Polymer coating for concrete floors: types, flooring and installation technology

Polymer coatings are a flexible and long-lasting option for improving concrete floors. These coatings are used to add functionality, enhance appearance, and offer protection to already-existing concrete surfaces. Polymer coatings come in various varieties, each with special qualities appropriate for various applications and conditions.

One of the most common options for polymer flooring is epoxy coatings. They are made of hardeners and epoxy resins, which combine chemically to produce a stiff plastic substance. Epoxy coatings are renowned for their extraordinary toughness and chemical resistance, which makes them perfect for use on floors in commercial and industrial environments where there may be chemical exposure and heavy traffic.

Contrarily, polyurethane coatings provide flexibility and UV protection, which makes them appropriate for both indoor and outdoor spaces where a more elastic surface is required. Polyurethane coatings are frequently utilized in areas like food processing facilities and auto workshops where temperature swings and thermal shock are frequent occurrences.

Melthacrylate (MMA) coatings are another kind that is becoming more and more popular. These coatings are perfect for projects that need to be completed quickly because they cure quickly and have a reputation for being installed quickly. Hospitals, retail establishments, and other settings where minimizing downtime is essential commonly use MMA coatings.

Polymer coating installation usually entails multiple steps to guarantee a long-lasting and visually appealing finish. To guarantee that the coating adheres properly, the concrete surface must first be properly cleaned and prepped. For improved bonding, this may entail shot blasting or grinding to get rid of impurities and roughen the surface.

The polymer primer coat is applied after the surface has been properly prepped. This serves as a foundation for later layers and aids in sealing the concrete. Multiple coats of the polymer may be applied, each adding to the floor’s overall strength and durability, depending on the particular product and desired thickness.

To satisfy esthetic and functional needs, extra finishing options like slip-resistant additives or decorative flakes can be added after the final coat is applied and cured. The polymer coating can last longer and preserve the best possible appearance for the concrete floor with proper maintenance, which includes routine cleaning and the periodic reapplication of a top coat.

All things considered, polymer coatings provide an adaptable and long-lasting way to improve concrete floors in a variety of settings. There is probably a polymer coating system that can satisfy your needs, whether you require a seamless floor for a laboratory, a decorative finish for a showroom, or a durable surface for a warehouse. You can select the best option for your particular application by being aware of the types that are available and how the installation works.

Type of Polymer Coating	Description and Installation Technology
Epoxy Coating	Epoxy coatings are known for their durability and resistance to chemicals. To install, clean and prep the concrete surface, apply a primer, then add the epoxy mixture evenly. Let it cure for a strong, smooth finish.
Polyurethane Coating	Polyurethane coatings offer excellent abrasion resistance and flexibility. Start with a clean surface, apply a primer, then spread the polyurethane coating. Allow it to dry and cure completely.
Polyaspartic Coating	Polyaspartic coatings are fast-drying and highly resistant to UV damage. Clean the concrete, apply the polyaspartic coating in thin layers, and allow each layer to cure quickly before adding the next.

Properties of concrete floors

Nowadays, the most enduring and robust flooring option for a variety of rooms is concrete. All the labor-intensive work of arranging floors can be done by you; the materials are readily available and reasonably priced.

A concrete floor is a coating made of a combination of water, different additives, fillers (such as sand, gravel, and stone chips), and a binder (cement). SP 29.13330.2011 "Floors" contains all the specifications needed for concrete floors. Concrete flooring is frequently seen in commercial, industrial, and warehouse settings because the base is particularly important under high load circumstances.

Concrete bases in residential apartments and homes must be finished, with the exception of lofts and high-tech designs, in which case the concrete is dusted and given special treatment to preserve its natural state without coatings.

• Durability – service life is measured in decades.
• Fire resistance – which is especially important in certain conditions where there is a risk of ignition.
• Resistance to high/low temperatures, humidity, mechanical stress, aggressive environments.
• Wear resistance and strength, reliability.
• Environmental friendliness and safety.
• Relatively low cost.

Concrete flooring’s low strength and propensity to dust its surface layer because of cement milk that has hardened are its only drawbacks. The layer gradually starts to show minor cracks and chips, creates a lot of dust, seeps into interior items and equipment, endangers people’s health, and degrades the floor’s aesthetics.

This feature necessitates either grinding and polishing, applying a finishing coat, or treating the concrete floor with specific impregnations and compounds.

Pouring a polymer floor is one way to create a decorative base that will dependable protect the concrete while also improving its usability and maintenance.

