Epoxy Resin Flooring

What is Epoxy Resin Flooring?

Epoxy resin is a thermosetting polymer, that, when mixed with a hardening agent, undergoes a chemical reaction resulting in a strong, durable, and chemically resistant material. Epoxy resin flooring coatings are commonly used in various industrial, commercial, and domestic settings due to their beneficial properties.

The Benefits of Epoxy Resin Flooring

Here are some key features and benefits of epoxy resin flooring:

  • Durability: Epoxy resin creates a tough and resilient surface that can withstand heavy foot traffic, machinery, and equipment. It is highly resistant to impact, abrasion, and wear.
  • Chemical Resistance: It is resistant to a wide range of chemicals, including acids, solvents, oils, and cleaning agents. This makes it suitable for environments where chemical spills or exposure are common.
  • Hygiene and Cleanliness: It is seamless and non-porous, making it easy to clean and maintain. It does not allow liquids, dirt, or bacteria to penetrate the surface, promoting hygiene.
  • Customization: These floors can be customised with various colours, patterns, and textures. These decorative floors offer an attractive finish for creative designs and branding in commercial spaces. Metallic pigments, coloured quartz and coloured flakes are all options that are regularly used. Couple these with the extremely wide range of colours and there are endless options of designs and finishes. 
  • Aesthetics: Matte, silk, or high gloss finishes are all available, enhancing the overall appearance of the space. Commercial and industrial environments often look and feel larger due to the reflective nature of a seamless epoxy resin installation. 
  • Quick Installation: Epoxy coatings can often be installed relatively quickly compared to other flooring options. This can minimize downtime during installation.
  • Resistant to Moisture: Epoxy flooring is generally moisture-resistant, which can be advantageous in areas prone to water exposure.
  • Low Maintenance: Due to its durability and resistance to stains, epoxy flooring typically requires minimal maintenance, reducing long-term costs.

UV Stability: Some epoxy formulations are UV resistant, which means they won’t yellow or degrade when exposed to direct sunlight in outdoor use.

What are the Different Types of Epoxy Flooring?

There are many types of different epoxy floor finishes. They are all based around the same epoxy resin chemical technology, however, the systems vary depending on the thickness of the application and the other minerals, aggregates, dyes, and substances that are added to them. Below is a list of the main types and some of the applications that they are used in. We have also included the FeRFA (The Resin Flooring Association) classification, which provides a clear distinction between the different systems available:

Epoxy Floor Sealer

Ranked as a FeRFA classification 1, this is the thinnest of the systems which epoxy is used.  Normally applied as a one coat or two coat application, this system is no more than 150 microns (0.15mm) thick. Due to the extremely thin nature of the finished floor, no wear warranty is given for high-traffic areas. Available as a coloured or clear sealer, this basic floor covering is usually used in areas that have relatively low usage or foot traffic. The water based epoxy version does have the benefits of it being impervious to water but still being able to breathe. This characteristic makes it ideal for areas that have damp issues, as it is not affected by moisture from below.

High Build Epoxy Coating

The term “high build” refers to the thickness of the epoxy coating that is applied to the surface. Classed with a FeRFA 2 certification, high build epoxy coatings are designed to be thicker than sealer systems and range from 0.3mm to 1mm in thickness.  

Epoxy resin coatings in this bracket are extremely popular for industrial and commercial flooring applications. Once the correct subfloor preparation has been undertaken and an appropriate epoxy primer has been installed, these heavy duty coatings offer excellent value for money and are the best selling product in this category. Usually applied with a squeegee, trowel or roller, this hard wearing resin system provides a seamless glossy finish that can with stand fork lift and wheeled traffic.

Self Levelling Epoxy

Where the coatings and sealers previously mentioned are applied as resin floor paints, self-levelling epoxy is applied at 2-3mm thick. This system is perfect when a smooth and extremely robust flooring solution is required. Ideal for use in industrial or commercial applications that are subject to high usage from footfall, wheeled traffic and any heavy abrasive wear. FeRFA classifies these systems as Type 5, and you can expect warranties for these floor for up to 8 years or possible more dependant on the traffic it will be receiving.

“Out gassing” or “pin holing” can be an issue due to the thickness of these resin floor products. This is caused by tiny air pockets releasing air from prepared concrete floors. To combat this it is imperative that 1-2 coats of epoxy floor primer are used before the main system is installed.

Due to its very smooth surface, pleasing aesthetics and hard wearing properties, it is a go-to choice for warehouses, garage showrooms, clean rooms, pharmaceutical companies, and anywhere hygiene and cleanability are major concerns. 

