Reaction resin flooring systems are thin layers of epoxy or polyurethane resins, which, after hardening, acquire high mechanical strength and outstanding chemical resistance. They can be applied to both new and old floors, in areas that are exposed to great mechanical or chemical wear. Epoxy floorings demonstrate excellent durability in time, keeping simultaneously the maintenance cost at the minimum. Furthermore, they form a smooth, durable, non-absorbent and easy-to-clean final surface.
Considering the market requirements for floorings of high strength and excellent level of aesthetics, ISOMAT based on its long-standing experience has developed a complete range of epoxy and polyurethane flooring systems that fulfill all modern design requirements. Besides that, ISOMAT offers the necessary technical know-how and solutions to any industrial flooring problem.
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BASIC PROPERTIES OF EPOXY FLOORINGS
HIGH MECHANICAL STRENGTH
Epoxy floorings are extremely resistant to mechanical wear, such as in areas with increased traffic loadings (industrial production sites and storage facilities, small industries, parking sites, hotels, shopping malls etc.).
They are characterized by:
- Increased resistance to abrasion, as to avoid dusting and wearing out.
- Excellent compressive strength.
- High adhesion to the substrate, as to avoid delamination.
- Major punctual hardness, as to avoid incising.
EXCELLENT CHEMICAL RESISTANCE, EASY-TO-CLEAN
Epoxy floorings are non-absorbent, easy-to-clean layers that demonstrate exceptional chemical resistance. Therefore, they are suitable for use in production facilities, slaughterhouses, gas stations, car repair shops etc. They prove resistance to organic and inorganic acids, solvents, petrochemical products, lubricants, harsh cleaning agents, etc.
Epoxy floorings of ISOMAT are certified with the CE marking according to the European standard EN 13813.
COST-EFFICIENT FLOOR RESTORATION
Epoxy floorings are a cost-efficient solution when compared with other recommended alternatives for floor restoration, as they are easy-to-apply and can be walked on, shortly after application. Additionally, their ability to endure is longer when comparing with other floor construction alternatives.
SMOOTH OR NON-SLIP SURFACE FINISH
A non-slip surface finish with different levels of slip resistance can be formed through a specific laying technique apart from the smooth finish, in areas where there is a high risk of slipping (industrial production facilities, ramps etc.).
In areas there is an increasing demand to prevent the negative impact of the static electricity, such as computer rooms, printing houses, textile factories, hospitals, gas stations, power stations, ammunition stores etc., the installment of conductive epoxy flooring systems is recommended.
APPLICATION ON PARTICULARLY DIFFICULT SUBSTRATES
Epoxy floorings are usually applied to clean and dry cementitious substrates that are at least 28 days old. However, by using adequate primers, they can be also applied to surfaces that are only 7 days old or appear to have rising moisture/damp problems. Moreover epoxy floorings can be installed to substrates that are contaminated with oil, provided that these surfaces have been previously treated chemically by special cleaning agents.
The epoxy flooring systems of ISOMAT have been certified for their suitability for use in food process and food storage facilities, freezers, and hospitals etc., where the decision for a proper floor covering is determined by strict hygienic requirements. Furthermore, due to their smooth surface finish, they can be cleaned fast and easy.
RAPID CURING – QUICK USE
The required time for the installment of an epoxy flooring system is particular short and depends on the substrate’s condition and the type of the epoxy flooring that shall be applied. The applied flooring system, depending on the prevailing temperature conditions, may be walked on, the following day upon completion of the installation, while it can be exposed to maximum loading in seven days.
SELECTION OF THE DESIRED COLOR
The epoxy floorings are produced in a variety of colors so to meet the aesthetics’ criteria of each customer and fulfill also the utility requirements of the construction site (e.g. possibility of floor marking and floor lining).
BASIC PROPERTIES OF POLYURETHANE FLOORINGS
RESISTANCE TO SOLAR RADIATION
The polyurethane floor coatings have an excellent resistance to solar radiation (UV).
