34 D+D MARCH 2015

Broadcasted flake is the traditional“garage floor” system that can beused to spruce up any garage floor.Photo courtesy of Durex Coverings.

Coatings Technology35

Coatings Technology

arly in the last century, when the automobile

industry was in its infancy and variety was

limited, General Motors CEO Alfred P. Sloan

said the company had “A car for every purse

and purpose.” Sloan established a pricing

structure and ladder of brands — Chevrolet,

Pontiac, Oldsmobile, Buick, and Cadillac —

that allowed a range of economic classes to

purchase a vehicle from the GM family. The buying public could pur-

chase the GM vehicle that met their needs and budget.

By the 1920s, though, many Americans desired more than a basic,

sturdy, affordable car — they wanted style, speed and luxury, too. “It

doesn’t cost any more to make something pretty,” Jaguar Cars

founder Sir William Lyons said of his firm’s design philosophy. This

evolution and increase in the variety of vehicles resulted in what we

see today on the roads across America. Now a vehicle exists to meet

every need and taste.

The resinous flooring industry has followed a similar path over the

last 45 years. The protection of concrete floors has evolved to a fairly

sophisticated process involving various types of polymer resin coat-

ings or surfacings. The reasons for installing or applying these types

of materials vary, but the main reason is to protect the slab from dete-

rioration or contamination. Other common reasons include aesthetics,

wear resistance, non-slip functionality, chemical resistance, ease of

maintenance and physical performance.

Selecting a resinous floor is very similar to choosing among the

many types, styles and price points of vehicles. To choose the ap-

propriate system and avoid the dreaded “lemon,” you need to un-

derstand the options and evaluate your customer’s needs and

desires. Consider the desired look and feel of the floor, project

budget, performance conditions, maintenance, expected lifespan,

and warranties. As when buying a vehicle, these characteristics

are key to specifying the correct resinous floor.

With so many commonalities existing between these two indus-

tries, we wanted to highlight some of the current polymer flooring

system types according to their automotive parallels.

The Economy/Compact Car — Basic Thin-Mil CoatingsEconomy cars are designed for low-cost purchase and

operation. Small and lightweight, they are chosen for transport

without fuss or fanfare.

EA Resinous Floor for Every Purse and PurposeGet up to speed on polymer resinflooring systems, materials and performance.

To mimic the look of asphalt, the contractor used a pure black broadcastflake floor finished with a matte finish urethane. Photo courtesy of Key Resin Company.

Jon C. Lattin, Corrosion Technology Systems Inc., and Eric Borglum, Key Resin Company

The Family Sedan — Epoxy High-Build CoatingsCommon on the roads today, the family

sedan was designed primarily as a pas-

senger car with adequate cargo capacity

for short travel or shopping trips. More

fuel-efficient than minivans and SUVs,

family sedans are economical choices for

those on a budget and where safety is a

concern.

Like their automotive counterpart,

epoxy high-build coatings and mortar sys-

tems are an efficient workhorse in the

polymer industry. Installed at thicknesses

ranging from 1/16 inch to 3/16 inch, these

self-leveling or trowelled floors provide

impact and abrasion resistance while hid-

ing surface imperfections and damaged

concrete.

Typically built from epoxies to maintain

their economic value, they can also be

topcoated with polyaspartics and ure-

thanes for increased chemical and stain

resistance and UV stability. Offered as a

smooth surface or with non-skid additives

for slip resistance, these floors are ideal

for medium- to heavy-duty industrial

36 D+D MARCH 2015

From a resinous flooring perspective,

that is similar to a basic, thin-mil coating

system. Typically two or three coats total-

ing less than 25 mils in thickness, these

solid-color, durable systems provide a

chemical-, slip- and stain-resistant finish.

The resins found in thin-mil coatings

are epoxies or urethanes and are best

suited for light- to medium-traffic areas

where owners desire cleanability and a

general brightening of the area. Due to

the relative thinness of these floors (ap-

proximately 5-10 sheets of paper), surface

preparation is less aggressive than with a

thicker system.

These easy-to-clean floors are com-

monly found in residential and commercial

applications, light manufacturing, ware-

houses, airport hangars, and storage

rooms.

A simple epoxy coating can make a garage brighter and easier to clean.Photo courtesy of Key Resin Company.

Broadcast flake can be an inexpensive way to imitate the look of epoxy terrazzo. Photo courtesy of Key Resin Company.

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38 D+D MARCH 2015

rooms, laboratories, animal facilities, appa-

ratus bays and automotive service bays,

and warehouses.

The Sports Car — MMAsSports cars in their most basic form have

two seats and two doors and are designed

for spirited performance and nimble han-

dling. Sports cars can be spartan or luxuri-

ous in their execution, but their focus is

the same: high maneuverability and maxi-

mum speed.

With the same goals in mind, the poly-

mer industries equivalent is methyl

methacrylate (MMA). The MMA class of

resins can be formulated to provide a vari-

ety of types and styles of finished floors.

