Epoxy Floor Coating for Concrete: How Thick Should Your Application Be?

Epoxy floor coating is a popular choice for concrete surfaces due to its durability, aesthetic appeal, and ease of maintenance. However, achieving the optimal benefits from an epoxy floor coating largely depends on applying it at the correct thickness. 

Applying a thick, epoxy coating to a concrete floor is an excellent way to make your floors more durable and impact resistant while also offering an anti-fatigue cushioning. Whether you’re looking to enhance the flooring in a residential garage, a commercial retail space, or an industrial warehouse, understanding the right application thickness is crucial. 

In this guide, your surface prep product experts from Buy Manufacturers Direct are exploring the factors that influence epoxy coating thickness. Join us as we provide detailed recommendations for various environments, and share expert tips to ensure your epoxy floor coating project is a success. 

What is Epoxy Floor Coating? 

Epoxy is a robust, long-lasting floor coating solution created by combining resin and hardener, resulting in a chemical reaction that forms a hard, plastic-like surface. Known for its exceptional durability, epoxy floor coating is widely used in a variety of settings, including residential, commercial, and industrial spaces. It provides a seamless, high-gloss finish that is not only visually appealing but also resistant to chemicals, stains, and abrasions. 

What Is 100 Percent Solids Epoxy?

Epoxy products labeled as “100 percent solids” contain no fillers, such as water or solvents, that evaporate during the curing process. Comprising only resin and a hardening agent, these products maintain their thickness from the moment they are poured to after they have fully cured. When applied correctly to a properly prepared surface, 100 percent solid Epoxy floor coatings form a hard, durable surface that can last for several years, providing exceptional protection and longevity.

How to Properly Prepare Concrete for Epoxy Coatings

Prior to applying a 100 percent solids epoxy, be familiar with the manufacturer’s instructions for how to apply it. You may need to use a shot blaster to create the necessary surface profile that increases your slab’s surface area and provides a better adhesion. 

Factors Influencing Epoxy Floor Coating Thickness

Selecting the appropriate thickness for your epoxy floor coating is crucial to ensure its longevity and performance. 

Several factors play a significant role in determining the ideal thickness for your specific application, including: 

• Type of Surface and Condition: Rough or uneven surfaces may require thicker coatings to achieve a smooth finish, while smooth, well-prepared surfaces can often suffice with thinner layers.
• Intended Use of the Floor: Residential areas, such as garages and basements, typically need thinner coatings, whereas commercial and industrial spaces often require thicker layers for enhanced durability.
• Traffic Load and Frequency: Light-duty areas like home garages can manage with thinner coatings, but heavy-duty areas such as warehouses and factories need thicker applications to withstand constant wear and tear.
• Chemical Exposure and Resistance Needs: Thicker coatings are recommended for floors exposed to chemicals, oils, and harsh substances to enhance their resistance and longevity.
• Environmental Conditions: In areas with extreme temperatures or high humidity, thicker applications may be necessary to ensure the epoxy cures properly and maintains its durability.
• Desired Aesthetic and Finish: Decorative epoxy floors with embedded materials or high-gloss finishes often require thicker layers to encapsulate decorative elements fully and achieve a smooth, reflective surface.

Standard Thickness Recommendations for Epoxy

Choosing the right thickness for your epoxy floor coating is essential to ensure its durability and functionality. 

These standard thickness recommendations serve as a guideline to help you select the appropriate epoxy floor coating products for your specific needs. By considering the intended use and environment, you can ensure your epoxy floor coating provides the optimal balance of protection, durability, and aesthetic appeal.

Garages and Basements

Typically, a thickness of 2-3 mils (0.002-0.003 inches) is sufficient for residential spaces like garages and basements. This provides a protective, easy-to-clean surface that can handle light to moderate foot traffic and occasional vehicle use.

Retail Spaces and Offices

For commercial environments such as retail stores and offices, a thicker coating of 10-20 mils (0.01-0.02 inches) is recommended. This thickness offers enhanced durability to withstand higher foot traffic and daily use while maintaining an attractive appearance.

