Polymer Flooring: One Solution Does Not Meet All of Your Industrial Needs

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What is Polymer Flooring?

Polymer floor coatings are created by combining two or more liquid chemical components to create a predictable, controlled chemical reaction that results in a thermoset monolithic, impermeable “plastic” protective sheet over the concrete substrate.

Polymer floor coatings were designed to protect and repair concrete substrates. Additional performance requirements, such as increased hardness, thickness and chemical-resistance are addressed by further customizing the components to include specialized aggregates, powders, flexibilizers, UV stabilizers, decorative broadcast media, and specialty pigments.

Polymer material technologies can vary with regard to performance characteristics. The most commonly known polymer floor coatings are derived from epoxy technologies. Other polymer technologies include urethanes, MMA’s, vinyl esters, to name a few. Each technology offers unique benefits, such as faster cure time, enhanced chemical resistance, increased UV stability, and increased impact and abrasion resistance. Additionally, these technologies can be further modified to address specific industrial safety concerns, such as electrostatic discharge and microbe growth control.

A complete floor coating system is created by combining these technologies. For example, a simple coating system might consist of an epoxy-based primer, followed by a high-build epoxy “body” coat, topcoated with a chemical and UV-resistant polyurethane. Concrete surface conditions and intended finished use requirements dictate the combination of products that will perform the best for each specific floor area.

Further Classifying Polymer Flooring Systems

For industrial floor coating applications, polymer flooring systems can be broken down into four main categories, grouped by system thickness.

High-Build Coating Systems (15 to 40 mils total system thickness)

High-build floor systems typically consist of a primer and subsequent topcoat(s). Depending on use requirements there are different polymer coating technologies available, from fast-cure epoxies and polyaspartics, to chemical-resistant novalacs and urethanes, to flexible and thermal shock-resistant coatings.

Coating systems provide adequate coverage to hide slight imperfections in the concrete slab, creating a long-wearing, easy to clean, smooth surface. High-build coatings systems are an excellent choice for general manufacturing areas and warehouses, as well as institutional, commercial or retail areas subject to normal foot, forklift and equipment traffic. Coating systems offer color stability, light-reflectivity and overall pleasing aesthetics. These systems are easy to apply and are relatively maintenance-free.

Polymer Flooring: One Solution Does Not Meet All of Your Industrial Needs

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High-Build Coating System Features:

• Hides slight imperfections in concrete substrate

• Extremely low odor/Low VOC options

• Available in wide array of colors

• Very good wear and impact characteristics

• Bright and light-reflectant

• Very easy to clean and maintain

• Return to service in as little as three hours

• Easy to install

Broadcast Aggregate Coating Systems (50 to 75 mils total system thickness)

Broadcast floor systems are created utilizing high-performance polymers with aggregate broadcast into the body coat. A broadcast system typically starts with a primer, followed by a high-build intermediate "body" coat broadcast with various aggregates depending on intended use of the finished floor area. Broadcast aggregates can range from small angular quartz for slight "grit" slip protection to aluminum oxide (ALOX) for high-wearing system properties. High-performance polymer topcoat(s) then complete the system.

Broadcast systems are ideally suited for industrial, commercial or institutional "shop" applications where a slip resistant, durable finish is desired over new or existing sound concrete. These systems are easier to apply than slurries or troweled mortars, making them an ideal choice for areas that require more wear and abrasion characteristics than a high-build coating system.

Broadcast Aggregate Coating System Features:

• Enhanced slip-resistance for safety

• Hides previous floor repairs

• Excellent durability and wear-resistance

• Quick turnaround minimizes facility downtime

• Low odor/Low VOC options

• Light-reflective

• Available in a variety of colors & textures

• Chip-resistant

• Numerous surface profiles can be achieved

Typical High-Build Coating System

Typical Broadcast Aggregate Coating System

Polymer Flooring: One Solution Does Not Meet All of Your Industrial Needs

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Self-Leveling Slurry Mortar Systems (60 to 90 mils total system thickness)

A slurry is a "soupy" self-leveling floor system consisting of a polymer filled with finer aggregate(s). Slurries are applied with a notched squeegee or a slurry/cam rake over uneven, pitted, spalling or slightly damaged concrete substrates. After placement, the aggregate settles into the surface voids and the polymer liquid settles on the top. This type of cure does two things. The thicker, aggregate-filled polymer mixture fills voids and levels uneven concrete slabs, and the polymer liquids create a durable, smooth and glossy surface.

Slurry systems are extremely durable and offer excellent abrasion-resistance, combined with high-gloss and light-reflectivity. And because slurries are less labor-intensive to install than troweled polymer mortars, they are often an excellent choice for light to moderate concrete resurfacing where a faster return to service is a requirement. In fact, a fast-cure slurry system could allow foot traffic in as little as three to four hours.

