Bulletproof Floors: Comprehensive Guide to Epoxy Mortar Floors

If you’re look­ing for a durable and ver­sa­tile floor­ing solu­tion that can with­stand heavy traf­fic, chem­i­cal spills, and even extreme tem­per­a­tures, you’ll find that epoxy mor­tar is one of your best options. This post will pro­vide all the infor­ma­tion you need about this floor­ing system.

What Is an Epoxy Mortar?

Epoxy mor­tar is a durable, long-last­ing floor­ing mate­r­i­al applied on top of an erod­ing sur­face like a con­crete slab. It is a poly­mer-based bond­ing mor­tar con­tain­ing epoxy resins that is the binder and a spe­cial­ty blend of aggre­gates. The epoxy is blend­ed with the aggre­gates that mesh togeather to add strength and tex­ture to the floor­ing system.

Epoxy mor­tars are trow­eled into a sur­face, cre­at­ing a durable and high­ly resis­tant floor that can meet the require­ments of com­mer­cial and indus­tri­al facil­i­ties. The prod­uct can be used for struc­tur­al repair for fill­ing dam­aged areas, when the entire floor has an epoxy mor­tar sys­tem the floor­ing sys­tem will out­per­form vir­tu­al­ly any oth­er floor­ing system.

When Should You Con­sid­er Epoxy Mor­tar Floors?

There are many floor­ing solu­tions avail­able in the mar­ket. How would you know if an epoxy mor­tar floor­ing solu­tion is the right option? When should you con­sid­er this floor­ing material?

Your Facil­i­ty Has a Dam­aged Con­crete Floor

Over time, con­crete floors can become cracked, pit­ted, or worn down due to con­stant traf­fic, heavy machin­ery, or chem­i­cal expo­sure. Dam­aged con­crete floors can become a safe­ty haz­ard that caus­es trips and falls and even vehi­cle col­li­sions. These acci­dents can result in injury and even legal liabilities.

Epoxy mor­tar can be used to repair dam­aged con­crete, pro­vid­ing a smooth and lev­el fin­ish. It effec­tive­ly fills in cracks and div­ots, cre­at­ing a seam­less and aes­thet­i­cal­ly pleas­ing surface.

Your Busi­ness Needs Durable, Last­ing Floors

If you’re in the plan­ning stage of your prop­er­ty’s con­struc­tion and look­ing for durable and long-last­ing floors, epoxy mor­tar is an ide­al choice. The com­bi­na­tion of epoxy resin and aggre­gate cre­ates a tough and impact-resis­tant sur­face. It will be strong enough to with­stand dai­ly wear and tear in indus­tri­al and com­mer­cial environments.

Whether it is a man­u­fac­tur­ing plant, ware­house, or auto­mo­tive facil­i­ty, epoxy mor­tar floors can han­dle heavy loads, fork­lift traf­fic, and oth­er demand­ing con­di­tions with­out dete­ri­o­rat­ing or show­ing signs of wear for many years.

The Floor Will Be Exposed to Chem­i­cal Spills

Epoxy mor­tar floors offer excel­lent chem­i­cal resis­tance, mak­ing them suit­able for facil­i­ties that deal with spills or expo­sure to harsh chemicals.

The epoxy resin cre­ates a pro­tec­tive bar­ri­er that pre­vents chem­i­cals from seep­ing into the con­crete and caus­ing dam­age. This fea­ture is valu­able in lab­o­ra­to­ries, food pro­cess­ing plants, and phar­ma­ceu­ti­cal facil­i­ties where spills and chem­i­cal expo­sure are common.

Ben­e­fits of an Epoxy Mor­tar Floor

Dura­bil­i­ty

Epoxy mor­tar is favored because of its extreme dura­bil­i­ty. A prop­er­ly trow­eled epoxy mor­tar applied at 250-mil­lime­ter thick­ness can have com­pres­sion strength up to 12,000 pounds, which is much high­er than stan­dard con­crete. This char­ac­ter­is­tic of epoxy mor­tar makes the mate­r­i­al a great option for facil­i­ties that endure a high amount of traffic. 

Longevi­ty

Oth­er types of floor­ing sys­tems need to be replaced after a num­ber of years. Any­one who runs a facil­i­ty knows that the need for floor­ing replace­ment or recoat­ing means work­flow dis­rup­tion, added costs, and gen­er­al inconvenience.

While epoxy mor­tar floors will not last for­ev­er, they will out­last their com­pe­ti­tion, includ­ing wood, car­pet, and tile. With prop­er instal­la­tion, epoxy mor­tar can last up to 20 years, even when used round-the-clock.