Polymer coatings provide a flexible option for concrete floors, with different types catering to different requirements. Every type of polyurethane or epoxy has advantages over the others in terms of maintenance needs, durability, and appearance. Choosing the appropriate flooring for your room requires taking into account elements like chemical exposure and traffic volume. Although there are differences in installation techniques, they usually include surface preparation, primer application, and final coating. Polymer coatings are a popular option in commercial, industrial, and residential settings because they not only improve the look of concrete floors but also shield them from damage.

Types of polymer coatings

The following factors should be taken into account when selecting a polymer coating: the room’s intended use, the kinds of loads that will affect the base, the state of the concrete floor, the operational environment, and the significance of decoration. Many manufacturers supply a variety of compounds that are used for the final finishing of a concrete floor.

Impregnations

Utilized for a variety of rooms. Impregnations are typically applied to concrete floors prior to the installation of the finishing layer. Increasing the adhesion of the concrete and polymer layers is required to guarantee the maximum strength and durability of the polymer floor. A composition that is not appropriate for these uses could result in a future floor that is distorted and cracked.

A homogenous liquid mass containing a binding polymer, a few fillers, and several specialty additives is known as floor impregnation.

• Filling all small pores of concrete.
• Ensuring reliable adhesion of materials to each other.
• Dust removal and strengthening of the base.

Choosing the right primer ensures improved adhesion and a longer service life, so skipping this step of the process won’t save you money on impregnation.

Polymer

Dust is removed from the concrete floor by impregnations on an organic basis, which also reliably and qualitatively fill the upper layer’s pores by penetrating the base of the concrete to a depth of 2 to 6 millimeters. As a result, the concrete gains strength and durability and is better equipped to resist the effects of various adverse factors.

Epoxy, acrylic, PVC, and polyurethane materials are the basis for polymer impregnations. The composition allows for the elimination of repair risks as well as the possibility of dust and contaminated equipment shutting down. Coatings become easier to clean, resistant to mechanical loads and harsh environments.

Polymer impregnation approach polymer concrete floors’ characteristics include doubled impact strength, tenfold abrasion resistance, and multiple times strength by grade. Additionally, it’s critical that impregnations be able to seal the surface and stop dusting and filler chipping.

Acrylic

This kind of composition needs to be renewed every two to three years and is assumed to have a limited service life. Where there aren’t any excessively large loads, acrylic impregnations are typically used. They effectively stop dusting and withstand moisture and UV rays. An average of 0.2-0.35 liters per square meter are consumed.

Polyurethane compounds

The most affordable and widely used kind of concrete surface impregnation. The compounds ensure total dust removal, greatly improve the base’s appearance, and greatly increase strength, wear resistance, and moisture resistance. The primary drawback of polyurethane compounds is their strong smell, which prohibits their use in environments with base humidity levels higher than 5%. The consumption (single-layer coating) is 200–400 grams per square meter.

Epoxy

Epoxy impregnations made of two components precisely dust concrete and dependablely shield it from moisture, fuel, and lubricant exposure. Compared to polyurethane compounds, impregnation offers a marginally reduced resistance to loads, but it does not imply an odor. 200–300 grams of the material are consumed per square meter.

Water-epoxy compositions, which differ in their decreased viscosity and thus penetrate the surface layers of concrete monoliths much better, have only recently become available on the market.

Latex

Latex-based materials are resilient to UV rays, handle dust formation well, and form a protective layer that is unafraid of harsh conditions and abrasives. Since water serves as the composition’s solvent, they have no smell. Concrete that has just been laid can still be impregnated. However, they are not intended for covering floors subjected to elevated loads.

Based on PVC resins

This kind of material consistently protects concrete from abrasion and stress by penetrating deeply into the surface layer. Impregnations are fast to dry, resilient to harsh conditions, and have a limited capacity to repel dirt.

200–350 grams of composition are used per square meter on average. Pigments are frequently added to impregnations to enhance their decorative qualities and give the floor color.

Polymer paint

Paints are appropriate for surfaces that don’t require a lot of load because they are applied in thin layers of 500 microns. The concrete floor is impregnated with a special substance prior to painting. The best way to achieve a stunning and long-lasting floor is to paint after priming and impregnation. There shouldn’t be any trouble choosing because Moscow and the surrounding areas now provide a wide variety of compositions.

1. Decorativeness and aesthetics – giving concrete a certain shade, which significantly ennobles the floor.
2. Protection – applying paint significantly extends the service life of the floor, increases resistance to aggressive and atmospheric influences, moisture, improves hygiene and mechanical strength.
3. Elimination of minor defects and cracks, smoothing out small irregularities.

— a trendy new coating that is applied to recently poured and old concrete floors in a thin layer. The composition increases the material’s resistance to different kinds of impact, deepens its penetration into its pores, and lengthens its service life. The 150 micron thick film can be applied without priming, dries in 4 hours, and increases in load capacity on the floor in 24 hours.