Self-Leveling Slurry Mortar System Features:

• Self-levels to smooth surface

• Extremely low odor

• Slurry can be pigmented to match topcoat(s)

• Restores slightly damaged concrete substrate

• Bright and light-reflectant

• Easy to clean and maintain

• Return to service in as little as three hours

• Simplified Installation

Heavy-Duty Trowel-Applied Mortar Systems (1/8” to 3/8” total system thickness)

A mortar/resurfacer floor system typically consists of a primer followed with an application of a trowel-finished mortar. This mortar is a blend of high-performance polymer resin combined with custom-blended aggregates or concrete powders. Subsequent polymer topcoats are then applied as determined by the intended use of the floor area. These heavy-duty systems not only protect concrete substrates, they can resurface badly damaged concrete providing a long-lasting, stronger concrete cap.

Mortar systems offer superior durability, adhesion, abrasion and impact resistance. These systems are best suited for heavy industrial operations, or any area exposed to harsh traffic or processes. Since mortar systems are trowel-applied, they require qualified installation. Protective Industrial Polymers works with only the best application contractors in the coatings industry. You can be assured we will recommend the right floor system to address your specific requirements, combined with the best installation services.

Typical Slurry Mortar System

Polymer Flooring: One Solution Does Not Meet All of Your Industrial Needs

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Heavy-Duty Mortar System Features:

• Superior durability

• Superior Adhesion

• Superior impact and abrasion resistance

• Superior wear characteristics

• Restores badly damaged concrete slabs

• Excellent chemical-resistance

• Available in a variety of colors

• Thermal shock-resistant options

• Low odor/Low VOC options

Why Polymer Flooring?

Concrete is the basic foundation of every structure. But, concrete is a porous material that is subject to damage by impact, abrasion, chemical saturation, corrosion, and thermal expansion. Polymer floor systems were designed to protect, rehabilitate and restore concrete substrates.

Industrial polymer floor coatings are specifically designed to meet the various performance requirements present in industrial manufacturing and processing environments.

All Areas of Your Manufacturing Floor Are Not the Same

When it comes to industrial flooring, it’s all about performance. You want your floor to perform adequately based on its intended use. Not every industrial area has the same performance requirements, and there is no “one size fits all” solution.

Say , for instance, the majority of your industrial plant is subject to light to moderate-duty foot and cart traffic. A general-use, high-build epoxy coating system with a urethane topcoat would likely be all you would really need to protect the floor and provide a safe, bright, durable and easy-to-clean surface. But, what about forklift traffic aisles that require something much more aggressive that can stand up to heavy impact and abrasion from heavy loads scraping across the floor? These areas would require a more adequate flooring solution, such as a heavy-duty mortar system. The same goes with areas where chemicals or solvents are stored, or areas where microbe growth is a concern. Many facility professionals outside of the electronics industry might not think about the damaging effects of ESD (Electrostatic Discharge), but static and ignition-control is certainly a safety concern in many industries.

Typical Slurry Mortar System

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By understanding each unique floor area of your industrial process, you can select the right industrial flooring system for each area that will perform optimally for its intended purpose. This can mean the difference between not providing enough flooring protection for critical process areas, or paying too much for general purpose areas that don’t necessarily require a heavy-duty, or specialty, solution. Truly understanding the various industrial flooring needs for each area or your industrial process can accomplish a number of goals, including measurable life cycle analysis and proper maintenance budgeting, both of which can contribute to a healthy bottom line.

Understanding Your Floor’s Needs is Important

In any large-scale industrial environment there can be a number of specialized manufacturing areas, with specific flooring performance requirements for each function.

For example:

Plant Area Key Requirement Floor Coating Solution Work Cells 5S program Color Floor Markings Hazardous Waste Storage Fire Prevention Spark Resistance Electronic Assembly ESD Static Dissipation Food Manufacturing Sanitation Microbe Control Traffic Lanes Durability Abrasion Resistant Chemical Storage Containment Corrosion Control Lunchroom Attractiveness Friendly Design Repair Area Lighting High Reflectivity Assembly Line Safety Non-Slip

As you can see, the flooring requirements presented in each area require a specific floor coating solution. But, you will often find each specialized flooring area could have multiple requirements. By reviewing each area of your plant and analyzing its intended use, you can better determine the right flooring solution to meet your specific performance requirements.

How To Manage a Floor Coating Project

Floor coating projects require more effort than one might expect. A typical floor coating renovation consists of the following phases:

• Manufacturer’s Consultation • Floor System Specification • Labor & Materials Proposal • Proposal Review • Scheduling • Installation • Punch-list & Closeout • Warranty

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However, managing all of these phases can put an unnecessary strain on facilities personnel. There is help out there. Turnkey service and material providers offer a “one-stop shop” for floor installation projects.

One such turnkey program is Protective Industrial Polymers’ SingleSource. This program manages all aspects of a floor coating project, from initial consultation and floor system recommendation, through the scheduling and installation phases. This program even helps with operation and maintenance and post-installation support. Utilizing a turnkey solution can ensure consistency among your facilities, providing consistent construction materials combined with professional installation support and project management and consultative services. Best of all, it’s a single point of contact, a single contract, and a single invoice.

Still Need More Help Determining Your Flooring Needs?

Our Industrial Systems Selector Guide may be the answer!

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