FloroCrete Urethane Mortar, installed with skill by FloorCare USA of WI.

With our cutting edge R&D and QC laboratories, floor coating engineering and manufacturing capabilities, regional factory technical representatives, and full network of local, approved specialty contractors, you can be assure that you’re getting the optimal concrete floor resurfacers for your facility.

Durable & Long-Lasting

Epoxy Mortar is designed to be used as a heavy-duty coating for creating seamless floors in manufacturing plants, mechanical rooms, warehouses, commercial kitchens, restaurants, garages, and service areas where heavy use, such as forklift traffic will apply.

Epoxy mortar systems and other troweled flooring solutions can offer incredible benefits to building owners, depending upon their needs.

When combined with graded sand or quartz sand and troweled into place, Epoxy Mortar provides a high-build system that is 100% solid, highly impact resistant, chemical resistant, and very resilient.

In addition, our products are available with FDA-registered antimicrobial protection and meet USDA requirements for food production facility flooring. We offer everything from quick-fix concrete crack repair kits to complete floor resurfacing; no matter the need, we have the ideal product.

Our Epoxy Mortar Flooring Systems FloroBuild PT/HT

The heavy duty FloroBuild Epoxy Mortar System can be used as a concrete resurfacer to patch and completely level slabs, create mild inclines and build integral floor-to-wall cove bases. FloroBuild PT/HT repairs moderate to severe spalling, pitting and other forms of deterioration that concrete floors are subject to. They also provide sanitary, skid-resistant and highly impact resistant surfaces, exhibiting impressive compressive strength and load capacity. FloroBuild adds performance, longevity and durability to concrete, offering outstanding lifecycle value.

FloroBuild XT FloroCryl Build MMA Mortar

When a fast curing acrylic MMA resin-based resurfacer is desired, FloroCryl Build is the answer. This three component MMA flooring system is ideal for areas that are subject to high mechanical and chemical wear. Florocryl Build is an easily cleanable floor that can be made with smooth or slip-resistant finishes.

FloroCrete HD Cementitious Urethane Mortar

With thermal shock and steam-cleaning resistant properties, superior acid and alkali resistance, and quick one-coat troweled installation, FloroCrete HD is an ideal solution for facilities requiring a solvent free, low odor, heavy duty, one-step mortar that can withstand abrasion and chemical exposure. It allows moisture to move through it at a safe rate, and it can be installed from a 1/4” to 3/8” thickness (6.0 to 9.5 mm).

 

Beautiful FloroBuild Flooring Installation by Hubbard & Associates, Inc. of NC.

Every manufacturing operation presents unique challenges that call for precise flooring solutions. In addition to adding visual interest to industrial facilities, warehouses, or factories, industrial epoxy and other high performance resinous floor coatings can help improve workers’ productivity, as well as support their health and safety.

Like many design and engineering decisions, site conditions play a key role in the type of floor coating that should be applied. For instance, food and beverage production plants, storage facilities, laboratories, and pharmaceutical plants require high performance and sanitary floor surfaces that are easy to clean and resist abrasion, staining and deterioration from chemicals.

Why Choose Epoxy Floors?

Benefits of applying epoxy coatings and other high performance flooring in industrial manufacturing facilities include:

