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System performance (relative
to the environment in which it
is installed) depends greatly
on the chemistry and flooring
type selected for the
application. Although there are
a myriad of technologies used
in the industrial coating
industry, the most traditional
and widely available include
acrylic, epoxy, polyurethane,
polyurea, polyaspartic, polyester, or vinyl ester.

CONCRETE HARDENERS OR DENSIFIERS

Concrete hardeners are usually sodium silicate, potassium silicate, lithium

silicate, solutions or metallic fluorosilicates. Where hardeners have been
used, the concrete will usually appear glossy and may be a grey to brown
color. Hardeners used instead of sealers and for new concrete as well as
existing concrete. These products typically improve with age. The Densifier
actually crystallizes in the concrete accelerated by the general scrubbing of
the floor or by concrete polishing. Over time these floors develop a very
attractive gloss and are excellent for warehouse areas where cost is the first
priority but appearance is also important.

ACRYLIC RESINS, also known as Methyl methacrylate resins and co-

polymers, are used for waterborne coatings, such latex house paint. It is
also used in adhesive formulations. Acrylics coatings - vary from extremely
hard, brittle solids to elastomeric (rubber-like) structures to viscous liquids.
These materials tend to have excellent water, weather and UV resistance. In
addition, they are stable under moderate thermal shock conditions, but
provide lesser mechanical strength, chemical resistance, and adhesion
compared to alternate systems.
 MMA (Methe Methacrylate)

MMAs are fast curing acrylic

coatings that are resistant to
weak acids and alkalis and
have moderate resistant to
solvents. Fast curing is a big
advantage of MMAs, especially
at low temperatures. At room
temperature MMA has a
working time of 10 to 15
minutes and reaches a full
cure in 1 to 2 hours. MMAs are
two-component systems in
which the MMA resin is mixed
with a solid powder initiator.
After mixing, curing of MMAs
is inhibited by oxygen in the
air. Manufactures overcome
this problem by including paraffin wax in the resin. During cure, the wax
rises to the surface forming a protective barrier.

When applying as a resurfacer it is important to use the continuously graded

aggregates from the manufacturer to avoid trapping air within the
resurfacer. MMAs must be applied to dry concrete because moisture
interferes with binding. MMA have excellent intercoat adhesion and are
resistant to ultra-violet light. Their maximum surface temperature is
normally 140 degrees F. MMAs release a strong odor and are flammable, so
it is important to ventilate the work area.

EPOXY RESINS

Epoxy resins are thermosetting products known for excellent surface and
sub-surface adhesion, mechanical properties, and chemical resistance. Epoxy
resin systems are made up of an epoxy resin and a curing agent (also called
a hardener or catalyst). Many epoxy products also contain additives such as
organic solvents, fillers such as fiberglass or sand, and pigments.

When epoxy resin systems are used, single molecules (monomers) of the
epoxy resin chemical and the curing agent combine to form long chains of
molecules (polymers). As the mixture "cures," it becomes a hard polymer.
Some epoxies cure in a few minutes at room temperature. Other epoxy
systems need additional time or heat to harden. The characteristics of
hardened epoxies (such as whether they are firm or flexible, or resistant to
heat or chemicals) depend on which epoxy monomers, curing agents,
solvents, and fillers are added.

There are two primary epoxy resins A epoxy resin which is a cost-effective,
general-purpose resin which demonstrates excellent alkali resistance, good
acid resistance and fair-to-good solvent resistance.

BISPHENOL F epoxy resin is a low-viscosity material which provides excellent

alkali resistance and offers improved acid and solvent resistance compared
to BISPHENOL A.

While there are few epoxy resins that are suitable for application, there are
literally hundreds of epoxy curing agents. As a result, epoxies can be
formulated to have a variety of physical properties, which makes it difficult
to generalize their chemical resistance as a polymer coating. Cure rate of
epoxies is affected by temperature and should not be applied with
temperatures under 32 degrees. Epoxies have limited service temperatures
and generally soften with temperatures over 150 degrees. They are also not
resistant to ultraviolet light and will yellow with age.

The hardened, finished polymers are almost non-toxic; it is exposure to the

uncured resin components that can be harmful. In a two-component epoxy
product, the epoxy resin and the curing agent are packaged separately and
must be mixed together just before being used. Each component can be
hazardous. In a single-component product, the resin and the curing agent
are supplied in a pre-mixed
form.

