Epoxy Flooring

Epoxy Flooring

Finding an experienced epoxy flooring contractor is a challenging task.  Obviously, the right contractor will need to know how to install the resinous floor material.  But do they know how to assess industrial and commercial areas, and address the points of failure?

  • Are the joints exposed?
  • Is the existing floor delaminating?
  • Is the customer concerned about dust mitigation?

These are all important factors that Capital Coating keeps in mind when assessing your epoxy floor project. Our epoxy floor coating contractors have installed commercial and industrial floors in PennsylvaniaMaryland, Delaware, and New Jersey. We have the equipment and experience to repair damaged concrete, prepare the substrate, and properly apply the epoxy, urethane cement, or polyaspartic to ensure that floors get maximum longevity.

A commercial floor with a freshly applied epoxy coating.

Epoxy Floors

Epoxy is the most common material used for self-leveling flooring projects.  Epoxy offers excellent adhesion, chemical resistance, and durability, and creates nice floor installations in shop rooms, distribution centers, and commercial environments. Epoxy floors are built to withstand hard, everyday use.

100% solid epoxy coatings can be clear, or pigmented.  This gives the customer the flexibility to customize their floor for their preference.  Customers practicing 5S utilize epoxy’s many colors to create visual work places that help promote worker accountability and organization. An industrial grade epoxy floor can help with the safety and the aesthetics of your workplace.

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decorative broadcast floors

Decorative Broadcast Floors

Resinous material can be used to create beautiful floors in commercial and industrial environments.  Broadcast floors can improve the area’s aesthetics. But they can also help hide dirt, and increase the safety by adding some slip-resistance texture in the area.

There are 2 types of broadcast material: micro-chip and decorative quartz.  Micro-chip is normally used used on commercial floors. It can be manufactured in multiple sizes, and is less angular than quartz.  This means that micro-chip floors can be easier to clean than quartz.

Decorative quartz floors will offer the same aesthetics of micro-chip.  But because the quartz is made from sand, they will offer more texture than micro-chip.  These are popular floors in pharmaceutical areas because of their increased slip-resistance in wet areas.

Decorative broadcasts floors always receive grout coats of a clear resinous floor material.  Epoxy is the most common. However, clear epoxy naturally ambers/yellows over time. So if your decorative floor receives grout coats of epoxy, expect that clear epoxy to discolor over time.

An experienced epoxy flooring contractor should recommend polyaspartics as a grout coat.  Polyaspartics are fast-curing urethanes. They can’t replace epoxy in every situation. But they are a perfect replacement for grout coats over broadcast floors.  They will not amber, and they will maintain their clarity.  Polyaspartic flooring is strong and maintains its color.

Capital Coating will help you explore your options and help you make a decision that fits your needs.

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Solid Color

Many commercial and industrial facilities just want a smooth, easy-to-clean surface, in a solid color.  These are the most common floors we install as an epoxy flooring company. And they can come in a variety of colors.  Many factories create their own, standard colors, which normally includes tile reds, slate greys, and bright yellow. But if a facility has a specific color they are trying to achieve, many epoxy manufacturers can match that specific color.

Solid colors can be used to define areas.  Safety colors alert foot traffic of the hazards, and directional markers can inform pedestrians where they need to walk.  Solid colors are a great way for facility managers and designers to organize employees and tools.

A hallway with a slip resistant coating.

Slip-Resistant Floors

If you’re managing a food manufacturing facility, then it’s more than likely that you have some type of wash down area.  These areas are normally wet, and frequently covered in animal fat, grease, and even wafer dust.  These environments are necessary for every food plant’s operation.  However, they can create a safety hazard for employees.  Slippery floors can cause costly accidents and down time.  Which is why it’s important to consider adding a textured, slip-resistant epoxy floor in your process areas.

Quartz sand and aluminum oxide are the common aggregates sprinkled into the epoxy.  These tough, durable aggregates will hold up against constant fork lift and pedestrian traffic, while still offering the slip-resistant safety your workers need.

Slip-resistant epoxy floors can be found in areas outside of wash down areas.  Auto-shops, laboratories, and animal shelters are facilities that typically have some type of textured floor.

Urethane cement polysiloxane floor.

Urethane Cement Overlayments

Cold, hot, and wet are challenging environments for anyone specifying an industrial floor.  And in these environments, urethane cement has proven to be one of the most durable, long-lasting flooring solutions on the market.  They are thermal-shock resistant and will not buckle under drastic temperature fluctuation from hot and cold water.  They are anti-microbial, which discourages bacteria and listeria from growing in your plant.  And they are surface tolerant, and can be installed over wet or contaminated slabs.  These performance features make urethane cement floors one of the best flooring options available for food manufacturing plants.

Because food manufacturing facilities are always cleaning surfaces and substrates, it’s important that floor can hold up to the constant temperature change, and chemicals.  And since Pennsylvania and Maryland are one of the top food producers in the country, they are one of the top states that require urethane cement floor systems.

If your facility does not have a vapor barrier, but it has high vapor transmission, then you probably know that epoxy floors will blister and delaminate under the pressure.  Urethane cements have a much higher tolerance to vapor transmission, and can tolerate up to 20 lbs of vapor per 1000 SF over a 24 hour period.  This is significantly stronger than epoxy.  So if these are normal conditions for your Pennsylvania or Maryland facilities, then you’ll want to consider the urethane cement overlayment as your #1 choice for industrial flooring.