Installed at thicknesses ranging from 1/8

inch to 1/4 inch, MMA floors can be in-

stalled rapidly with cure times of about an

hour between coats.

Unlike other polymers, MMA resins also

allow for the flexibility to install at ex-

tremely low temperatures, down to as low

as -20°F. These systems are very durable

and resist cracking, which makes them

ideally suited for chemical processing

areas, food processing facilities, exterior

decks, freezers, refrigerated warehouses

and any project requiring a very rapid re-

turn to service.

The Luxury Sedan — TerrazzoProviding luxury features beyond strict ne-

cessity, four-door luxury sedans stand at

the top of the people-mover food chain.

They offer higher-quality materials and

construction, increased performance and

comfort, and technologically innovative de-

sign with state-of-the-art features. They

convey an image of sophistication and

prestige while transporting people and

their goods in style.

For hundreds of years, terrazzo has been

the pinnacle of flooring materials. The evo-

lution from cementitious to epoxy terrazzo

has elevated that status. Epoxy terrazzo

provides owners with a showcase floor,

combining the benefits of bright colors

and chemical resistance from the epoxy

matrix with the beauty and durability of

the aggregates.

Creative designs and timeless beauty

provide the image of sophistication and

Epoxy mortar flooring systems are ideal surfacesfor automotive service bays because of their abil-ity to withstand the wear and tear of active me-chanics. Photo courtesy of Key Resin Company.

(Below) The artistic luster metallic coating system makes any showroom sparkle. Photo courtesy Key Resin Company.

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P

Equally unique and

desirable, highly deco-

rative and artistic

metallic coatings are

the latest craze in the

resinous flooring mar-

ket. These thin-film

coating systems have

a bright metallic finish

that can be installed

using creative tech-

niques to provide a

multitude of textures

and styles in the fin-

ished shimmering

floor.

Typically finished

with a clear urethane,

polyaspartic or epoxy

sealer for excellent

wear and abrasion re-

sistance, you can plan

designs that offer a

unique look to your

customer’s floor. The

coatings are appropri-

ate for residential use,

office complexes, com-

mercial areas, restaurants or lobbies.

The Pickup Truck — Industrial Flooring SystemsKnown for their heavy-duty frames, rugged

looks, sizable open cargo area and ability to

conquer any terrain, pickup trucks are de-

signed to work hard.

These features line up perfectly with the

heavy-duty industrial flooring systems that

resinous manufacturers provide. Installed at

3/16 inch to 1/4 inch, these industrial sys-

tems are designed to perform in the most

severe environments.

A resinous flooring system may experi-

ence four types of abuse: (1) chemical expo-

sure, (2) abrasion from foot and wheeled

traffic, (3) impact from heavy loads, (4) and

thermal shock caused by a dramatic change

40 D+D MARCH 2015

prestige an owner desires, while benefits

like increased performance and long-term

value raise epoxy terrazzo above other

flooring materials.

You will often find these floors in high-

traffic areas in locations such as airports,

cafeterias, hospitals, museums, office

buildings, schools, shopping malls and

convention centers.

The Exotic Supercar — Metallic Decorative CoatingsExotic supercars are ultra high-perfor-

mance sports cars. Marketed by elite

automakers as unique, with limited pro-

duction specials incorporating the very

latest racing technology, supercars offer a

desirable one-of-a-kind status to their

owners.

in temperature from hot substances. Indus-

trial flooring systems can comprise epoxies,

vinyl esters, MMAs and urethane cements.

The specific requirements from these four

categories of abuse will influence their

selection.

These industrial flooring systems are

commonly seen in food processing, com-

mercial kitchens, heavy manufacturing,

loading docks, chemical storage and main-

tenance facilities.

The Sport Utility Vehicle (SUV) — Decorative Industrial SystemsSport utility vehicles were designed to

combine the ruggedness of a truck with

the passenger-carrying space of a minivan

or large family sedan. These large vehicles

have the ability to scale rocky trails while

carrying a family of six in comfort and style.

Industrial flooring systems with decora-

tive topcoats, like a urethane cement chip

or quartz system, deliver a powerhouse in-

dustrial system with a bit of style for good

looks. These 1/8-inch to 3/16-inch systems

combine the durability of the rugged indus-

trial systems with the more attractive

broadcast systems.

These applications have proven them-

selves in government facilities, EMS facili-

ties, commercial kitchens and locker rooms.

The Crossover — Resilient Polymer FlooringAttempting to blanket all of the market-

place’s potential needs, crossovers

(crossover SUVs) combine the perceived

advantages of a traditional truck-based

SUV (increased clearance, cargo space,

etc.) with an automobile platform for

lighter weight and better fuel efficiency.

Advancements in the resinous world

have created its own crossover: a new

class of resilient polymer flooring systems.