Epoxy Formulations

Epoxy for concrete coatings

generally come in one of three
formulations. Solvent based,
water based, and 100%
solids. Solvent based and
water based tend to be most
commonly used for DIY
applications due to their ease
of application and long curing
window after catalyzation.
100% solids formulations
while more difficult to apply are more cost effective when comparing cured
thickness and can be applied at much greater thicknesses allowing the
material to self level.

100% solids epoxies are the most popular form of epoxy. The percent solids
describe the amount of solvent in the product. In this case there is no
solvents or liquid fillers of any kind. As a result these epoxies offer odorless
installation. They cure exclusively by chemical catalyzation between the
parts. What is surprising for some is that 100% solids epoxy are normally
97% plus solids but typically have the addition of bonding additive, leveling
agents or other additives to aid application. As a result not all epoxies are
equal.

Solvent Based Epoxies can vary significantly from one another. What holds
them together is there use of solvents to aid in application, adhesion and/or
leveling properties. They normally range from 30-70% solids are easier to
apply than 100% solids epoxy and due to their solid content are much
thinner after the solvent has evaporated and they have cured. Solvent based
epoxies are generally more tolerant of petroleum based surface
contaminants such as oil.

Water Based Epoxies are much the same as solvent based epoxy. There
major difference is the use of water as the carrier rather than a solvent. With
the increase government regulation and the harmful odors of solvent based
epoxies these are much more popular. They are however a little more
expensive than solvent based due to the technologies and can be a little
more fickle for installation.

Specialized Epoxies

Flexible Epoxies are modified to provide elongation in addition to epoxies

normal properties. Like Polyurea they can be used for joints and areas
susceptible to movement like exterior slabs and multi story structures
parking ramps.

NOVOLAC EPOXY - is fast curing and offers excellent protection for

secondary containment where resistance to strong alkalis, acids, and
solvents are required. Novalac epoxies have many properties of conventional
100% solids epoxy. Their difference lies in their polymeric structure. In
chemical terms, novalacs have a higher cross-linked density than
conventional epoxies. This makes them more rigid and chemical resistant,
and allows them to withstand higher service temperatures. These properties
lend themselves for use in chemical containment and battery charging areas.
The downside to their higher cross-linked density is that novalacs are
typically more viscous than conventional epoxies, which make them more
difficult to apply.

POLYURETHANE RESINS

Polyurethane resins, commonly referred to as urethane, are thermosetting or

thermoplastic and demonstrate moderate chemical resistance and good
resistance to diluted acids and alkali. Polyurethane resins generally offer
moderate adhesion, but good resistance to shrinkage and good flexibility.
Urethanes are a popular high-performance floor coating. They have many
desirable properties, including fast cure times, high abrasion resistance and
toughness, and good chemical resistance. They are typically the most
resistant to water exposure, high humidity, temperature extremes, and
fungus or mildew. Urethanes performed best when placed on dry concrete.
Moisture inhibits the cure of two-component systems and can cause
blistering of moisture-cured coatings because of its reaction with water
generate carbon dioxide gas.

The first essential component of a polyurethane polymer is the isocyanate.

Isocyanates can be classed as aromatic, or aliphatic. Important
characteristics of isocyanates are their molecular backbone, solvent content,
functionality, and viscosity.

Moisture cured Urethane

The “old stand-by” of urethanes are aromatic urethane also described as

moisture cured urethane. Most commonly installed on wood floors, these
urethanes are normally single components and dry through reaction with the
moisture or humidity in the air. They can vary from 20% to 70% in solids
with the remainder evaporating. As a result this percentage determines the
dry film thickness once the solvent has evaporated. Still a good product for
some applications its biggest drawback is its tendency to yellow over time
due to low UV resistance and offensive solvent smell during application.
Moisture cured urethanes are widely used because they perform well and
offer the convenience of a one-component system but in aliphatic urethanes
generally provide better performance.

Aliphatic Urethane

Aliphatic Urethane is the next step urethane resin technology. It is still likely
solvent based and a two component product much higher in percent solids.
The primary performance difference between moisture cured urethanes and
Aliphatic Urethanes is due to its chemical resistance being significantly
higher. These products can resist solvents including methylene chloride (the
active ingredient in paint stripper). The main reason that aliphatic
isocyanates are used in making polyurethane coatings is the two-part
product it is also UV stable holding its color with time.

