- At a glance
- 1. Purpose
- 2. Quick Selector
- 3. System Types (overview)
- 4. Reference Standards
- 5. Typical Build‑Up
- 6. Survey Checklist (pre‑selection)
- 7. Indicative Performance Ranges
- 8. Quality Data Additions (spec targets)
- 9. PU Concrete — Consultant Guide
- Disclaimer
How to use this page
- Use the table of contents to jump to system overviews, selectors, and QA targets.
- Start with the Quick Selector to shortlist systems.
- Review Reference Standards and QA checkpoints before finalizing specs.
At a glance
- Typical uses: heavy traffic bays, pharma and cleanrooms, food and beverage wet zones, car parks, cold storage
- Duty ranges: thin film coatings to heavy‑duty PU concrete
- Common thicknesses: 0.5–2 mm coatings, 2–3 mm epoxy SL, 4–12 mm PU concrete
- Key standards: EN 13813, ASTM D4060, ASTM D4541, ASTM C579, IEC 61340
1. Purpose
Industrial floors must resist abrasion, impact, chemicals, and thermal cycles while staying seamless and easy to clean. Choose systems by exposure, movement, hygiene, and lifecycle cost.
2. Quick Selector
Condition | Recommended System | Key Parameter |
Heavy traffic and abrasion | Dry shake hardener or PU concrete | Base concrete ≥ 30 MPa, system compressive ≥ 60 MPa |
Chemical spillage | PU concrete or epoxy screed | Chemical resistance per datasheet and EN/ASTM |
Food and beverage with washdowns | PU concrete 4–9 mm | Thermal shock resistance |
Pharma and cleanrooms | Epoxy self‑leveling 2–3 mm | Seamless, low‑porosity, high gloss |
Cold storage down to −20°C | PU concrete | Thermal stability |
Car parks and outdoor | UV‑stable PU coating | UV stability and skid resistance |
3. System Types (overview)
Type | Build | Typical Thickness | Typical Use |
Concrete densifier | Silicate liquid treatment | Surface only | Warehouses, parking |
Dry shake hardener | Mineral/metal aggregate shake‑on | 2–5 mm (integral) | Heavy traffic bays |
Epoxy coating/screed | 100% solids epoxy | 0.5–2 mm coat, 3–6 mm screed | Pharma, labs, dry process |
PU coating | Aliphatic/AR PU | 1–3 mm | Walkways, mezzanine, UV areas |
PU concrete | PU‑cement hybrid | 4–12 mm | Breweries, dairies, kitchens |
Anti‑static/ESD | Epoxy/PU with conductive fillers | 1.5–3 mm | Electronics, cleanrooms |
4. Reference Standards
- EN 13813 screed materials and floor systems
- ASTM D4060 abrasion (Taber)
- ASTM D4541 pull‑off adhesion
- ASTM C579 compressive strength (epoxy mortars)
- IEC 61340 ESD requirements
5. Typical Build‑Up
Concrete substrate → Primer → Intermediate layer (epoxy, PU, or PU concrete) → UV or chemically resistant topcoat. Integrate densifiers or dry shake at casting where applicable.
6. Survey Checklist (pre‑selection)
Structure and exposure: dry or wet, thermal, chemicals
Substrate condition: compressive strength, moisture (ASTM F2170), flatness
Joints and cracks: type and movement
QA targets: pull‑off ≥ 1.5 MPa for resin systems
7. Indicative Performance Ranges
- Epoxy SL: compressive 60–80 MPa, adhesion ≥ 2.0 MPa
- PU coating: flex 12–15 MPa, adhesion ≥ 2.0 MPa
- PU concrete: compressive 80–100 MPa, adhesion ≥ 2.5 MPa
8. Quality Data Additions (spec targets)
- Substrate moisture (ASTM F2170): internal RH ≤ 75% for epoxy systems. PU‑cement typically tolerates higher RH. Confirm product‑specific limits.
- Surface preparation: ICRI CSP 3–5 for self‑leveling resin screeds. CSP 2–3 for thin film coatings. Verify laitance removal and open pores.
- Minimum pull‑off adhesion (ASTM D4541): Epoxy ≥ 2.0 MPa. PU coating ≥ 2.0 MPa. PU concrete ≥ 2.5 MPa.
- Typical DFT by duty: Epoxy SL 2–3 mm. PU coating 1–2 mm. PU concrete 6–9 mm production halls, 4–6 mm corridors, 9–12 mm heavy impact or thermal cycling.
- ESD floors (IEC 61340): surface resistivity 1.0×10^6–1.0×10^9 Ω. Validate footwear and person‑to‑ground.
- QA checkpoints: slopes to drains verified. Adhesion re‑test after prep. Batch and cure records. Mock‑up approval.
9. PU Concrete — Consultant Guide
Composition:
- 3‑component polyurethane‑cement hybrid. High compressive strength with good thermal and chemical resistance.
Where it excels:
- Food and beverage, Dairies, Breweries, Commercial kitchens, Freezers, Thermal‑shock zones, Wet process areas.
System builds and thickness selection:
- 4–6 mm trowel or roller‑applied: medium duty wet zones, corridors, ancillary rooms.
- 6–9 mm self‑smoothing or trowel: production halls, washdowns, forklift traffic.
- 9–12 mm trowel or heavy‑duty: severe impact, thermal cycling, frequent steam or hot‑wash.
Texture and slip resistance:
- Broadcast quartz to achieve required CoF. Specify PTV or pendulum values per local code. Typical target R10–R12 depending on wet or oily conditions.
Thermal performance:
- Suitable for cycling between sub‑zero and near‑boiling surface temperatures when installed at 6–9 mm+. Confirm grade’s thermal‑shock test data.
Detailing rules that avoid failures:
- Coves: 75–100 mm radius PU‑cement coves at wall‑floor junctions in wet areas.
- Drains: slope 1:80 to 1:100 to stainless drains with mechanical locks. Seal transitions with compatible elastomeric sealant. Avoid sharp arrises at gulleys.
- Joints: honor existing movement joints. Use backer rod and compatible PU sealant. Maintain width:depth ≈ 2:1 for joints > 10 mm.
- Terminations: key‑cut at edges and around equipment plinths to lock the system.
Chemical resistance checklist:
- Verify exposure list: alkalis, acids, sugar solutions, fats, cleaning agents, sanitizers. Cross‑check manufacturer immersion or splash data and max temperature.
Substrate and environmental conditions:
- Base concrete ≥ 25–30 MPa compressive. Moisture tolerant but standing water must be removed. Install within temperature band recommended for cure.
Acceptance criteria (typical):
- Thickness within −0/+1 mm of specified average. Pull‑off ≥ 2.5 MPa with concrete failure preferred. Uniform texture and color acceptance from approved mock‑up. No pinholes or exposed aggregate at topcoat.
Maintenance plan (brief):
- Daily neutral detergent scrub. Avoid strong solvents unless verified. Periodic inspection of coves, joints, and drain terminations. Repair chips immediately.
Disclaimer
Conix is an industry initiative & a neutral resource, compiled from industry references and best practices. It is not brand-specific. Always cross-check with project requirements and local codes before finalizing specifications.