HIGH MECHANICAL STRENGTH AND ELASTICITY
Polyurethane floor coatings offer high strength, abrasion resistance and they are used in areas that require high elasticity. Therefore, they are ideal for refrigerators and freezer rooms, industrial areas, warehouses, laboratories, hospitals, wine factories, slaughter-houses, canned food factories, car workshops etc.
EXCELLENT CHEMICAL RESISTANCE, EASY-TO-CLEAN
Polyurethane floorings are non-absorbent, easy-to-clean and demonstrate exceptional chemical resistance to:
- Dilutions of organic and inorganic acids.
- Alkalis, petrochemical products, specific solvents, wastes, water, salt and harsh weather conditions.
RESISTANCE TO LOW AND HIGH TEMPERATURE
Polyurethane floorings have been exposed to extreme weather conditions without abolishing their properties. They can be applied both to areas with low and high temperature (e.g. freezers and industrial production facilities).
INSTALLATION PROCESS OF THE EPOXY FLOORING SYSTEMS
4 STEP INSTALLMENT
1 – Substrate preparation
2 – Substrate priming
3 – Filling up substrate irregularities
4 – Final coating/sealing
In every step of the installation process it is important to use the proper tools and materials and to have good knowledge of all construction details, for ensuring a sound construction solution.
1 SUBSTRATE PREPARATION
The successful installation of an epoxy flooring system starts with the proper preparation of the substrate. The substrate (industrial floor, concrete slab, cementitious screed, mosaic floor) must be free of residues that prevent bonding of the flooring layer to the substrate (such as dust, loose particles, grease etc.), dry (moisture content < 4%) and sound with sufficient strength.
MOISTURE CONTENT DETERMINATION
Measuring the moisture content of the concrete substrate is essential in order to decide for the adequate primer. Concrete floors that are 28 days old usually have moisture content less than 4%. However, when the concrete is relatively fresh or exposed to rising moisture, then it may not be free of excess moisture. Therefore it is recommended to determine the moisture content before any application either by use of an electronic moisture meter or preferably with a Wagner type Calcium Chloride or Relative Humidity test.
The concrete substrate must be prepared properly by shot blasting, grinding etc., in order to remove cement laitance and achieve an open textured surface, thus helping the primer penetrate deeper into the pores to induce increased anchoring and bonding of the upcoming epoxy layer to the substrate, while reaching also sufficient surface leveling. Subsequently, all dust and loose particles should be thoroughly removed by a high suction vacuum cleaner.
SUBSTRATES CONTAMINATED WITH OIL
Surfaces contaminated with oil require thorough cleaning before being covered with epoxy floorings. At first, the floor is cleaned from the superficial dirt by hot water blasting. Then it is rubbed by shot blasting in order to reach an open textured surface. Subsequently, the industrial cleaning agent FD-CLEAN is spread onto the surface and rubbed diligently with a hard brush, thus enabling the material to penetrate into the floor pores and emulsify the oil. After 30 minutes the emulsified oil is removed by hot water blasting. Thereafter, the floor should be primed directly with a special primer before the oil rises to the floor surface again.
Metal substrates (e.g. lofts) which shall be covered by epoxy coatings must be free of rust and any type of erosion to ensure good bonding. The treatment of these substrates shall be done by sand blasting. Thereafter, the surface should be cleaned thoroughly with a high suction vacuum cleaner.
2 SUBSTRATE PRIMING
Priming shall take place on the thoroughly prepared surface to ensure the proper bonding of the subsequent flooring. ISOMAT offers a wide range of primers, both solvent-based and solvent-free, dealing with all possible kinds of substrates (cementitious or metal substrates, green concrete, cementitious substrates with rising moisture or contaminated with oil). During application the primer penetrates and anchors in the pores of the substrate, thus stabilizing the substrate and acting as a bond layer between the substrate and the final coating.