Odorless Urethanes

Next generation or as they are commonly described “Odorless” Urethanes

have come about as a result of the restrictions on solvent use in
manufacturing facilities as well as government influence. There are
numerous formulations that vary greatly in performance as well as cost. The
difficulty is determining the quality. The main formulation techniques used to
achieve odorless urethane is the use of water instead of aromatic solvents
and the development of very high to 100% solids urethane products (80 to
100% solids). The increased desires for odorless polyurethanes have also led
to the development of the sub group of urethanes known as Polyureas and
Polyaspartics.

Urethane Mortar

Developed roughly 30 years ago urethane mortars have increased in

popularity from the original BASF’s “Ucrete” to more than a dozen major
manufacturers producing them currently including Sherwin Williams, General
Polymers, Tennant, Crawford Laboratories, Garland and Rustoleum.
Urethane mortars combine cement with water based urethane technology to
produce a mortar product exhibiting properties of both.

Continued development over the past 15 years has in these systems with
increasing high resin content and low viscosity. Designed to exhibit a high
cross-linked density, cementitious urethane systems are non-toxic, non-
hazardous, and highly chemical resistant and further developments allow for
more effective and efficient installation.

Because of low temperatures during installation urethane mortar flooring is

ideal for food processing and pharmaceutical manufacturing facilities. Floors
in these environments are subjected to abuse, heavy traffic, chemical attack,
extreme temperatures resulting in extremely hostile conditions. Urethane
mortars do well in these abusive environments but may not be required in
every plant area. Epoxy mortar systems, due mostly in part due to cost, are
still the preferred material for less demanding environments.

The advantages of applying a urethane mortar flooring system are

numerous. The cementitious urethane composition has a similar modulus of
elasticity to that of concrete. This all but eliminates differential flexing that is
prevalent with most other resins.

In addition to being able to absorb and withstand extreme heat and cold
temperature change, urethane mortar systems also have sound deadening
properties. These are particularly useful in areas exposed to steel wheel
traffic such as bakeries. Urethane mortars can also effectively withstand
abuse from impact such as dropping of objects such as pots and pans found
in commercial kitchens.

Another advantage of urethane mortars is that typically do not require a

primers saving considerable installation time. Primers for urethane mortars
do allow for installation over dairy brick and tile eliminating the need for
removal of existing flooring while eliminating the need for regular
maintenance of grout joints. In the case of new concrete the unique
chemical composition of urethane mortars with their similarities to concrete
allow for installation over freshly poured concrete, thus eliminating the need
for the typical 28-day wait time for the concrete to cure.

While there are numerous advantages to urethane mortar flooring systems,

there are several disadvantages too. Having a cement and water cure,
installation of these systems should be avoided at temperatures over 90
degrees F to reduce the risk of blistering from increased carbon dioxide
being trapped during the rapid initial curing process. Due to their rapid cure
time the installation of a urethane mortar system their primary purpose is
for performance where as epoxy floor systems tend to allow for more
decorative installations.

Urethane mortars are available in three primary forms a trowel applied

mortar, a self-leveling slurry and a self-leveling slurry that can also be
broadcast into for an aggressive anti-slip texture and/or a decorative quartz
or ceramic carpet finish. All of thise installations typically range in thickness
from ¼ inch to 3/8 inch with some newer products that can be applied as
thin as 1/8 of an inch.

Polyurea

Polyurea is a subset of Polyurethane when isocyanates react with water to

form a urea linkage and carbon dioxide gas; they also react with
polyetheramines to form polyureas.

Polyurea applications include joint sealant technology. coatings and linings

are most commonly seen applied over truck bed liners for corrosion
protection and abrasion resistance. They also have tremendous advantages
over conventional materials for joint fill and caulk applications due to their
fast set nature, high elongation typically in excess of 300% and
durability/abrasion characteristics. Polyurea comes in three primary
formulations spray, caulk grade (packaged in dual component cartridges with
special mix tips, and hand mix formulations.

Due to polyureas extremely fast cure nature (usually in less than a few
seconds) specialized application equipment is often needed for installation.
Polyureas are generally odorless with 0 VOC’s, extremely flexible and when
sprayed due to lack of solvents allow for almost unlimited thickness in a
single application.

