Choosing the Right Commerical Concrete Coating
Whether it’s for a residential garage or a commercial manufacturing facility, concrete flooring is a cost-effective, durable option. However, concrete flooring requires a surface coating to protect it from wear, moisture, and damage. Concrete coatings also provide a sleek, attractive surface.
The four most common types of concrete floor coatings are epoxy, polyurethane, Novolac, and urethane mortar. In this guide, we’ll break down the pros and cons of each floor coating. We’ll also look at what you should consider in order to make the right choice.
Epoxy Flooring
Epoxy is a versatile floor coating that works well in various settings. It uses a blend of resin and hardening agents to form a strong, high-gloss surface. Decorative flaking and pigments can also customize the color of an epoxy floor.
Many production facilities, such as warehouses and manufacturing companies, opt for epoxy due to its resistance to heavy traffic and slip resistance. Its resistance to moisture and staining makes it a good option for garages and hangars as well.
Pros of Epoxy Flooring
- Durability: Epoxy can handle heavy loads and frequent use without wearing down
- Chemical Resistance: Concrete floors with an epoxy coating are protected from oils, solvents, and other chemicals
- Aesthetic Appeal: Epoxy comes in a broad range of finishes, including high gloss and decorative flaking
- Easy Cleaning: Thanks to their non-porous surface, epoxy floors are easy to clean
Cons of Epoxy Flooring
UV sensitivity: Will yellow over time with exposure to sunlight if not protected with a UV-resistant topcoat
Curing time: Often takes multiple days to cure completely, requiring a space to shut down operations
Ideal Applications for Epoxy
- Manufacturing
- Healthcare
- Aeronautical
- Automotive
- Education
- Civic
Polyurethane Flooring
Polyurethane is one of the most popular choices for concrete flooring. The mixture of polyols and isocyanates creates a more flexible polymer than epoxy, which gives it a softer underfoot feel. Although it isn’t as hard as other flooring options, polyurethane is extremely durable due to its flexibility. It can withstand extreme temperature changes without cracking and withstands chemicals, impacts, and the elements.
Pros of Polyurethane Flooring
Flexibility: Because it can bend and shift, polyurethane can absorb impacts without cracking
Durability: In addition to impact damage, polyurethane can withstand scratching, chemicals, extreme temperature shifts, and humidity
UV Stability: Even in direct sunlight, polyurethane resists yellowing over time, ideal for outdoor applications
Fast Cure Time: Most polyurethane coatings cure in less than 24 hours, minimizing downtime
Cons of Polyurethane Flooring
Requires a topcoat: In order to be watertight, polyurethane flooring requires an additional protective topcoat.
More difficult to apply: Polyurethane is not DIY-friendly and requires experienced technicians to install pit properly
Ideal Applications for Polyurethane
- Food and drink production
- Healthcare
- Retail and offices
- Garages
- Manufacturing
- Warehousing
Novolac Flooring
Novolac is a specially formulated type of epoxy designed for chemical resistance. It’s a great choice for facilities that deal with harsh chemicals, corrosive substances, and extreme heat. Novolac offers all the strength of epoxy as well as added protection against hazardous materials. With two coats, Novolac floors can also withstand heavy equipment and high traffic.
Pros of Novolac Flooring
Chemical Resistance: Concrete floors with Novolac are safe from exposure to even the harshest chemicals
Heat Resistance: Novolac is fire and heat-resistant
Cons of Novolac Flooring
Cost: Novolac’s specialized formula makes it more expensive than other flooring options
Rigidity: While extremely strong, Novolac is also more brittle than urethanes
Ideal Applications for Novolac
- Pharmaceutical
- Chemical processing
- Laboratories
- Automotive
- Healthcare
- Wastewater treatment
Urethane Mortar Flooring
Urethane mortar blends urethane and cementitious materials to create a cement-like mixture. The result is a self-leveling coating with a strong bond. Beyond its adhesive strength, urethane mortar is flexible enough to withstand thermal shock and impact damage. During application, urethane mortar flooring also releases fewer VOCs (volatile organic compounds), making it an eco-friendly option.
Pros of Urethane Mortar Flooring
Fast application: Urethane mortar cures faster than epoxy flooring
Wide range of colors: Manufacturers can use any color of sand/slurry in urethane mortar
Heat and thermal shock resistance: Urethane mortar won’t crack with sudden temperature changes or extreme heat
Cons of Urethane Mortar Flooring
Less glossy finish: Although suitable for a wide range of applications, urethane mortar doesn’t have the high-gloss finish of epoxy or polyurethane
- Commercial kitchens
- Food processing
- Manufacturing
- Pharmaceutical
Factors to Consider When Choosing a Concrete Floor Coating
Environment: What elements and hazards will your floors need to withstand?
Downtime: How long can you afford to have your facility out of commission during installation?
Aesthetics: What look/style do you want for your floors?
Traffic: How much foot traffic and heavy equipment traffic will your floors see daily?
Which concrete flooring is best for your facility depends on your specific needs. Choosing the right floor coating is an investment that can pay for itself by preventing maintenance and repairs. When you schedule a consultation, one of our flooring experts will survey your facility and recommend the best flooring option for you.
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