Two-component epoxy primer with solvents
Cement-based substrates (industrial floors, concrete, cement-mortar, mosaic) are primed with the two-component epoxy primer DUROPRIMER. Due to solvents, the primer penetrates deeply into the substrate providing excellent anchoring. The surface must be clean, dry and protected from rising moisture. DUROPRIMER is applied by roller, brush or spray in one layer. The installation of the selected epoxy system follows within 24 hours after priming and when the primer has dried
Two-component, solvent-free epoxy primer
In cases where the presence of solvents is not desirable (e.g. in-cabin rooms with insufficient ventilation), the use of DUROFLOOR-PSF instead of DUROPRIMERis recommended. The surface must be clean, dry and protected from rising moisture. DUROFLOOR-PSF is applied by roller, brush or spray in one layer. The installation of the selected epoxy system follows within 24 hours after priming and when the primer has dried.
Two-component, water-based epoxy primer
In cases where the presence of solvents is not desirable, EPOXYPRIMER-W could be used alternative to DUROFLOOR-PSF. EPOXYPRIMER-W can be applied on dry to slightly wet substrates, without standing water. EPOXYPRIMER-W is applied on the substrate as it is or diluted up to 10% b.w. with water. It can be applied by brush or roller in one layer. The installation of the selected epoxy system follows within 24-48 hours and only when the moisture content of the primed surface is less than 4%.
Three-component, water-based epoxy primer
In case the selected epoxy floor will be installed on wet (moisture content higher than 4%) or green concrete (up to 5 days old), the substrate must be primed with the three-component, water-based epoxy primer DUROPRIMER-W. It has the adequate diffusion coefficient to compensate the pressure created by the water vapor of moisture. DUROPRIMER-W is applied by brush or roller on the wet, with no standing water, substrate in one layer. After 48 hours and provided that the moisture content of the DUROPRIMER-W layer is less than 4%, the installation of an epoxy system may follow.
Two-component, solvent-free moisture mitigating primer
For oil contaminated concrete floors or floors with rising moisture, priming of the surface with the two component special primer DUROPRIMER-SG is required. Oil contaminated substrates must be treated with special cleaning agents chemically and then washed out with water. Due to its high specific weight DUROPRIMER-SGcan displace the water from the capillary pores of the substrate, while anchoring sufficiently. DUROPRIMER-SG is applied on the wet, but without standing water, substrate by a roller or squeegee and brushed thoroughly. The installation of the final epoxy coating follows after 24 hours.
Two-component, anticorrosive epoxy primer
Metal surfaces can be primed with the anticorrosive epoxy primer EPOXYCOAT-AC. EPOXYCOAT-AC is a two-component, colored epoxy system with solvents. It offers excellent protection against corrosion to metallic surfaces. The surface must be clean, dry and free of rust. EPOXYCOAT-AC is applied by roller, brush or spray in two layers. The second layer follows within 24 hours and when the first has dried. The installation of the selected epoxy coating should follow within the next 24 hours and after the second layer of the anticorrosive epoxy primer has dried.
One-component polyurethane primer with solvents
PRIMER-PU100 is applied on porous substrates and ensures the proper adhesion of the liquid applied, polyurethane coating DUROFLOOR-PU. It is suitable for substrates like concrete, cement-mortars, wood etc. The surface to be primed must be dry, free of dust, grease, dirt etc. PRIMER-PU 100 is thoroughly stirred and uniformly applied on the substrate by brush, roller or spraying.
3 FILLING UP SURFACE IRREGULARITIES
After the primer has dried and before applying the final epoxy or polyurethane flooring, any existing substrate imperfections (cracks, holes etc.) shall be filled up in order to achieve a smooth and continuous surface. Especially in cases where the selected reaction resin flooring shall be installed in a thin layer (DUROFLOOR-R), the filling up of the surface irregularities is important for providing a smooth substrate. Patching and filling up of surface irregularities can take place with the ready-to-use epoxy putties EPOMAX-EK and EPOMAX-STUCCO especially when the area of application is limited, or by preparing a resin mortar (mixing of epoxy resin with quartz sand of particle size 0-0.4 mm). The reaction resin flooring shall be applied after the leveling material has hardened and within the time limits that are set for each type of primer.
Two-component epoxy putty
EPOMAX-EK is a two-component epoxy system without solvents. After hardening it offers very strong bonding to the substrate, high hardness and high mechanical resistance. The two components are mixed with a trowel.
