Before diving into the world of epoxy floor coatings, it’s crucial to understand the key components and considerations that will ensure you make the right choice for your project. From selecting the appropriate primary film-forming substances to choosing the right curing agents and modifiers, each element plays a vital role in achieving a durable and high-quality finish. In this guide, we’ll walk you through the essential factors to keep in mind before purchasing epoxy floor coating materials.
Main Components of Epoxy Floor Coating Materials
Epoxy Floor Coating materials consist of various substances mixed, dissolved, and dispersed through production processes. Based on the different effects of each component, Epoxy Floor Coating can generally be divided into primary film-forming substances, secondary film-forming substances, and auxiliary film-forming substances.
Characteristics Required for Primary Film-Forming Substances
a. Good alkali resistance.
b. Film formation at room temperature.
c. Good water and weather resistance.
d. Wide material sources, abundant resources, and low cost.
The primary base material of floor paint is mainly synthetic resin, which is a necessary component in floor paint construction:
(1) Polyurethane Resin: Composed of isocyanate with polyester, polyether, epoxy resin, castor oil, or its derivatives (oxidized polymers, glycerolysis products), and hydroxyl-containing thermoplastic polymers (such as polyacrylate resin containing B-hydroxyethyl, hydroxy-containing chlorovinyl copolymer resin), and butyl acetate cellulose, forming various polyurethane coatings. For example, TDI or MDI with polyether is the main base material for elastic floor coatings; HDI with B-hydroxyethyl polyacrylate resin is the base material for high-grade floor coatings.
(2) Epoxy Resin: When used in floor coatings, low molecular weight polyamide resin is often chosen for curing. Currently, epoxy resin is used as a seamless floor coating material and the main base material for water-based exterior wall paint.
Secondary Film-Forming Substances
Secondary film-forming substances are also key components in forming the film but cannot form the film alone without primary film-forming substances. This component is the pigment used in the paint. Adding pigments to the paint not only improves the film’s performance but also increases the variety of paints.
Auxiliary Film-Forming Substances
Auxiliary film-forming substances do not form the film themselves or are not the main components of the film, but they significantly impact the film formation process (application process) or play auxiliary roles in the film’s function. They mainly include solvents and auxiliary materials:
(1) Solvents: Solvents are evaporative liquids that dissolve film-forming substances, reducing paint viscosity to meet application requirements, but they affect the quality and cost of film formation.
(2) Auxiliary Materials: Besides the film-forming substances, pigments, and solvents, auxiliary materials are often used to improve performance. Many auxiliary materials are used in paints, each with specific strengths, but in small quantities, typically a few percent or less. Despite the small amounts, they have a significant impact. Based on their functions, they can be divided into driers, plasticizers, wetting agents, UV absorbers, etc., with driers and plasticizers being more commonly used.
SiOResin’s Water-Based Epoxy Resins – Specially Selected for High-Quality Epoxy Floor Coatings
Epoxy resins are typically used with additives to gain application value. Additives can be selected based on different purposes, with common ones being curing agents, modifiers, fillers, diluents, and others. Curing agents are essential additives, as epoxy resins cannot cure without them. Due to varying performance requirements, there are different requirements for epoxy resins, curing agents, modifiers, fillers, and diluents.
Selection of Epoxy Resins for Floor Paint
One) Based on Purpose:
- For adhesives, it is best to choose resins with medium epoxy value (0.25-0.45).
- For casting materials, it is best to choose resins with a high epoxy value (>0.40).
- For coatings, generally, resins with low epoxy value (<0.25) are chosen.
Two) Based on Mechanical Strength:
- Resins with too high an epoxy value have greater strength but are more brittle.
- Resins with medium epoxy value have good strength at both high and low temperatures.
- Resins with low epoxy value have poor strength at high temperatures.
Three) Based on Operational Requirements:
- If no high temperature resistance is needed and strength requirements are not high, and quick drying is preferred, resins with a lower epoxy value can be chosen.
- For good permeability and better strength, resins with a higher epoxy value can be selected.
SiOResin offers a variety of high-quality water-based epoxy resins to meet different application needs. Please contact our engineers anytime for the best solutions.
Selection of Curing Agents for Epoxy Floor Coating
Types of Curing Agents: Common curing agents for epoxy resins include aliphatic amines, cycloaliphatic amines, aromatic amines, polyamides, anhydrides, resins, tertiary amines, and UV or light-induced curing agents.
Dosage of Curing Agents:
- For amines as crosslinkers, the formula is: Amine dosage = (molecular weight of amine) / (number of active hydrogens) x (epoxy value of resin).
- For anhydrides, the formula is: Anhydride dosage = (molecular weight of anhydride) / 100 x (epoxy value) x (experimental coefficient 0.6~1).
Principles for Choosing Curing Agents:
- Based on performance requirements (e.g., high temperature resistance, flexibility, corrosion resistance).