Chemically Resilient: Well-designed epoxy floor coatings and other resinous finishes can survive exposure to strong chemicals, solvents and exposure to extreme pH. This is ideal for manufacturing facilities that may use such substances on a regular basis. Depending upon formulation, once the high performance coating components cure, the resulting solid polymer surface can be incredibly strong and prevent chemical and physical breakdown. Safety: Epoxy and other resin-based finishes have customizable skid-resistance to help prevent slips and falls. Some offer static control properties and most have a “self-extinguishing” fire rating. By nature, resinous flooring does not promote the growth of harmful mold, however additional antimicrobial additives, such as FloroSeptic can help further inhibit the spread of pathogens. These and other factors will help uphold both the safety of your employees and your structure. Cost-Effectiveness: Concrete floors coated with resinous finishes, such as epoxy, last longer and resist substantial wear, thus saving facilities money and allowing managers to devote resources to other aspects of the business. Time-Saving: In most cases, epoxy flooring and other resinous systems can be installed relatively quickly, reducing or, depending upon scheduling, even eliminating lost production time. Inexpensive and Easy Cleaning: Once concrete has been properly prepared and coated in a high quality resin or epoxy floor covering, it is no longer porous. That means dirt, chemicals and other substances remain on the surface and the floor is easier to clean. Lack of grout lines means quicker sanitation and fewer man hours scrubbing. Plus, many resinous finishes, such as Florock Floors, never need waxing. Visual Appeal: Florock offers a wide variety of floor coatings in an array of colors, patterns, and even customized logos to fit each facility’s specific style. Brightness: Many of our customers prefer a high-gloss option for coatings, which can enhance lighting due to reflection. Light-colored floors can also help brighten the space and occupants’ mood. Easy on Forklifts and Vehicles: A properly coated concrete floor has a safe, monolithic surface, free of unevenness, cracks and potholes. This helps keep forklift loads level, vehicle suspension systems and tires intact. As the result of well-selected epoxy or resinous floor, the money and time spent maintaining and repairing truck loading equipment can be greatly reduced. Eco-friendly: Epoxy and other resin-based flooring can be a green option for your business, eliminating the installation cut-off waste of tile and rolled goods. Facility managers like knowing that the majority of today’s liquid flooring components contain zero VOC, and that products from leading manufacturers contain no heavy metals. In addition, Florock is formaldehyde and phthalate-free, offers recycled glass aggregate blend options and furnishes recyclable packaging for many products. The infrequent replacement and sheer long-term durability of epoxy flooring and other fluid-applied alternatives add to their environmentally-friendly benefits.

Florock Antimicrobial Flooring, impressively installed by Garcia Smester of Dominican Republic.

Why use an epoxy primer?

It is a common misconception that epoxy primers are an extraneous added cost. However, they provide a variety of important solutions to several widespread problems associated with concrete surfaces. If superior adhesion and endurance is needed, the use of an epoxy primer is a necessity, not an extra. Some benefits provided by epoxy floor primers include:

Penetration into the concrete substrate, providing an overall better mechanical bond to the slab. Superior chemical bond for subsequent epoxy base coats. Because of their lower viscosity, epoxy primers fill the pores of the slab substrate and help to eliminate bubbles and pinholes that can form due to concrete They allow subsequent coats to achieve a higher dry film thickness and uniform finish. Some epoxy primers can serve help mitigate moisture vapor transmission (MVT) from beneath the floor slab. Some are moisture tolerant and work well when being applied over higher relative humidity floors.

Depending on the type of primer used, dry times and recoating windows vary. This includes both fast-curing and slower-curing options, moisture tolerant formulations and moisture vapor mitigating options. Primers may be selected for their ease of handling, lower or higher viscosity, installation temperature range, ability to cure well in a given environment or temperature, pot life, and a host of other reasons.

Compatibility of a given epoxy primer with a chosen flooring system may vary according to resin types and other factors. High performance fluid-applied flooring is intended for use by professionals. Therefore, utilizing a manufacturer-approved installer is the best way to get a correctly applied floor that performs as designed. When in doubt, contact the manufacturer for assistance in selecting a local installation company.

Epoxy Primers Options Floropoxy 4700: A quick-curing 100% solids epoxy primer Floropoxy 4755: A slower-curing, 100% solids, tacky epoxy primer Floropoxy MVT: A 100% solids epoxy primer that can help mitigate lower levels of moisture as part of the FloroProof System FloroCrete P: A moisture tolerant cementitious urethane primer, which is also part of the FloroProof Moisture Mitigation System Prime & Protect

Regardless of the purpose, high quality epoxy primers, applied as the first coat over properly prepared concrete, furnish the best foundation for your polymer flooring systems.

They provide your concrete floor coatings with better adhesion, improved aesthetics and increased durability.

With different formulas available for a variety of needs and applications, our selection of epoxy primers helps ensure the best performance possible from your concrete floor coatings.

 

FloroCrete RT with FloroSpartic 5 topcoat, expertly installed by Floorcare USA of WI, cleans up quickly and easily, even in extreme environments.

