Epoxy Floor Coatings: Protecting the Concrete Floor in a Factory.

The Challenge

As with many factories the floor was in bad shape. To save the floor it needed to be and leveled then protected with an epoxy coating that could withstand the harsh abuses of every day factory operations.

The Outcome

A protective epoxy coating that was impact and wear resistant was installed. The floor was also made safer for the employees through the use of an anti-skid additive.

Overview

Razac, Inc. is a hair care products company based in Newark, NJ. They needed to upgrade their manufacturing facility’s floor as it was in bad shape from years of use in the factory setting.

To level, strengthen and bury imperfections in the concrete floor the contractor first applied Duraamen’s Paramol which is a primer for self-leveling underlayments. It helps the underlayment adhere to the old worn concrete floor.

Next Param 4500 self-leveling concrete underlayment was applied. Our self-leveling underlayment is easy to install, has around 25 minutes working time and can be walked on in 3-4 hours helping to complete the job with minimal down-time.

With the substrate smooth and level it was time for the application of the epoxy coating. First an epoxy primer was applied (Perdure E02). Then the Perdure E10, combined with Self-leveling Additive (SLA), was applied. Unlike other epoxy coatings on the market, our Perdure E10 Self-leveling Epoxy Coating can be applied up to 1/16” thick. This helps with impact resistance, especially necessary in a factory setting.

Finally, the entire floor was sealed with Perdure P72 combined with an Anti-skid Additive. P72 is a polyaspartic polyurea coating that penetrates deep into the epoxy to provide superior adhesion so it will never lift or peel. It provides the ultimate protection from UV rays, abrasions, impacts, and wear. Our Anti-Skid additive (ASA) provides a textured surface so factory employees are safer from slips and falls.

Benefits

Perdure E10

• Low odor for use in occupied areas
• Available in fast cure systems
• USDA approved for food handling applications

Perdure P72

• Self-priming, excellent penetrating to achieve excellent bond strength
• Superior abrasion, impact and wear resistance
• Excellent hot tire pickup resistance
• UV resistance, does not turn ‘yellow’ or ‘amber’
• Reduces floor care, cleaning and maintenance costs

Anti-skid Additive

• Achieve slip-resistant surfaces
• At lower dosages, the surface will be barefoot friendly
• Excellent durability

Cost:

$12–$14 sq. ft. ( ½” thick coverage) depending on your geographic location and the thickness of the underlayment. Thickness is determined by the condition of the existing substrate. Is the substrate new, old, level, good condition, deteriorated, plywood, or gypsum?

The cost of this flooring system (all products needed to complete the project) is even less if you’re willing to do it yourself: $4.50–$5.00 sq. ft.

The cost is comparable to other types of flooring including:

• Hardwood
• Ceramic or Porcelain Tile
• Commercial Carpet
• Marble

The Success:

Razac Products now has a new factory floor that is easy to clean and maintain, and will last for years. The new floor coating also makes for a safer work place and happier employees thanks to its anti-slip properties.