These dense, sanitary finishes provide an

acoustical quietness underfoot by combin-

ing the advantages of an elastomeric resin

Firehouse apparatus bays demand high-performance flooring surfaces, andthis high-build mortar with an aliphatic urethane topcoat provides this. Photo courtesy of CTS.

Engineered for long-term superior performance, HP SPARTACOTE® polyaspartic fl oor coating systems are designed to meet the needs of the most demanding heavy-traffi c environments.

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HP SPARTACOTE polyaspartic coating systems offer:Seamless and impermeable coatingsVOC-free and no odor systemsExcellent abrasion resistanceFast return to serviceNon-slip textures

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L

42 D+D MARCH 2015

with the seamless qualities of a traditional

epoxy or urethane floor.

With many versions providing varying

aesthetics, these floors have proven to be

softer under foot while retaining the re-

quired resistance to chemical and bacterial

growth. These resilient polymer floors are

ideal for use in health care facilities (operat-

ing rooms, laboratories and lobbies), light

manufacturing and assembly areas, schools

(corridors and classrooms), and any facility

where people spend a large amount of time

on their feet.

The Minivan — Broadcast Flake/Broadcast QuartzA utilitarian people mover, minivans are

vans designed for personal use. They offer

maximum interior volume and are marketed

as the perfect multipurpose vehicles for

simply doing their job of moving people and

supplies.

The most common, utilitarian flooring

systems are the basic broadcast quartz and

broadcast flake floors. These affordable, all-

around performing systems provide a deco-

rative and seamless solution.

Like any resinous floor, they can be cou-

pled with integral cove base for a com-

pletely seamless floor. They can also be

tailored to offer resistance to a variety of

chemicals, are easily cleanable, and provide

a floor resistant to microbial growth.

The most common resinous flooring sys-

tem, these floors are found in toilet and

locker rooms, laboratories, residential

garages, water treatment plants, and

corridors.

Electric Vehicles (EVs) — ESD and Conductive Flooring SystemsAlthough the automotive marketplace has

been slow to change, electric vehicles are

starting to gain traction in America as bat-

tery development improves. Electric vehi-

cles replace the internal combustion engine

with electric motors for instantaneous

torque and less dependence on fossil fuels.

The resinous world has been addressing

electrical charge for decades with a variety

of electrostatic dissipative (ESD) and con-

ductive flooring systems. These floors are

applicable in any areas where the buildup

of static electricity is a concern and can be

tailored to cover either the conductive

range of 2.5x104 to 1x106 ohms or the ESD

range of 1x106 to 1x109 ohms electrical re-

sistance, depending on the needs of the

customer.

Using combinations of epoxies and ure-

thanes, the final ESD/conductive floor can

range in thickness from thin-film (15-18

mils) to 1/4-inch trowelled systems, and

they can offer excellent abrasion, chemical

and stain resistance.

Common applications include electronic

component assembly areas, data process-

ing, military/aerospace and ammunitions fa-

cilities, pharmaceutical plants, hospitals,

and hazardous storage areas (dust or explo-

sion hazards).

Protect Your InvestmentJust as in dealership negotiations, standard

warranties often come up when discussing

resinous floors; they vary by manufacturer

and application.

A failure as a result of moisture vapor

emissions is one condition typically

excluded in a standard resinous floor war-

ranty, unless moisture vapor transmission

(MVT) was specifically addressed during

the specification and installation process.

MVT is the natural migration of water

vapor through the concrete slab. This be-

comes a problem when moisture is trapped

by an impervious flooring material, result-

ing in the potential for a failure due to os-

motic blistering or alkali-silica reactivity.

You can prevent this by first testing for

the presence of moisture using ASTM

F2170, Standard Test Method for Determin-

ing Relative Humidity in Concrete Floor

Slabs Using in situ Probes. Once the levels

of moisture are known, you can

select a suitable MVT primer from

the resinous manufacturer to provide

the peace of mind behind your floor

installation.

Lay the Way for Success“The quality is remembered long after the

price is forgotten,” said Sir Henry Royce on

the value proposition of the Rolls-Royce au-

tomobile. That statement is applicable for

any product you purchase, and resinous

floors are no exception. When choosing

your floor, understanding the parameters

and requirements of the project, as well as

confirming the quality of the materials and

experienced installers, are critical to suc-

cess.

About the AuthorsJon C. Lattin, CSI,

CCPR of Corrosion

Technology Systems

(CTS) is an independent

manufacturer’s repre-

sentative for Key Resin

Company and an avid

car fan. A Rensselaer

Polytechnic Institute graduate, he spent

some time in manufacturing before transi-

tioning to concrete restoration and resinous

coatings. He has assisted customers in the

proper selection of resinous systems for the

past eight years.

Eric Borglum, Executive Vice President of

Key Resin Company, has more than 19

years of experience in

the field of resinous

coatings. A graduate

of Purdue University,

he manages the mar-

keting, sales and prod-

uct development at

Key Resin. D+D

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