Epoxy flooring and other seamless commercial, industrial and institutional systems provide durable surfaces that are not only attractive, but also very simple to maintain. With just a few steps, keeping a facility’s resinous or epoxy flooring investment in top condition is easy and inexpensive. A regular schedule of routine sweeping and occasional light scrubbing will help preserve the floor’s striking appearance and excellent performance for many years.

These include everything from smooth high gloss surfaces, monolithic satin finishes, stippled “orange peel” effects, and slip-resistance ranging from extremely mild to more aggressive profiles for areas with excessive grease or oil.

Depending upon the formulation of the protective resinous or epoxy flooring topcoat, as well as the level of skid-inhibiting aggregate, cleaning and maintenance procedures may vary. However, the basics apply to all.

Sweep Daily

As with any surface in an public setting, coated concrete floors will gather loose debris and dust. Make sure to sweep resinous flooring well at the end of each workday.

Wash Weekly

When washing resin-coated concrete floors, whether using a mop-and-bucket or soft bristle mechanical scrubber, employ a dilute solution of warm water and mild detergent cleaner. Note that strong acidic substances, such as vinegar, or highly alkaline cleaners, such as ammonia, are neither recommended nor needed. And depending upon the floor type and composition, these extreme pH liquids may actually damage the topcoat.

If required, give extra care to areas subject to heavy traffic, hard rubber wheels or any type of machinery that leaves marks.

Remove Abrasives & Contaminants Promptly

Any abrasive particles should be swept or vacuumed up as soon as possible. Liquid contaminants should be removed by mopping or light scrubbing using the solution described above. Make sure to rinse thoroughly with clean water, multiple times if needed.

Guard Against Staining

Epoxy and resinous flooring is available in a broad spectrum of high performance protective finishes. Proper selection for a specific facility takes the operation’s daily activities and chemical use into account. It is therefore unlikely that a carefully chosen and properly installed resin-based floor system will get damaged by everyday spills. However, prompt cleanup of liquids is a good practice for both the sake of the floor, as well as occupants’ safety. In the event that a substance does leave a shadow or stain after cleaning, it’s best to consult your flooring representative rather than immediately proceeding with untried cleaners.

Optional Occasional Buffing Refinish if Necessary

When a resinous or epoxy floor nears the end of its useful life, it can be professionally refinished with the same look relatively quickly. Alternatively, an entirely different type of fluid-applied flooring system may be installed over the existing material. The selection is unlimited!

Florothane MC Hangar Flooring with embedded squadron logos, beautifully installed by RP Coatings of CA.

When embedding graphics or epoxy logos into resinous flooring, every seasoned professional installer has his or her own secrets for achieving the crisp, clean-edged result desired. It takes significant technique and skill to get it right and the different shapes, sizes, color combinations and other factors can play a role, challenging even the most experienced pros.

In general, one of four different methods is typically employed when adding unique graphics to polymer flooring systems:

1) Logo or message pre-printed on special perforated mesh

2) Logo or message pre-printed as an adhesive decal

3) Logo or message cut out of coated paper in the form of a stencil.

4) Freehand drawing and painting

How to Choose a Logo Method

The reasons for using one method over another are varied and many. The size, shape and number of colors involved in a given graphic design can play a roll, as can the installation crew’s preference and experience in using a specific material.

In addition, the thickness, cure time and composition of the floor coating system can influence which logo application technique gets employed.

Common to all methods of floor graphics installation is the need for meticulous planning. Decisions about the logo’s design and size, as well as its location on the floor must be carefully made.

An appropriate background for the graphic can then be selected from an almost unlimited number of offerings, ranging from solid colors to blends of multi-colored chips or quartz, or even one of the new shimmering “metallic” floors.

When using a pre-printed design or stencil, ordering the graphic as early as possible can be important. Using the services of a reputable specialty printer may cost a bit more, but can save time and headaches at the job-site.

Once the graphic is delivered, getting the facility manager’s approval on the final printed or cut-out design before installation onto the industrial floor is always good practice.

Preserving the Graphic

After the logo or message is embedded into the resinous flooring system, one or more topcoats of clear, non-yellowing epoxy, urethane or other high performance resin helps ensure that the beautiful graphic and floor design will adorn the facility for years to come.