Flake System and Quartz Systems

Coloured flake and quartz systems are both decorative and highly functional and are classed as multi layer “sandwich systems” Ferfa classification 4 or 6 dependant on the system thickness. These systems usually consist of applying a coloured mixed resin onto an epoxy primer that is then fully covered by coloured flakes or aggregates. We then allow the resin to cure, leaving a blanket of the decorative material fixed into the body coat below. The excess flakes or coloured aggregates are then brushed off, and the system is finished with clear resin. This encapsulates the decorative layer providing a strong anti slip surface. Then when we allow it to cure, extra layers of clear resin can be applied diminishing the slip resistance with every coat. This means that the floors slip resistance can be tweaked to be perfect for your particular application. 

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Epoxy Mortar

Possibly one of the strongest and most versatile products that we install, epoxy mortar is a floor made of a special blend of aggregates and coloured or clear epoxy resin that can be laid at 5mm and above. This product is usually installed after a primer coat of epoxy resin has been applied. The thick and mortar-like consistency of this product means that it isn’t easy to apply, and as with the majority of these products, we would recommend using professionals to obtain a first-class finish.  

How Does the Process of High Build Epoxy flooring work?

High Build Epoxy Resin flooring systems generally progress through these three steps, surface preparation, mixing and then application. The surface preparation stage is the most tedious and perhaps the most crucial, there are many things to consider. However, it can be said for all surface preparation works, that a clean and dry substrate is needed, as well as it being free from any contaminants. The mixing will then also need to be done with care, a mixing paddle or electric drill is used to ensure uniform colour and consistency. To finish, it is best advised to complete the application when the base temperature of the site is closer to room temperature.

Overseeing your Epoxy Flooring system installation

At DC Flooring, it is important to us to see a job from the initial planning stages, right through to the end. This is why we have developed an integrated service that takes care of every need you will have. Meaning that we take care of consultation and design planning, through to project management and aftercare. Through the years of our epoxy resin works, we have encountered nearly all types of problems that may arise, resulting in us being able to deal with these problems with certainty and first-hand expertise.

Maintaining and Cleaning Epoxy Resin Flooring

Maintaining and cleaning epoxy resin flooring is essential to ensure its durability, appearance, and safety in various commercial, industrial, and residential settings. Proper maintenance can extend the life of the flooring and keep it looking its best. Here are some guidelines for maintaining and cleaning epoxy resin flooring:

Daily and regular cleaning usually involves a soft-bristle broom, dust mop, or a vacuum with a soft brush attachment to remove dirt, dust, and loose debris from the surface. Regularly sweeping or vacuuming can prevent scratches caused by abrasive particles. For routine cleaning, damp mop the floor with a mild detergent solution and warm water. Avoid using harsh chemicals or abrasive cleaners as they can damage the epoxy finish. Always follow the manufacturer’s recommendations for cleaning products.

When it comes to spill clean-up, you must take Immediate action. Quickly clean up spills to prevent staining and damage to the floor. Use absorbent materials like paper towels or clean cloth to blot and wipe away liquids. For stubborn stains, you may need to use a mild detergent and water. If chemicals or acids are spilled on the epoxy, follow the manufacturer’s guidelines for handling chemical spills. Some chemicals can react with epoxy, so it’s crucial to clean them up promptly and safely.

We recommend periodically deep cleaning your floor. Depending on the traffic and usage of the area, perform a deeper cleaning using an epoxy floor cleaner or a pH-neutral, non-abrasive cleaner. Dilute the cleaner as instructed on the product label, apply it to the floor, and scrub the surface with a soft nylon brush or a rotary floor scrubber. This a service that we offer as part of our maintenance package.

As well as these cleaning processes, one of the best ways of looking after your floor is preventative maintenance. Entrance mats, protective mats, and furniture pads are all excellent methods of preventing scratches and unnecessary damage. But above all of these, regular inspection can have the biggest impact on the longevity of your system. Catching an issue early can be the difference between it being a major issue or tweaking the maintenance regime that you are using.

Properly maintained epoxy resin flooring can maintain its appearance and functionality for many years. After we install any floor, we will provide you with the correct information to look after your new system. We are only a phone call away and are always on hand with any queries you may have.

Why Should you Consider DC Flooring for Your High Build Epoxy Needs?

After years in the industry, we are proud to look back over our body of work, and you can see it for yourself from our case studies. 