Polyaspartic

Polyaspartic is a type of polyurea (actually a polyaspartic aliphatic polyurea).

All polyureas are two-part systems, meaning that a resin has to be mixed
with a catalyst to create the curing reaction that hardens the material.
Polyurea has been used very successfully for corrosion-resistant coatings
and repair materials, although application is awkward since it has an
extremely short pot life—about 3 seconds, so the two parts must be mixed
at the spray tip, requiring lots of maintenance on expensive high-pressure
equipment.

Polyaspartic polyurea (or simply polyaspartics) overcomes many of those

difficulties, while retaining the advantages by combining the best properties
of polyurea and Aliphatic Urethane technology. According to Bayer Material
Science, polyaspartics are "based on the reaction of an aliphatic
polyisocyanate and a polyaspartic ester, which is an aliphatic diamine."

For most of us, the important thing to understand is that polyaspartics are a
polymer coating material that has a rapid cure time for 5 to 120 minutes
depending on formulation, can be applied to surfaces with extreme
temperatures from -30°F to 140°F. Polyaspartics generally have very low
viscosity, equivalent to water, which gives it outstanding wetting ability to
apply a high build in one coat, UV stability, and excellent chemical and
abrasion resistance thus providing some of the best properties of epoxy
resins and urethane resin technology.

The main drawback, cost. Polyaspartic resins tend to be 3 to 10 times more

expensive than 100% solids epoxy resins.

SPECIALTY PRODUCTS

Polyesters

Polyesters are two-component systems in which a pre-polymer resin

dissolved in styrene is mixed with a peroxide catalyst. Polyesters are fast
setting, high strength, and demonstrate excellent resistance to acids and
most solvents, but they are generally susceptible to alkali attack. Polyester
resins experience a relatively high amount of shrinkage. Styrene
flammability and fumes must be considered when using this product.
Polyesters resins are most commonly used for chemical containment both
primary and secondary in areas exposed to aggressive acids.

Vinyl Esters

Vinyl Esters are a type or subset of polyester resin, in which the pre-
polymers are formed by reaction of epoxy resin with acrylic of methacrylic
acid. Vinyl ester resins provide ultimate performance in chemical / corrosion
resistance. The products are typically formulated in high build, fast curing
systems for corrosion resistance and toughness. Again, styrene flammability
and fumes must be considered.
Oil Primers

Oil Primers are designed specifically for old concrete that has been
consistently exposed to oil. It is still a good idea to remove any surface oil as
it can become acidic and wear away at the concrete however they can
incorporate oil into their binding matrix and provide good adhesion to an
otherwise un-adhere able surface.

Moisture Tolerant Primers

Moisture tolerant primers these products many of which are water-based

epoxies provide a primer that can adhere to wet or damp concrete. Some
moisture tolerant primers allow for application to “green concrete” or
concrete less than 28 days old as well as creating a breathable surface
where water vapor can travel up through it but still creates a waterproof
surface.

Pre-Primers / Tack Coats

Pre-Primers are generally high solvent products that both clean and prime
difficult to adhere to surfaces such as ceramic tile, quarry tile, dairy brick,
and even glass allowing for the application of various resin systems as
topcoats.

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PHOTOS

Vanguard Concrete Coating

3030 Hillcroft SW
Grand Rapids, Michigan 49548
Phone: 616-742-1540

Fax: 616-742-3793
Ian@vanguardconcretecoating.com

© Copyright 2009-15 All rights reserved by Vanguard Concrete Coating of Grand Rapids, MI. For
residential epoxy coating of floors our service area includes the West Michigan cities of Grand Rapids,
Muskegon, Holland, Zeeland, Grand Haven, Kalamazoo, and Portage and small cites in-between. For
industrial & commercial floors we service a larger area including the greater Detroit & Ann Arbor area,
Northern Michigan (including Traverse City, Cadillac, Big Rapids, Petoskey, Charlevoix, Grayling and
Gaylord) Southwest Michigan (including St Joseph, Benton Harbor, South Haven,) Central Michigan
(Including, Marshall, Battle Creek, Jackson, Lansing, Charlotte, Eaton Rapids, Grand Ledge, Saint
John’s, Ithaca, Owosso, and Mount Pleasant) MI Thumb Area (including Flint, Saginaw, Lapeer, Bay
City, and Midland) as well as Northern Indiana.