Two-component epoxy putty, extra fine-graded
EPOMAX-STUCCO is a two-component epoxy system without solvents. After hardening it offers strong bonding to the substrate, high hardness and high mechanical resistance. The two components are mixed with a trowel.
RESIN REPAIR MORTARS
Resin-mortars can be prepared by the use of the epoxy primer DUROFLOOR-PSF with addition of quartz sand, in proportion 1:2 to 1:3 by weight. Alternatively, the epoxy resins DUROFLOOR and DUROFLOOR-R can be used for this purpose, by mixing with quartz sand in proportion 1:2-1:3 and 1:1.5-1:2 b.w. If the surface has been previously primed with DUROPRIMER-W, then the same epoxy primer must be used as it is for filling up any irregularities. Finally, in case of priming with EPOXYPRIMER-W, then only the same epoxy primer can be used as a resin mortar, mixed with quartz sand in proportion 1:2 to 1:3 b.w., for filling up any irregularities.
4 FINAL COATING
Following the requirements for the final flooring, in terms of mechanical and chemical resistance, the appropriate final epoxy coating and the matching application method are selected. DUROFLOOR is a self-leveling epoxy flooring suitable for areas that are subjected to high wear, DUROFLOOR-R is a coating for areas that are subjected to wear of medium intensity, while DUROFLOOR 11 can be applied as a self-leveling epoxy flooring or as an epoxy coating. DUROFLOOR-PU is a polyurethane coating with excellent resistance to solar radiation that is suitable also for exterior applications. Finally, DUROFLOOR-C is a self-leveling, conductible epoxy flooring applied onto areas where static electricity is undesirable.
SELF-LEVELING EPOXY FLOORING SYSTEM
DUROFLOOR – Self-leveling epoxy flooring
DUROFLOOR is a two-component, solvent-free, colored, self-leveling epoxy system. It offers high strength and abrasion resistance. It is resistant to organic and inorganic acids, alkalis, petroleum products, wastes, water, salt and a large number of solvents. Also, it is resistant to temperature alteration from -30ºC to +100ºC for dry loading and, up to +60ºC for wet loading. During application it is mixed with quartz sand of 0-0.4 mm particle size (Q35)in proportion 1:2 by weight. It is applied in a thickness of 2-3 mm with a notched trowel.
DUROFLOOR is used as pourable, self-leveling flooring on cement-based floors where high mechanical or chemical resistance is required. It is suitable for industrial areas, warehouses, retail stores, car workshops, supermarkets, laboratories, hotels, garages, gas stations, and areas with heavy traffic etc. It is also suitable for coating surfaces that will come in direct contact with food products, according to W-347, ISO 8467.
BRUSHABLE EPOXY FLOOR COATING SYSTEM
DUROFLOOR-PSF – Brushable epoxy coating
DUROFLOOR-PSF is a two-component, solvent-free, clear epoxy system, offering high strength and abrasion resistance. It is resistant to organic and inorganic acids, alkalis, petroleum products, specific solvents, waste water, salt and weathering conditions. It is resistant to temperatures from -40ºC up to +100ºC in dry loading and up to +60ºC in wet loading.
DUROFLOOR-PSF is used as a coating on floors that require high mechanical or chemical resistance. It is suitable for cement-based substrates, e.g. concrete or cement screeds, as well as for steel or iron surfaces in industrial areas, warehouses, laboratories, slaughter-houses, hospitals, wine factories, canned food factories, garages, car repair shops etc.
DUROFLOOR-R – Brushable epoxy coating
DUROFLOOR-R is a two-component, solvent-free, colored epoxy system, offering high strength and abrasion resistance. It is resistant to organic and inorganic acids, alkalis, petroleum products, specific solvents, waste water, salt and weathering conditions. It is resistant to temperatures from -40ºC up to +100ºC in dry loading and up to +60ºC in wet loading.
