Epoxy floor coatings play a major role in meeting the standards required for high quality flooring, especially in public buildings like hospitals or food processing plants, where hygienic floors are of the utmost importance.

Epoxy floor coatings are durable hard wearing solutions for both commercial and industrial floorings. These can be applied over concrete floors to provide a high performing film, both aesthetically and functionally.

It’s different
The conventional floorings that are available include tiles, stones, and vitrified etc. However, epoxy floors are found to be unique from them for the following reasons:
• Unlike tiles and stones, the epoxy floorings are joint free leading to a surface which has no potential for dirt pick like in case of the joints in tiles
• Epoxy floors other than polyurethanes are the only floors on which forklifts can easily move
• One can provide any colour that is desired by the client and if the client wishes to change the colour after some time, it can be done with a simple flash coat.

“The epoxies have become part of the drawing in industrial constructions. The coatings are easily repairable at the localised level. The labour has become very expensive in our country,” points out Amit Mathur, Director, Mathur Corr Tech Pvt. Ltd. “A team of 6 persons can hand over an extent of nearly 3,000 sq. ft in a day’s time that makes the labour cost very inexpensive. The epoxies bring a world-class looks and appearance to the industry which actually has been mandatory in the first world.”

“Epoxy floorings are formulated by various polymers, hardeners and graded filler. They can lengthen the life of the floor and achieve a great appearance. They can be applied over many different materials, including steel, concrete, and wood. However, concrete is the best surface,” says Hasan Rizvi, Vice President , STP Ltd.

V Raghunathan, Vice President, Cera-chem Pvt. Ltd. shares, “Using an epoxy floor coating over the concrete floors will create a durable, high gloss, hard wearing surface. They stay intact for a long period of time and are widely used due to the inherent tough nature of the film to withstand operating pay loads if the loads are not pointed ones.”

However, epoxy floor coating performance is directly affected by surface preparation.

“The integrity and the service life will be reduced significantly if the surface is improperly prepared. A proper surface preparation ensures epoxy coating adhesion to the substrate and prolongs the life of the epoxy coating system,” adds Mr Rizvi.

Advantages
Epoxy floor coatings offer a number of benefits and advantages. The following are some of the main advantages associated in choosing an epoxy floor coating for commercial or industrial purpose.
• Chemically inert nature: Epoxy floor coatings are chemically resistant flooring option for manufacturing plants, warehouses, garages,  and industrial plants and commercial establishments
• Environment friendly: Epoxy floor coatings are an environment friendly flooring solution for corporates interested in choosing “green” alternatives and building materials as the coatings become plastic and inert for chemical exodus
• Self-levelling, easy and quick to apply: Epoxy floor coatings are self-levelling products which allow any experienced professionals to apply the coatings with ease. Self-levelling overlay system itself offers numerous advantages. It can correct uneven floors, repair damaged concrete, and provide a smooth and durable new surface for decorative requirements.
• Style: Epoxy floor coatings offer an excellent gloss and sheen and are available in a variety of colours and styles. One can chose to use one solid colour or create a decorative pattern using several colours in order to create an attractive and durable flooring solution.

Safety + Economy + Productivity
Epoxy floor coating products can improve safety by creating a slip, impact, heat, and fire resistant flooring solution. These high gloss floor coatings can also improve brightness in a work area by 300 per cent. Also it is possible to use different colours of epoxy floor coatings simultaneously to define safety zones, forklift traffic zones, and other work zones.

Its application cost is also affordable and no maintenance is required for long run which helps on ROI front. Thus it proves to be a cost effective flooring solution. Further it can be applied over any new or old concrete floors.

Moreover, productivity could be greatly enhanced by using epoxy floor coatings in a factory, warehouse, or industrial plant. Because it can reduce wear on transport vehicles, allows faster material movement, and prevents wear and damage to the floor.

Choice of epoxy floor coating
Now the obvious question arises is how to choose the best epoxy floor coating for the required purpose.

Mr Mathur helps to understand, “The choice of system depends primarily on the service requirement of the industry. Epoxies are basically chosen on the basis of two parameters: physical and chemical.”