We have always been invested in the long-term performance of every surface we have ever advised for and then laid. Keeping track of its efficiency over time allows us to continually sharpen our skills and ensure we always deliver exactly the product that is most suited to your needs.

We are proud to be long-standing members of FeRFA and The Contract Flooring Association, as well as many other governing bodies. Health and Safety is extremely important to us, and we have been certified by a large number of industry-leading companies in this field.

There are a number of DIY products on the market these days. There are some 5kg and 10kg kits available and people are using these to do their own epoxy garage floors. This is great, and we are always happy to offer advice to those brave enough to do a resin garage floor. Just remember that preparation is key, always follow the instructions and health and safety advice.

Invest in a tough Epoxy Resin floor

Epoxy Resin is also well-known for its toughness and long-lasting resistance to impacts, making it suitable for heavy traffic areas. It can perform well in conditions that involve forklifts, and industrial floors where there is constant movement and burden on the floor.

Some team members at DC Flooring have spent their entire working lives becoming experts in all forms of surfacing works. So, you can rest easy knowing they are able to deliver expertise with every roller and brush of epoxy floor coating. Call our experienced team now – and we will advise you on any questions you may have.

For any info on our other services please click here and find out more about all the other expertise in our team and how we could help and advise you. You can reach us by filling in the form on our site, by sending a message to info@dcflooring.co.uk or by calling us on 01268 293014. We will get back to you as swiftly as we possibly can so you can quickly get the information that you need about our epoxy flooring systems. 

All subfloor preparation is done in-house using our specialised equipment – shotblasting, scabbling, and concrete grinding
You’re only a phone call away from investing in leading-class flooring systems, all approved by FeRFA.

FAQs

How much does it cost to epoxy resin a floor?

As discussed above, there is a huge number of different systems ranging from coatings for use in industrial settings right across to domestic garage floors. Thin floor sealers, thick heavy duty systems, all the way to decorative metallic epoxy resin and table top cast resins used for penny floors. Due to the extremely diverse nature of all of these products and applications, the cost per m2 can vary from anywhere between £10 – £250.

We are always happy to offer our advice on your existing surface and recommend the use of the correct material to suit your budget and expectations of performance. Sometimes resin flooring is not the most suitable product, we would rather tell you this and guide you to the correct solution. This is how we have earned the trust of our existing clients, and this is what we will continue to promote as a business.

Can Epoxy Resin Flooring be installed over existing floors like concrete or tiles?

Epoxy floor resin can usually be applied to ceramic tiles or existing concrete, as long as they are of a sound nature.

Ceramic tiles can be costly and time-consuming to remove, so being able to install systems over the top of them can in some instances, be very beneficial to customers. Solid epoxy resin is extremely hard, but very brittle (unlike polyurethane resin which is flexible in nature). Due to this any movement in the subfloor underneath can result in the resin surface cracking. At DC Flooring we have a few different methods of preventing this ranging from flexible primers, to fibreglass matting.

We would first check that the ceramics are sound and free from movement, this is followed by diamond grinding the tiles to remove any coatings or lacquer and to provide a suitable key. We can then install the resin system, sometimes with a fibreglass mesh that acts as a bridging mechanism, this is dependent on the existing surface and the top coats being applied.

It is extremely common to choose an epoxy resin floor to give existing concrete a new lease of life. However, there are a number of factors to consider when choosing the correct primer, system, and finish. Some problems that need to be considered are moisture issues, weak concrete or screeds, and contaminated floors. We have testing systems and solutions to overcome all of these potential pitfalls, which is why it is always important to use a contractor who is experienced and knows what to look out for. Get in touch and we will be happy to offer you our expertise and knowledge.

Is Epoxy Resin Flooring suitable for areas with extreme temperature fluctuations?

In areas with extreme temperature fluctuations, the best resin flooring system will typically be one that is specially designed and engineered to withstand these conditions. Polyurethane and methyl methacrylate (MMA) resin flooring systems are often considered more suitable for environments with extreme temperature fluctuations than standard epoxy resin systems.

When selecting a resin flooring system for areas with extreme temperature fluctuations, it’s crucial to consider the specific needs of your environment. We can provide guidance on the most suitable resin formulation, thickness, and installation methods to ensure the flooring can withstand the temperature extremes in your area.

In addition to choosing the right resin system, proper surface preparation, installation, and regular maintenance are essential to maximize the performance and durability of the flooring in extreme conditions. We would highly recommend using a professional company that is FeRFA-approved, as this expertise is invaluable in ensuring a successful and long-lasting resin flooring solution for your specific environment.

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