DUROFLOOR-R is used as a coating on floors that require high mechanical or chemical
resistance. It is suitable for cement-based substrates, e.g. concrete or cement screeds, as well as for steel or iron surfaces in industrial areas, warehouses, laboratories, slaughter-houses, hospitals, wine factories, canned food factories, garages, car repair shops etc. It is also suitable for surfaces that shall come in direct contact with food, according to W-347, ISO 8467.
DUROFLOOR-RL – Brushable epoxy coating
DUROFLOOR-RL is a two-component, colored epoxy system. It has the same properties, fields and way of application with DUROFLOOR-R. In addition, it complies with the LEED requirements, concerning the Volatile Organic Compounds content (VOC).
SELF-LEVELING and BRUSHABLE EPOXY FLOORING
DUROFLOOR 11 – Self-leveling or brushable epoxy flooring
DUROFLOOR 11 is a two-component, solvent-free, colored epoxy system. It offers high strength and abrasion resistance. It is resistant to organic and inorganic acids, alkalis, petroleum products, waste water, salt and a large number of solvents. It is resistant to temperatures from -40 C to +100 C in dry loading and up to +60 C in wet loading.
DUROFLOOR 11 is used, with the addition of quartz sand with a particle size of 0.1-0.4 mm (M32 quartz), in proportions 1:1 as a self-leveling epoxy flooring on cement-based floors that require extremely high mechanical or chemical resistance, in a thickness 2-3 mm. Its application is similar to the one of DUROFLOOR.
DUROFLOOR 11 can also be used, without the addition of quartz sand, as a coating on floors that require extremely high mechanical or chemical resistance. It can be applied on cement-based substrates, as well as for steel or iron surfaces. it is suitable for industrial areas, warehouses, stores, car workshops, supermarkets, laboratories, hotels, garages, gas stations, areas with heavy traffic etc.
POLYURETHANE FLOOR COATING
DUROFLOOR-PU – Brushable polyurethane floor coating
DUROFLOOR-PU is a two-component, aliphatic, solvent-free, colored polyurethane system. After its application it forms a strong and elastic membrane with excellent resistance to solar radiation (UV). It offers excellent abrasion resistance; it is resistant to organic and inorganic acids, alkalis, petroleum products, to most solvents, waste water, salt and weathering conditions. It is resistant to temperatures from -40 C to +100 C in dry loading and up to +60 C in wet loading.
DUROFLOOR-PU is used as a coating on floors that require high elasticity, mechanical and chemical strength. It can be applied on cement-based substrates, steel or iron surfaces, existing epoxy floors. It is suitable for refrigerator and freeze rooms, industrial areas, warehouses, laboratories, hospitals, wine factories, slaughter-houses, canned food factories, garages, car workshops, etc.
Slip-resistant surface finish
After hardening, epoxy and polyurethane floorings provide a smooth surface finish of R9 slip resistance, suitable for ordinary use. In applications where there is high danger of slipping and thus the slip resistance is requested to be higher than R9, it is possible to form an adequate slip-resistant surface finish. Primarily, the first layer of the epoxy flooring is applied and then quartz sand is broadcasted until saturation on the still fresh layer. After hardening of the layer, any loose grains are removed using a high suction vacuum cleaner. Finally, a sealing layer of DUROFLOOR (A+B), DUROFLOOR-R, DUROFLOOR 11 or DUROFLOOR-PU is applied with a roller. The slip resistance of the floor surface depends on the particle size of the quartz sand that has been used and the density of spreading.
The slip resistance level of a floor should be selected carefully taking into consideration both the danger of slipping according to the specific site conditions and the effort in maintaining cleanliness and hygiene. The greater the granulometry of quartz sand, the greater the slip resistance, but cleaning and hygiene requirements become more difficult to maintain.
CONDUCTIVE SELF-LEVELING EPOXY FLOORING SYSTEM
The desired level of slip resistance depends both on the particle size of the quartz sand and the density of spreading. In the following table the consumption of the sealing layer is presented in relation to the desirable level of slip resistance.
