooring has proven to be the ideal choice. With epoxy flooring, you can be sure that vehicles in a workshop or factory will not slide about on a damp floor which might cause accidents. In a commercial kitchen where the floor is always wet, your workers will appreciate having slip-resistant epoxy flooring for them to work safely and securely. In school, children must be allowed to run around freely without fear of sliding on a wet playground. In these areas and other similar settings, epoxy flooring is not only appealing but also beneficial.
Hot & Cold Temperature Resistance
In situations where extreme temperatures—hot or cold—occur often, finding a suitable floor coating can be a challenging task. However, with epoxy flooring, you will be assured that your floors are resistant to extreme temperatures that typically deteriorate any other flooring option.
In order for a resinous floor to function well in high temperatures, it must be able to absorb and transmit heat. Epoxy flooring is capable of doing this, and more! When applied as a thick coating, epoxy flooring can repeatedly absorb and withstand extremely high temperatures. This makes epoxy flooring perfect for spaces such as commercial kitchens where there are hot ovens, grills, and fryers.
On the other extreme side, epoxy flooring is also resistant to cold temperatures. Epoxy flooring maintains its resistance, durability, and antimicrobial properties even at water’s freezing point.
Eco-Friendliness / Low VOC Content
One of the lesser-known benefits of epoxy flooring that is true for almost all flooring solutions now on the market is its eco-friendliness. As this is pertaining to the environment, it is important to raise awareness and educate people about it and how epoxy flooring is the right choice among all flooring options when it comes to such criteria.
Due to the worsening global condition, there has never been a better time to “go green” than now, and if you choose epoxy flooring, you are doing your part. Waterborne epoxy resins and 100% solid resins are two of the most ecologically friendly flooring solutions that other flooring options simply cannot claim to have.
Furthermore, in commercial and industrial settings where worker safety is a top consideration, new epoxy flooring has low quantities of volatile organic compounds (VOCs) which can be harmful to the environment as well as to the workers.
Short Installation Lead Time
Because it requires much less time to cure and dry than other floor coatings—like, say, a urethane coating, epoxy is the ideal coating material to use for your floors, especially in a commercial or industrial setting where downtime must be as short as possible. With epoxy flooring, the floor area can be used immediately after installation which results in reduced downtime, which in turn results in cost savings for your business.
The choice of epoxy flooring will pay off in more ways than one by saving both time and energy, which leads to improved productivity at work or at home.
Cost-Effectiveness
If you are looking to improve the appearance and feel of your floors but do not want to spend a lot of money, epoxy coating might be a great answer for you.
Epoxy flooring can be availed at a reasonable price. It’s also possible to check a variety of pricing ranges to find the best fit for your needs since there are so many epoxy flooring options to pick from.
Due to its durability and long-term usage, epoxy flooring has been particularly cost-effective. In many circumstances, epoxy flooring requires little or no maintenance. And while epoxy is a high-quality material that needs a lengthy installation process, it has been demonstrated to be cost-effective in the long term considering the benefits mentioned above.
Types of Epoxy Flooring
Self-Levelling Epoxy Flooring
Concrete floors are common in commercial and industrial buildings, but they can be difficult to maintain. So, if you plan to buy or rent a building with this sort of flooring, you should consider self-levelling epoxy flooring instead. This substance will fill up dents and cracks while providing a smooth finish that outlasts typical paint treatments. A bright, smooth, durable, and even surface finish can be achieved with self-levelling epoxy flooring.
With a variety of colours to choose from, self-levelling epoxy flooring is ideal for almost any setting. In addition to self-levelling features, using epoxy flooring in storage facilities, office buildings, warehouses, kitchens, garages, dining rooms, sporting facilities and more is common because of its appealing high-gloss seamless surface and durability to heat and chemicals.
Quartz-Filled Epoxy Flooring
Quartz-filled epoxy flooring combines high-performance epoxy resin with tinted quartz grains. Quartz permits this sort of epoxy material to be attached to itself, making it simple to apply.
You can make your place stand out with this amazing flooring option. You can customise your style by choosing from a variety of patterns and colours. In the absence of complicated rules on epoxy flooring designs, it allows you to concentrate on your personal design objectives and financial constraints.
This option is mainly used for areas that need hygienic, slip-resistant flooring. Quartz-filled epoxy floors are also glossy and decorative. This makes quartz-filled epoxy flooring ideal for locker rooms, toilets, schools, cafeterias, lobbies, offices, and showrooms.
Epoxy Flake Flooring
Epoxy flake flooring is actually a method of applying the coating rather than a distinct form of epoxy flooring. Because of its rough surface, epoxy flake flooring is a fantastic choice for places like convention centres and sports arenas.
This is accomplished by having epoxy glue layered on top of flake sheets to create colourful surfaces with a little rough feel. This type of epoxy flooring can be used in any design while protecting against slips and falls. With a facility as mentioned above, whether you’re constructing your own space or just need something that will withstand repeated visits, there’s no better choice than utilising premium-quality flakes for the finest epoxy floor.
Epoxy Mortar Flooring
For industrial facilities such as mechanical rooms, warehouses and manufacturing plants, epoxy mortar flooring is the strongest epoxy coating available and can sustain high loads and forklift action. This epoxy floor is constructed of pure solid epoxies and quartz sand (graded) that has been troweled into place. It can also be used to patch cracks in existing epoxy flooring before pouring new epoxy.
Epoxy mortar flooring is the option used for the most demanding applications in commercial and industrial sectors as it provides excellent impact and chemical resistance, as well as being very durable. When it comes to heavy-duty flooring, this is the go-to flooring choice among epoxy coating options.