Floors

There are many different kinds of floors, and each type has unique characteristics, benefits, and drawbacks. It’s important to consider all the features and attributes before selecting a choice.

Self-leveling floor

Mixture that levels itself; typically, it is 4-5 millimeters thick. When the liquid composition is applied to a concrete surface that has been leveled, repaired, or fully hardened, it levels out on its own and forms a monolithic coating with exceptional strength and durability.

The surface can have decorations, be textured or smooth, and contain mineral particles.

Polyurethane-based

These coatings have excellent chemical and physical qualities, which makes them highly popular today.

• Can be poured onto bases that will experience high dynamic and static loads.
• The coating is not afraid of temperature changes, ultraviolet radiation, retains elasticity and strength.
• Polyurethane flooring does not slip, is hygienic, fireproof.
• Excellent decorative properties.
• Unpleasant odor of the composition.
• The mixture cannot be applied to damp bases.

Epoxy-based

Epoxy floors are suitable for both new and old screeds (the solution can be applied to still wet concrete), and they can withstand medium loads. They are often poured over old screeds. The coating can be used outside, is resistant to chemicals and other harsh effects, and doesn’t need special maintenance. It also repels dirt effectively. In addition to being environmentally friendly and fireproof, the base exhibits excellent decorative qualities.

The components are mixed to create the solution, which needs to be used promptly and correctly. Heavy objects falling on the coating can cause cracks because it is afraid of impact loads.

On a methyl methacrylate base

A relatively new kind of coating with specific characteristics.

• The two-component composition hardens quickly and is not afraid of moisture, impacts and abrasion, temperature jumps or aggressive environments.
• Loads are allowed up to 15 tons per square meter.
• It is difficult to work with the coating, it dries quickly, so it is usually used only by professionals.
• The composition releases toxic substances during installation.
• The floor is quite expensive.

Highly filled polymer floors

During installation, this kind of coating fortifies the base to an extremely high degree, making it resistant to heavy transport loads, moisture exposure, temperature fluctuations, and aggressive materials.

The coating can be used both inside and outside the building. The coating layer’s thickness ranges from 4 to 10 millimeters. The mixture’s ingredients are quartz sand, polymer fixer, and pigments (if a particular shade of coating is desired).

Construction of a self-leveling polymer floor

Following the technology and procedure is required to set up a self-leveling polymer floor.

• Preparation of the base – cleaning, sealing minor defects, leveling, removing dust and dirt, grinding the surface. If the floor is applied to a fresh coating, you need to wait 28 days after pouring.
• Primer of the concrete base – you can add quartz fine sand to it, which will improve adhesion. When the primer is applied, wait a day, remove the remaining sand with a vacuum cleaner.
• Arrangement of the base layer of the self-leveling floor – the prepared solution is simply poured onto the surface, a squeegee is used for distribution, and air bubbles are removed with a needle roller. It is better to carry out the work at an ambient temperature in the range from 5 to 25 degrees Celsius.
• When the main layer has dried, a thin finishing layer of polymer is poured. There are mixtures that do not involve this stage.

Polymer coatings are a flexible way to improve concrete floors because they are long-lasting, aesthetically pleasing, and low maintenance. These coatings come in a variety of varieties, each with special qualities appropriate for various conditions and demands.

Because of their durability and resistance to chemicals, epoxy coatings are a popular option for use in commercial and industrial environments. They firmly adhere to concrete surfaces to produce a smooth, long-lasting finish that can tolerate severe weather and traffic.

Conversely, polyurethane coatings are prized for their UV stability and flexibility, which makes them appropriate for outdoor use and locations that receive direct sunlight. Depending on aesthetic preferences, they can be formulated to give a glossy or matte finish and have excellent resistance to abrasion.

To ensure correct adhesion and longevity, careful surface preparation is necessary before installing polymer coatings. In order to encourage bonding, this procedure usually involves cleaning, fixing imperfections or cracks in the concrete, and etching it. After preparation, the coating is applied in layers, each of which adds to the floor’s overall durability and strength.

It’s critical to adhere to manufacturer recommendations for mixing ratios, application methods, and curing times for best results. A perfect finish devoid of flaws also depends on careful temperature control and ventilation during application.

To sum up, polymer coatings offer a practical and long-lasting way to improve concrete floors. They also come with a number of advantages, like increased longevity, customizable aesthetics, and ease of maintenance. The secret to getting long-lasting and aesthetically pleasing results is selecting the correct polymer coating type and making sure it is installed correctly, whether for commercial, industrial, or residential applications.

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