Engineered Concrete Underlayment

Before any flooring system can be installed, the substrate below must be clean, level and free of imperfections. In industrial facilities, years of heavy use under harsh conditions can cause floors to become cracked and damaged. Whether due to normal wear and tear or direct impact, damaged and deteriorated concrete can present serious safety hazards to workers and damage valuable equipment.  And these floors may also allow unwanted pests, like bugs, inside your facility, as they crawl through the cracks in your floors. If your facility’s floors no longer perform as needed, you may want to consider resurfacing them with engineered concrete.

Engineered concrete is a reinforced composite material that improves on regular concrete. Engineered concrete tends to be more lightweight and ductile than regular concrete, which makes it suitable for use in areas where weight is a concern. Like other self-leveling floor coatings, engineered concrete can spread evenly without vibration or another method for even distribution. When used to resurface industrial floors, engineered concrete flows into cracks and crumbled sections, essentially repairing damage and adding a smooth new surface to the entire substrate.  However, it is important to properly prepare these cracks before installing the material.  Chasing them with a diamond wheel, and sucking the dirt and debris with a vacuum is a common way that industrial floor installers will prepare the floor. Proper surface preparation is important for safety and the longevity of your flooring.

In some industries, this type of flooring may be used as an underlayment. After using engineered concrete to correct imperfections in the existing concrete floor, you can install another type of flooring or floor coating. At Capital Coating, we provide engineered concrete for both underlayment and resurfacing applications. Capital Coating can help with your concrete restoration and your concrete repairs.

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Worker applying a yellow epoxy resin bucket on floor for the final coat.

Expansion and Control Joints

Concrete floors shrink after installation due to change in volume. When concrete shrinks, small cracks form in areas of weakness. The same occurs when concrete expands or contracts due to temperature changes or shifting foundations. To prevent cracks from forming in undesirable locations, a professional may cut joints into newly poured concrete. This makes it possible to control where cracks will appear.

Although control joints and expansion joints are essential to ensuring the concrete slab’s structural integrity, some commercial and industrial businesses prefer not to have noticeable joints in their concrete flooring. In the food processing and pharmaceutical manufacturing industries, for example, control joints may raise concerns about sanitation, since these indents can make cleaning more difficult. It is also critical that these joints be filled to prevent bugs and critters from breaching the clean facility.  For many food plants, unfilled joints are red flags, and can lead to FDA violations.

To address the practical and aesthetic problems associated with expansion and control joints, people often fill them with a semi-flexible epoxy at the same time that an epoxy floor coating is installed. This epoxy supports traffic and creates a uniform surface while allowing the concrete substrate to expand and contract. When applied by a professional epoxy floor coating contractor, this solution can conceal expansion and control joints and improve a facility’s cleanliness. At Capital Coating, we use semi-rigid polyurea to fill joints in concrete floors effectively and protect your flooring assets.  Semi-rigid polyurea is a great way to protect and reinforce the side walls of the concrete slab from deteriorating from constant fork lift traffic.

Line Striping and Floor Graphics

Regularly used in warehouses, distribution centers and manufacturing plants, industrial floor line painting allows workers and visitors to easily understand a facility’s workflow. Using a colored epoxy coating, Capital Coating can create striping and other visual elements to guide workers and mark potentially hazardous spaces like wash areas, increasing productivity and safety. Epoxy floor coatings offer stronger adhesion than common house paint, which makes them an ideal long-term line striping solution.  And these coatings are manufactured in safety colors, which helps create visual workplaces in hazardous and frantic environments.

We can apply the following types of floor graphics for industrial and commercial clients:

  • Pallet slot lines: Pallet slot lines help keep warehouses and manufacturing plants organized and productive. When workers can see where pallets are supposed to go, they can maximize the use of floor space and perform their jobs more efficiently.
  • Pedestrian walkway lines and aisles: In warehouses and other industrial facilities, workers often travel beside machinery. In busy areas, workers and machine operators need a reliable way to distinguish pedestrian walkways. Line striping in an eye-catching color offers an ideal solution. When workers know exactly where they should walk to stay clear of machinery, they can work more effectively and prevent accidents.
  • Company logos: A large representation of your company logo can add personality to an industrial or commercial space, brightening up the atmosphere and making visitors feel more welcome. Epoxy floor coatings come in many colors, which makes it possible to match your company’s branding.
  • Rodent and rat lines: Some food processing and pharmaceutical manufacturing facilities may need rodent and rat lines to meet inspection requirements. These lines make it easier to identify signs of rodent problems.
A freshly coating warehouse floor.

Choosing the Right Epoxy Flooring for Your Business

Resinous flooring can provide many benefits to your business, whether you own a restaurant or small retail store or manage maintenance at a large industrial facility. The benefits that your facility enjoys from a new floor coating will depend on the type of coating you select, and there are a variety of options, including epoxy, polyaspartics, urethane, urethane cement, engineered concrete and polyurea.

At Capital Coating, we help clients like you select the best industrial epoxy floor coatings for their needs. If you aren’t sure which type of floor coating will help you achieve your goals, we can answer your questions and help you compare the options.

Our skilled workers applying a protective coating to a flat commercial roof.

Contact Capital Coating for Epoxy Floor Coating Services

At Capital Coating, we work to make the epoxy floor coating process as seamless as possible. Our safety-trained workers are insured and will follow all facility guidelines and rules to protect their safety and your company’s property. We also complete work quickly and schedule our services at times that are convenient for you. This helps prevent unnecessary downtime and ensure you can return to business as usual as soon as possible.

Capital Coating has more than 20 years of service records to back up our dedication to client satisfaction and high-quality results. To provide an amazing finished product for every client, we use state-of-the-art equipment and tools and pay close attention to detail during every stage of the project, from initial inspection to completion. To request service or learn more about our epoxy flooring solutions, please reach out to us today.

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