Warehouses and Manufacturing Plants

Industrial settings require robust flooring solutions. A thickness of 30-40 mils (0.03-0.04 inches) is advisable for areas like warehouses and manufacturing plants. This provides a resilient surface capable of withstanding heavy machinery, forklifts, and continuous use.

High-Impact and Heavy Load Areas

For areas subjected to extreme conditions, such as heavy load-bearing floors or high-impact zones, a thickness of 100+ mils (0.1+ inches) is necessary. This ensures maximum durability and protection against severe wear and tear.

Why Is Thickness Limited in an Epoxy Floor?

When you apply epoxy neat, without filler, it’s generally applied no thicker than 35 mils. As you can see in the video demonstration below, when epoxy cures, it creates tension. The tension, created by cross-linking, is a mechanical action that binds the coating to the substrate. Too much tension, and the coating can pull apart the substrate. 

The amount of epoxy pulls against the plastic at a pressure rate of 12,000 psi. If this were concrete, it would pull at the slab, and could pop right off the surface with repetitive dynamic loads caused by the weight of foot traffic and vehicles. If the coating pops off the substrate, the whole coating will need to be removed and a fresh coat would need to be applied, which can be both expensive and time-consuming.

Epoxy Floor Coating Products

Choosing the right epoxy floor coating product is essential for ensuring durability, longevity, and suitability for the specific conditions of your environment. Buy Manufacturers Direct offers a range of high-quality epoxy coating products from Smith Paint Products designed to meet the demands of various applications, from residential to industrial settings. 

Epoxy Gel-150

Smith’s Epoxy Gel-150 is a heavy-duty epoxy ideal for abusive environments, capable of withstanding heavy forklift traffic. It offers enhanced pot-life and working time compared to traditional 100% solids thixotropic epoxy products. This versatile epoxy can achieve an orange peel texture finish and is highly resistant to acids, caustics, solvents, and alcohols. 

Smith’s Epoxy VCB38 – 1.25 Gallon Kits

Smith’s Epoxy VCB38 is a 2-component, low odor, low VOC, fast-curing waterborne epoxy used as a base coat for full broadcast Vinyl Chip systems in residential, retail, and commercial environments. It forms a tenacious bond at all recommended application temperatures and cures quickly, allowing for efficient removal of excess chips and immediate application of subsequent layers. This makes it an efficient and reliable choice for various settings.

Smith’s Epoxy MP300

Smith’s Epoxy MP300 is a versatile 2-component, 100% solids multipurpose epoxy suitable for a wide range of industrial, commercial, and residential floor coating applications. It can be used as a primer, solid color coating, vinyl chip system, shop floor coating, color quartz broadcast system, epoxy mortar, and for patching. This multipurpose epoxy is designed to meet the diverse needs of various flooring projects, providing durability and reliability across different environments.

Epoxy Application Accessories

When applying epoxy floor coatings, the right tools are essential for a professional, durable finish. Buy Manufacturers Direct offers high-quality epoxy application accessories from Bon Tool to meet the needs of both DIY enthusiasts and professional contractors.

The Bon 12-851 Epoxy Mixer, with its 23-inch x 3/8-inch shaft, ensures a smooth and uniform epoxy mixture. For precise application, the Bon 14-917 Epoxy Finisher features a blue steel 22-inch blade and a 60-inch wood handle, perfect for large surfaces. The Bon Epoxy Cove Tool is ideal for shaping and smoothing epoxy into tight corners and edges. For large area applications, the Bon 22-151 Epoxy Coater, with its coarse 18-inch head, distributes epoxy evenly and efficiently.

Using these BON epoxy application accessories ensures your epoxy floor coating project is executed with precision, resulting in a durable and professional finish.

Get Expert Advice on Epoxy Coatings & Surface Prep Products Today

Ready to elevate your flooring with durable and professional-grade epoxy coatings? Our team at Buy Manufacturers Direct is here to help you find the perfect products for your surface prep needs. Whether you’re tackling a residential project or a large-scale industrial application, we offer expert guidance and top-quality floor preparation solutions to ensure your success. 

Reach out to our team of product experts today by calling us at (815) 472-9754 or by filling out our contact form to get started!