- Based on curing methods (e.g., room temperature curing or heated curing).
- Based on pot life (the time from adding the curing agent to when it is no longer usable).
- Based on safety (prefer low-toxicity agents).
- Based on cost.
Selection of Modifiers for Epoxy Floor Coating
Modifiers improve the flexibility, shear strength, bending strength, impact resistance, and insulation performance of epoxy resins. Common modifiers and their characteristics include:
- Polysulfide Rubber: Improves impact strength and peel resistance.
- Polyamide Resin: Improves brittleness and adhesion.
- Polyvinyl Alcohol Tert-Butyral: Improves impact flexibility.
- Nitrile Rubber: Improves impact flexibility.
- Phenolic Resins: Improves temperature and corrosion resistance.
- Polyester Resins: Improves impact flexibility.
- Urea-Formaldehyde and Melamine Resins: Increases chemical resistance and strength.
- Furfural Resins: Improves static bending and acid resistance.
- Vinyl Resins: Improves peel and impact strength.
- Isocyanate: Reduces moisture permeability and increases water resistance.
- Silicone Resins: Improves heat resistance.
The amount of modifiers varies, generally between 50-300%. The higher the amount, the greater the flexibility, but the lower the heat deformation temperature of the resin product.
Selection of Fillers for Epoxy Floor Coating
Fillers improve the properties of the product, enhance heat dissipation during resin curing, reduce epoxy resin usage, and lower costs. Depending on the application, different fillers can be chosen, preferably less than 100 mesh in size. Common fillers include:
- Asbestos Fiber, Glass Fiber: Increase toughness and impact resistance.
- Quartz Powder, Porcelain Powder, Iron Powder, Cement, Carborundum: Increase hardness.
- Aluminum Oxide, Porcelain Powder: Increase adhesion and mechanical strength.
- Asbestos Powder, Silica Gel Powder, High-Temperature Cement: Improve heat resistance.
- Asbestos Powder, Quartz Powder, Stone Powder: Reduce shrinkage rate.
- Aluminum Powder, Copper Powder, Iron Powder: Increase thermal and electrical conductivity.
- Graphite Powder, Talc Powder, Quartz Powder: Improve wear resistance and lubrication.
- Carborundum and Other Abrasives: Improve wear resistance.
- Mica Powder, Porcelain Powder, Quartz Powder: Increase insulation performance.
- Various Pigments, Graphite: Provide color.
Adding 27-35% of oxides such as P, As, Sb, Bi, Ge, Sn, Pb in resin can maintain adhesion under high heat and pressure.
Selection of Diluents for Epoxy Floor Coating
Diluents reduce viscosity and improve resin permeability, classified into inert and reactive types, generally not exceeding 30% usage. Common diluents include:
- Diglycidyl Ether, Polyglycidyl Ether, Butyl Glycidyl Ether, Phenyl Glycidyl Ether, Ethyl Glycidyl Ether, Propyl Glycidyl Ether.
- Inert Diluents, Xylene, Toluene, Acetone.
Before adding curing agents, all materials such as resins, curing agents, fillers, modifiers, and diluents must be inspected for:
- Absence of water: Materials containing water should be dried, and solvents with slight water content should be used sparingly.
- Purity: Impurities besides water should preferably be below 1%; if impurities are 5-25%, the formula percentage should be increased.
- Validity: Ensure materials have not expired.
SiOResin’s Water-Based Product Sales
In addition to water-based epoxy resins and polyurethanes, SiOResin offers various curing agents and modifiers. We welcome customers to contact us anytime for consultation.
Precautions for Epoxy Floor Construction
Key points to note in epoxy floor construction include:
- Surface Preparation: Treat the ground before construction by removing oil, water stains, and impurities. Repair any cracks or sand issues to ensure a smooth surface, providing a solid foundation for a durable epoxy floor.
- Mixing: Follow the manufacturer’s ratios for mixing materials, ensuring full stirring. Avoid excessive amounts at once to prevent hardening during application.
- Temperature and Humidity: Apply the coating under appropriate conditions (10-30°C and humidity below 85%) to ensure proper curing.
- Application: Use appropriate tools and techniques for a smooth and even application.
- Curing Time: Allow sufficient time for curing to achieve optimal hardness and durability.
SiOResin provides comprehensive guidance on the entire process, ensuring top-notch results for your projects.
Epoxy Floor Coating: Smooth vs. Textured Finish
Depending on the environment, either smooth or textured finishes may be suitable for your epoxy floor. Smooth finishes are ideal for clean rooms and areas where hygiene is critical. Textured finishes provide additional slip resistance, making them suitable for industrial and commercial settings with high foot traffic or machinery movement.
Conclusion
SiOResin‘s expertise in epoxy floor coatings ensures the best solutions tailored to your specific needs. Contact us for detailed information and expert advice on selecting the right materials for your projects.