Anti-Static Epoxy Flooring
Anti-static epoxy flooring can withstand electrostatic charges, also known as ESD. ESD is a serious issue that can emerge in work situations with many insulators and conductors. It occurs when two items, including people, come into touch and an electrical flow develops.
Electrostatic discharge is harmful since the heat created may evaporate items, cause electrical device failure, and can be fatal at times. Because anti-static epoxy flooring contains a conductive core, it can stop ESD on its track. This conductive coating will absorb and drain the electrical flow, thereby damaging nothing or hurting no one in the process.
Epoxy Terrazzo Flooring
Epoxy terrazzo flooring is a relatively new form of epoxy flooring, or at least commercially. This type of flooring is ideal for business buildings and schools with long halls. It is typically regarded as an architectural element and a business method for generating a lasting, gorgeous effect on the floor.
It is simple to clean since it resists dirt, but its aesthetic appeal can drive up the price. So, if you want a gorgeous flooring system, epoxy terrazzo coating is the finest epoxy flooring option that you cannot go wrong with. And as has been observed, epoxy terrazzo flooring attracts more visitors than other flooring types—a good thing for most businesses.
Vapour Barrier Epoxy Flooring
If you reside in a place that is prone to flooding or excessive humidity, water vapour can do a lot of harm to your property—although at a rate that is not easily noticeable. In order to protect your home or business property, you can consider a rather new type of epoxy flooring known as vapour or moisture barrier epoxy flooring in your options. It is applied to concrete floors to create an impermeable covering that lowers if not completely eliminates the transfer of vapour.
In the case of hard surfaces such as hardwood floors, carpet, tile or sheet vinyl, the vapour barrier is traditionally installed prior to the final flooring layer being placed down. On the other hand, vapour barrier epoxy flooring on concrete has the barrier on the top layer.
3D Epoxy Flooring
3D epoxy flooring is fast becoming more and more popular among epoxy floor coating services today. In recent years, 3D epoxy flooring has become more popular in retail malls, companies, houses, and apartments. It is the latest trend in the world of beautiful floors.
3D epoxy flooring is a method of embedding 3D printed graphics in epoxy coating. Most homeowners prefer this option because they can pick and choose whatever image they like to embed or customise to match the rest of their home’s decor. And unlike a sticker or painted vinyl immediately beneath your feet, the epoxy 3D floor creates the illusion of depth and is resistant to harm.
If you have any questions about the types of epoxy flooring available, call our expert team now!
Installing Epoxy Flooring
Learning how excellent epoxy flooring is, it’s natural that you’d want to have it installed in your home or business. However, when it comes to laying epoxy flooring, it is best to leave it to the professionals. If you try to do it yourself with proper training and sufficient experience, you are risking ruining your floors and wasting your time and money.
In Australia, epoxy flooring must be installed in accordance with the particular criteria of the Building Codes of Australia (BCA). There are a number of requirements that need to be met—but no worries, we will also handle this for you! There is no need to worry about a thing once you have decided to hire us to do the epoxy flooring installation for you.
Repair and Maintenance of Epoxy Flooring
Despite the fact that epoxy flooring was stated several times as being durable and impact-resistant, unusually heavy or sharp loads may still break epoxy floors.
Some epoxy floor cracking occurs because the epoxy was applied incorrectly or unevenly, resulting in some places being too hot and cured quicker than others, which causes the epoxy to harden. By the rules of thermal expansion, materials that are subjected to temperature fluctuations will expand as the temperature rises and contract as the temperature falls. Even cured parts of epoxy flooring can break if it expands and shrinks.
Repairs are still possible even if the damage is limited to a few small surface cracks. The sanding and sealing of surface-level cracks can still save your floors and restore them to their former glory. However, it is important to note that epoxy should only be installed or repaired by qualified personnel as disaster awaits your floor if you do it wrong.
Disadvantages of Epoxy Flooring
When assessing a flooring option, it’s always best to see both sides of the coin. By weighing the benefits and drawbacks, you are more likely to make an educated choice. After all, this is a costly project, and every decision should be based on both the good and the bad.
The benefits have been stated and explored as above; now let’s look at the drawbacks. Using epoxy flooring has a few of them, as noted below:
- While epoxy cures quickly, it takes a considerable time to fully solidify.
- Epoxy is still weaker than metal and may chip and break in high-impact areas.
- Epoxy application creates noxious fumes that might be harmful.
- Epoxy coating is considered a temporary solution unless the foundation flooring is concrete.
- Choosing the correct epoxy is important if your room is constantly damp or prone to liquid spills.
- Epoxy flooring installation is a laborious and time-consuming task.
- Epoxy floor removal is a difficult process.
- Epoxy flooring can get uncomfortably cold under bare feet.
- Epoxy’s original colours may fade with time, particularly if exposed to sunlight.
- Some epoxy flooring options might be costly to maintain.
The Cost of Installing Epoxy Flooring
The cost of installing epoxy flooring is influenced by factors such as stock availability, project location, and accessibility, as well as epoxy’s intended use and the size of the floor being coated. A typical estimate is highly dependent on the amount of epoxy and the number of workers required to execute the project correctly and on time.
As with any flooring, there are several options when it comes to choosing an epoxy floor. The kind, colour, and tint of the floor you choose will all have an impact on its final cost. A bucket of epoxy is often used in the calculations. You can get a rough idea of the material cost by multiplying the floor area (plus some margin) by the price per bucket of epoxy.