DUROFLOOR-C Conductive self-leveling epoxy flooring
DUROFLOOR-C is a two-component, solvent-free, colored epoxy system. It offers permanent conductivity that prevents the build-up of static electricity on floor surfaces. Its electricalresistance is between 10 and 10 Ohm. DUROFLOOR-C provides high traffic and mechanical wear. It is resistant to organic and inorganic acids, alkalis, petroleum products, certain solvents, waste water materials, salt and to weathering. DUROFLOOR-C is used as a pourable, self-leveling coating on cement-based floors, in areas where static electricity should be avoided. It is suitable for use in computer rooms, laboratories, printing rooms, textile mills, hospitals, gas stations, electric distribution stations, ammunition storages etc.
DUROFLOOR-CV Conductive epoxy varnish (primer)
DUROFLOOR-CV is a two-component, colored epoxy system with solvents. It offers strong bonding to the substrate and high conductivity that prevents the build-up of static electricityon floor surfaces. Its electrical resistance is lower than 10 Ohm. DUROFLOOR-CV is used as an intermediate layer, below the epoxy flooring DUROFLOOR-C, to generate uniform conductivity on the whole floor surface.
FLOOR SURFACE HARDENING
The mechanical properties on the surface of cement-based floors (industrial floors, concrete slabs, screeds, mosaic) can be improved cost-efficiently with the use of the two-component transparent epoxy impregnation DUROFLOOR-BI or the polyurethane impregnation ISOMAT BI-120 PU.
DUROFLOOR-BI Transparent epoxy impregnation
DUROFLOOR-BI is a two-component, transparent epoxy system with solvents. Due to its low viscosity and its great fluidity, it can penetrate deep into the substrate by filling pores and capillaries. Therewith the impregnated surfaces become sound and durable, and particularly resistant to abrasion, chemicals and frost. Additionally, they prove enhanced resistance to wastes, mineral oils and petroleum products. DUROFLOOR-BI is suitable for floors in parking lots, warehouses, laboratories, industries, gas stations, car repair shops etc.
ISOMAT BI-120 PU Transparent polyurethane impregnation
ISOMAT BI-120 PU is a one-component, polyurethane, transparent coating of high penetrating ability. When applied on concrete floors or cement mortars, it seals and dustproofs their surface. It is also used as a surface hardener for crumbled floorings, in order to increase their strength and wear resistance. Moreover, it eliminates the permeability of floorings. It is suitable for concrete floors or cement mortars, in places such as basements, warehouses, light/medium traffic parking lots, etc. It may also be used as a protective coating for metal structures. BI-120 is also suitable for indoor use.
POLYURETHANE CLEAR COATINGS
VARNISH-PU 2K is a transparent, two-component solvent-based polyurethane varnish, that is:
- weather and UV resistant
- abrasion resistant and walkable
- chemically resistant to alkalis, oils etc.
- easy to clean (provides a smooth surface)
- available in mat and glossy texture
- It brightens up the appearance of surfaces
Fields of application
VARNISH-PU 2K is used for waterproofing and protection of cementitious surfaces, such as epoxy, concrete, cement screeds and decorative microcements (DUROCRET-DECO, DUROCRET-DECO FLEX and DUROCRET-DECO FINISH). Furthermore, it can be used as a protective coating for natural stones, wood, metal surfaces and as a UV protection coating above epoxy coatings inside swimming pools.
VARNISH-PU 2KW is a transparent, two-component, water-based PU varnish, that is:
- weather and UV resistant
- abrasion resistant and walkable
- chemically resistant to alkalis, oils etc.
- odorless, ideal for indoor applications
- easy to clean (provides a smooth surface)
- available in satin finish
- It brightens up the appearance of surfaces
VARNISH-PU 2KW is certified as a product for the protection and repair of concrete, according to EN 1504-2.
Fields of application
VARNISH-PU 2KW is used for waterproofing and protection of cementitious surfaces, such as epoxy, concrete, cement screeds and decorative microcements (DUROCRET-DECO, DUROCRET-DECO FLEX and DUROCRET-DECO FINISH). Furthermore, it can be used as a protective coating for natral stones, wood and metal surfaces.