How Much Can Epoxy Mortar Strengthen Your Concrete Flooring?
Epoxy mortar flooring is a popular option for strengthening concrete floors. This article will discuss everything you need to know about this material, including its benefits and applications.
What Is Epoxy Mortar Flooring?
Epoxy mortar is a durable, long-lasting flooring material that goes on top of a concrete slab. It is a polymer-based bonding system that contains a mixture of epoxy resins, and specialized aggregates. The epoxy portion is a two-component organic polymer — a blend of sand and/or coarse aggregate.
Epoxy mortar is also commonly used for repairing damaged or worn-out concrete floors. The material can effectively fill cracks, pits, and uneven surfaces, restoring the floor’s integrity and preventing further damage.
Benefits of Epoxy Mortar Floor Coatings
Epoxy mortar floor coating is one of the most popular options for flooring because of its favorable properties — mainly its exceptional durability and strength. In addition, it has excellent resistance to elements and substances, can be easily maintained, and can save you money over the long haul.
Let’s discuss each of its benefits further:
Industrial concrete floors usually have 4,000 to 6,000 pounds per square inch (PSI) of compression strength, often strong enough to endure heavy traffic from vehicles. Compression strength refers to the capacity of the material to withstand a constant load.
Despite its strength, concrete gets damaged over time. Common issues with concrete include cracking, spalling, chipping, etc. Any facility manager knows that a damaged floor can result in safety issues and legal consequences. If you have concrete flooring and don’t want to replace it, adding an epoxy mortar flooring system is a great way to fix any imperfections in your concrete and even boost its durability.
A typical epoxy system reaches 10,000 PSI, which is two to three times stronger than industrial concrete floors. But Kaloutas power-troweled epoxy mortar applied at a 250-millimeter thickness can have a compression strength of up to 12,000 pounds.
So you might ask, “Does epoxy strengthen concrete?” The answer is yes; epoxy mortar applied to concrete creates a strong surface that can endure nearly any set of demands.
Epoxy floors are known for their exceptional durability, which is made possible thanks to the material’s composition. The combination of resins and hardeners creates a tough and resilient surface that can withstand high impact and traffic.
Also, the surface is not easily damaged, so it stays pristine for many years.
Resistance to Elements
Epoxy is also known for its remarkable resistance to various elements, making it a preferred choice in numerous industrial, commercial, and domestic applications.
Moisture is one of the key elements that epoxy is highly resistant to. When properly cured, epoxy forms a dense and impermeable surface, preventing water and other liquids from seeping through. This makes it an excellent choice for coating surfaces in damp environments or applications exposed to frequent contact with water.
Furthermore, epoxy exhibits exceptional chemical resistance, which allows it to withstand exposure to acids, solvents, and various chemicals without undergoing degradation or deterioration. This property makes epoxy coatings suitable for protecting surfaces in chemical processing plants, laboratories, and industrial settings where harsh substances are handled.
Moreover, some epoxy products can endure thermal stress. The material remains stable even under extreme temperatures, from extreme cold to high heat, without losing its structural integrity.
Epoxy floors offer many benefits, and one of the most significant advantages is their low maintenance requirements. These high-performance flooring solutions have gained popularity across various industries and residential settings due to their ease of care.
The seamless and non-porous nature of epoxy floors makes them resistant to stains, spills, and chemicals. This attribute ensures that dirt, dust, and liquids do not penetrate the surface, allowing quick and effortless cleaning. Routine maintenance typically involves sweeping or mopping to keep the floor looking pristine.
You also do not have to worry about bacterial growth and allergen buildup. The seamless surface leaves no room for bacteria or germs to hide, making it a hygienic flooring option for healthcare facilities, restaurants, and food processing industries.
While epoxy flooring may need a higher upfront investment than other traditional flooring options, it can be cost-effective if you consider the money you will likely save over the long haul. The exceptional durability and resistance to wear and tear and other elements significantly reduce the need for frequent replacements.
In addition, the low maintenance requirements of this type of flooring can help you save on utility costs. All the money your facility can save over time will outweigh the initial investment.
Facilities typically have tight schedules and limited downtime for building renovations. Epoxy mortar flooring offers the benefit of fast installation and curing, minimizing disruption to your daily operations.
Epoxy materials usually cure in less than 24 hours and reach maximum compression strength within 14 days. This is much shorter than the amount of time concrete needs to cure, which is almost a week.
An experienced epoxy flooring installer can efficiently apply the material on your existing floor and expedite the installation process so your team can resume normal activities in a shorter time frame.
Epoxy mortar flooring has a seamless and polished appearance that exudes both durability and aesthetics. Its smooth and glossy finish adds a touch of sophistication to any space, creating an impressive ambiance.
The surface showcases a vibrant sheen, reflecting light to brighten the area.
With a range of color options, epoxy mortar can complement any décor style and architectural design.
Epoxy Mortar Uses and Application
Composed of a combination of epoxy resin and aggregates, epoxy mortar offers exceptional durability, chemical resistance, and high mechanical strength, making it suitable for a wide range of environments.
One of the primary uses of epoxy mortar flooring is in industrial settings, such as manufacturing plants, warehouses, and factories. Its ability to withstand heavy machinery and foot traffic and resist chemicals, oils, and solvents makes it an ideal choice for these types of areas.
The smooth nature of epoxy mortar also contributes to its popularity in places where hygiene and cleanliness are essential, such as pharmaceutical and food processing facilities.
In addition to industrial applications, epoxy mortar flooring is widely used in commercial spaces like hospitals, schools, retail stores, and automotive showrooms. Its seamless surface makes maintenance easy and ensures a long-lasting, visually appealing floor that can withstand daily wear and tear.
Epoxy Mortar Floor FAQs
How Much Weight Can Concrete Epoxy Hold?
The weight concrete epoxy can hold depends on the specific product and application. Generally, high-quality epoxy can bear significant loads, with some industrial-grade formulations supporting over 12,000 PSI. However, it is essential to adhere to the manufacturer’s guidelines and proper surface preparation for optimal performance and safety.
What Is the Difference Between Epoxy Mortar and Cement Mortar?
Epoxy mortar and cement mortar differ in their composition and properties. Cement mortar consists of cement, sand, and water, making it suitable for general applications. On the other hand, epoxy mortar utilizes epoxy resin and a hardener, offering exceptional strength, chemical resistance, and bonding.
Strong Floors That Last
No matter your industrial flooring needs, Kaloutas has got you covered.
Our company offers a range of industrial flooring services, including antimicrobial and anti-static flooring installation, concrete expansion joint repair, concrete floor polishing, flooring demolition, and epoxy flooring installation or resurfacing.
Let Kaloutas take care of all your facility’s flooring needs with one point of contact and one agreement. Contact our team today.