Strong Resis­tance

Epoxy floor­ing is known for its strong resis­tance to var­i­ous ele­ments that can dam­age con­ven­tion­al floor­ing options. With the right top-coats It is high­ly resis­tant to chem­i­cals, such as acids and sol­vents, mak­ing it an excel­lent choice for indus­tri­al envi­ron­ments. It is also resis­tant to impact and abra­sion, which is essen­tial in high-traf­fic areas like ware­hous­es, garages, and workshops. 

Cost-Effec­tive­ness

Epoxy mor­tar floor­ing sys­tems are a cost-effec­tive option, espe­cial­ly if you’re just fix­ing a dam­aged con­crete floor. The epoxy mor­tar will be applied direct­ly to the dam­aged con­crete, leav­ing you with a seam­less and durable sur­face with­out the cost asso­ci­at­ed with floor­ing replacement.

Addi­tion­al­ly, this type of floor can last for many years, so you don’t need to fund fre­quent replace­ments. This means you can get the most bang for your buck, and your facil­i­ty can avoid any relat­ed dis­rup­tions that could lead to prof­it loss.

Aes­thet­ic Value

Beyond the prac­ti­cal ben­e­fits, epoxy mor­tar floors also offer aes­thet­ic appeal. Epoxy floor­ing is avail­able in a wide range of col­ors, pat­terns, and fin­ish­es, allow­ing cus­tomiza­tion to match any design pref­er­ence. This ver­sa­til­i­ty makes epoxy an attrac­tive choice for indus­tri­al facil­i­ties, and com­mer­cial spaces.

Low Main­te­nance

Since epoxy mor­tar is resis­tant to stains and spills, clean­ing is a breeze. Reg­u­lar sweep­ing and mop­ping with deter­gents is usu­al­ly suf­fi­cient to main­tain the floor’s cleanliness.

The low-main­te­nance nature of epoxy floors saves time and effort, mak­ing them an ide­al choice for busy com­mer­cial spaces. Even the most abused floor­ing will con­tin­ue look­ing immac­u­late with epoxy mor­tar.

Com­pli­ance

By fill­ing cracks and gaps with epoxy mor­tar, you can pre­vent trips and falls. You can have floor­ing that is safe to use and meets com­pli­ance require­ments. As a facil­i­ty man­ag­er or own­er, you’ll be able to avoid headaches and unnec­es­sary expenses.

If you’re still unsure whether epoxy mor­tar is the right option for your facil­i­ty needs, you can always call pro­fes­sion­als like Kaloutas for some insight.

Epoxy Mor­tar FAQs

What Is Stronger Than Epoxy Flooring?

How Does Epoxy Mor­tar Dif­fer From Cement Mortar?

As men­tioned pre­vi­ous­ly, epoxy mor­tar uses epoxy resin blend­ed with aggre­gates. Cement mor­tar, on the oth­er hand, is a mix of fine aggre­gates like sand, cement, or lime and water.

How Is Epoxy Mor­tar Installed?

Epoxy mor­tar is quite dif­fi­cult to work with because of its sticky and fast-cur­ing nature. It is also impor­tant to get the right blend of mate­ri­als. If you want the best return on invest­ment, hire a pro even for the most minor epoxy mor­tar floor­ing project. Doing so guar­an­tees that safe­ty and pro­tec­tive mea­sures are fol­lowed through­out the instal­la­tion process.

The epoxy mor­tar appli­ca­tion process usu­al­ly starts with prop­er sur­face prepa­ra­tion, includ­ing clean­ing, repair­ing cracks, and remov­ing con­t­a­m­i­nants. Next, the epoxy mor­tar mix­ture is applied and pushed down with pow­er trow­els. Once applied, the mix­ture needs suf­fi­cient time to cure and hard­en. After that, your hired con­trac­tor will grind the sur­face and apply a topcoat.

Where Do I Find an Epoxy Floor­ing Con­trac­tor Near Me?

If you are look­ing for a floor­ing con­trac­tor to han­dle epoxy mor­tar, you can count on Kaloutas. Since 1987, our team has been pro­vid­ing a wide range of ser­vices, such as paint­ing and floor­ing, to indus­tri­al and com­mer­cial prop­er­ties across New England. 

Kaloutas has cer­ti­fied floor­ing installers that can han­dle any floor­ing project. Whether you need new floor­ing in your man­u­fac­tur­ing plant, car deal­er­ship, phar­ma­ceu­ti­cal plant, etc., the team has got you cov­ered. In the case of epoxy mor­tar instal­la­tion, our team has already per­fect­ed mix­es that can han­dle even the most abra­sive environments.

Con­tact Kaloutas and let us take care of all your facil­i­ty’s floor­ing needs with one point of con­tact and one agreement.