Physical aspect would be terms of usage of the floor being coated. Based on these aspects, one can choose the film thickness ranging from 250 microns to 6 mm dry film thickness.

Whereas chemical aspect depends on the application industry in which floor would be used. Different industries, such as chemical, computer, oil etc need different type of coating.  So keeping this in mind, suitable grade of epoxy should be implemented.

Mr Raghunathan suggests using the following checklist for the purpose:
• Whether the product has good film built up?
• Has it a good self levelling?
• On what primer it is recommended?
• Is the primer a screed and what thickness does it offer?

Applications
Epoxy floor coating products, once dried, become durable, seamless surfaces that can easily be wiped free of dirt, dust, and debris. Because of this ability for easy cleaning, these are ideal for food, beverage, and pharmaceutical as well for the packaging plants. Additionally, in OEM plants, commercial facilities, warehouses, chemical plants ad laboratories are some more areas where epoxy floor coatings are being widely used.

Moreover, today they are considered to be suitable for a variety of applications like computer rooms, hotel and restaurant kitchens, hospitals, sports facilities and gyms, shopping malls, cinema halls, galleries and lobbies, etc.

Solutions offered today
Taking into consideration all the benefits and probable application areas of epoxy floor coatings, it is now useful to see what solutions are being offered today in the industry.

Mr Mathur says “We offer various types of epoxies including anti- corrosive coatings, grades of floor coatings, epoxy tile adhesives, tile jointing compounds, marine finishes and epoxy mortars. Further we are into polyurethanes, construction chemicals, acrylics, and alkyds as well.”

Cera-chem mainly offers Cera Screed EP and Cera Self Level EP. Cera Screed EP is a three component epoxy system specially formulated to provide chemical and abrasion resistant topping for industrial floors, corrosion resistant lining in chemical industries for foundation protection, run ways, roads etc.

While Cera Self Level EP is a two component solvent free, pigmented self levelling epoxy flooring that complies with standard regulations of an epoxy floor coat system. It is available in almost all colours and can be stored for 6 months in sealed packs.

STP also offers variety of products in epoxy floor coatings as confirms Mr Rizvi. Some of the STP products are as follows:
• ShaliScreed SL UL is a self-levelling epoxy underlayment screed flooring material. It is a three component epoxy system with selected aggregates. It has good adhesion and abrasion resistance on floors. It can be coated over with any epoxy coating, self-levelling system or polyurethane coating.
• ShaliScreed SL AS is a self-levelling anti-static epoxy applied over a properly prepared concrete surface. Its property of dissipating the static charge protects sensitive electronic equipment and components. It is anti-static, anti-fungal and anti-bacterial. It is available in all selected colours as per shade card.
• ShaliScreed is a three-component epoxy screed system designed to provide abrasion, impact resistant, tough and chemical resistant floorings. It is formulated to withstand heavy industrial traffic and is available in a variety of colours as well. It should ideally be top coated with transparent epoxy/polyurethane sealers or with self- levelling epoxy.
• ShaliDeck SL is a four component pigmented epoxy floor topping which is laid at a thickness of 1 mm to 2 mm. It is joint less, textured, non-porous, hygienic and chemical resistant and easy to clean, maintain. It is available in a number of colours and has sufficient strength to withstand industrial traffic with nylon and rubber wheels.

Conclusions
To sum up, epoxy floor coatings are making their significance and hence the existence also felt in many segments. In addition, their versatility and continuous development are certainly showing the more productive and efficient way to future.

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Epoxy floorings are formulated by various polymers, hardeners and graded filler. They can lengthen the life of the floor and achieve a great appearance.

Hasan Rizvi, Vice President ,
STP Ltd.
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The epoxies bring a world-class looks and appearance to the industry which actually has been mandatory in the first world.

Amit Mathur, Director,
Mathur Corr Tech Pvt. Ltd.
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Using an epoxy floor coating over the concrete floors will create a durable, high gloss, hard wearing surface.

V Raghunathan, Vice President,
Cera-chem Pvt. Ltd.