A warehouse aisle and a chemical filling area have different coating requirements. Assessing concrete condition, service loads and layer compatibility together allows flooring selection to reflect the operation's actual needs.

Why should a factory floor be treated as a coating system?

Selecting an epoxy coating for a factory floor requires defining service conditions before colour and price per square metre. A warehouse aisle, assembly line, chemical filling section and maintenance workshop may be in the same building, yet experience different loads. Forklift turns, pallet dragging, liquid spills and cleaning operations should be considered together. This technical assessment aims to provide a selection framework built on the right questions, rather than recommend one product for every area.

Sika's approach to industrial flooring also involves assessing mechanical, chemical and operational effects together. In practice, this means dividing the production area into zones according to their functions. Product research can begin with the industrial paint and coating options; however, suitability for flooring must be confirmed through the selected product's current technical data sheet and a system recommendation that defines all layers together.

How should concrete moisture and surface tensile strength be assessed?

A surface that looks dry does not, on its own, indicate the moisture condition within the concrete. The measurement method, concrete age, ambient conditions and potential rising moisture should be recorded together. Results from different methods should not be interpreted against the same limit. For example, Sika's technical information for a polyurethane coating provides separate moisture criteria for different methods. The essential principle is not to transfer another product's limit to the selected coating.

The soundness of the surface layer that will support the coating matters as much as the concrete's compressive strength. A dusty, deteriorating surface or one covered with old adhesive will not be improved automatically by a strong topcoat. The technical team should determine the tensile strength assessment and scope of surface preparation. If a moisture problem is identified, an ordinary primer should not be assumed to solve it. Specialist moisture-control primers are separate product classes, and their uses are limited by their own documentation.

What problems do surface preparation and primer selection prevent?

The initial survey should identify more than cracks. Oil stains, loose areas of the old coating, repair mortars, drain surrounds and interfaces between separate concrete pours should also be marked on the plan. In addition to removing contamination and weak surface layers, the preparation method must create the profile required by the selected system. Removing dust after preparation and protecting the prepared surface from recontamination are separate steps in the application plan.

A primer does more than create the first coloured coat; it is a system component that controls the interface between the substrate and subsequent layers. The word "epoxy" in a catalogue therefore does not mean that every primer is suitable for concrete. For example, the Nanomix Epoxy Primer product page describes prepared metal surfaces. A primer for a flooring project must be verified separately against the concrete, moisture condition and subsequent coating. The quotation should clearly state the primer's full name, preparation scope and acceptance criteria.

How should you choose between self-levelling and textured epoxy?

Self-levelling coatings are considered for projects seeking a smooth surface appearance. Systems with increased surface texture, by contrast, may meet a different operational need arising from wet or contaminated conditions. Fosroc's industrial flooring classification is a useful example because it shows different layer structures and textured options for dry and wet production areas.

When assessing Nanomix Epoxy Self-Levelling Paint, provide information on substrate flatness, layer structure and service loads as well as the desired appearance. The term "self-levelling" does not mean that the coating will correct every level defect in the floor. Drainage areas requiring a fall and assembly areas requiring a level appearance should not use an identical detail. A sample area can be used not only to select colour but also to assess surface texture and compatibility with cleaning equipment.

Define forklift traffic, chemicals and temperature separately

Stating only the number of vehicles in a warehouse is insufficient. Wheel type, locations where loaded vehicles turn, sudden braking, falling components and the way pallets contact the floor complete the operating picture. Aisle entrances and spaces between racks may not wear at the same rate. It is therefore more informative to mark high-traffic zones separately than to prepare a quotation using one average service description for the whole site.

Chemical resistance assessment requires concentration, temperature, contact duration and cleaning method as well as the substance's name. A drop that is wiped away intermittently and a pool left for hours are different scenarios. Manufacturers' information on chemically resistant coatings also refers users to technical services for detailed assessment. When researching an epoxy topcoat, do not infer unlimited chemical resistance from the generic product name; suitability for actual exposure should be confirmed in writing.

Design slip resistance and cleanability together

A very rough surface cannot be described as the best choice for every operation. As surface texture increases, the method of removing dirt and the mechanical cleaning effort required may change. Wetness, oil, footwear, slope and cleaning frequency should be considered together. Sika's guidance on surface selection for production areas shows that this relationship cannot be resolved by the coating material's name alone.

The operation's existing floor-cleaning machine, brush and dirt collection method can be tested on a sample area. The aim is to prevent the cleaning team from encountering an unexpected surface after application is complete. Having cleaning staff and the production manager assess the same sample balances appearance-led decisions with operational knowledge. The RAL colour catalogue can provide a starting point for colour; dirt visibility under actual lighting and area markings should be reviewed separately.

Why must joints, cracks and drainage details not be overlooked?

A coating that looks seamless does not mean that all movement in the structure has disappeared. Movement joints, column surrounds, door thresholds and drainage interfaces require designed details. Covering an existing crack without assessing its cause may provide a smooth appearance temporarily, but gives no assurance about subsequent behaviour. Technical guidance on floor joints emphasises that these areas accommodate both movement and service loads.

Mark joint locations, any broken edges and wheel crossings on the survey plan. Observe where water flows around drains, and define coating selection and level adjustment as separate tasks. At handover, the operator should include these interfaces in the acceptance scope rather than focusing solely on the gloss of large areas. This clarifies maintenance responsibilities, application boundaries and areas that may require future intervention.

How should curing and opening to service be scheduled?

The time before foot traffic is permitted is not the same as the time before forklift traffic or chemical service. Read the temperatures and conditions to which the waiting periods in the technical data sheet apply. The separate entries for foot traffic and full cure in the technical data sheet for an epoxy flooring product illustrate the practical importance of this distinction. The times in this example cannot be applied to other products.

The production shutdown plan should include separate allowances for surface preparation, repairs, waiting between coats, inspection and protection. Alternative routes can be arranged for employees who need to pass through the application area. Where there is pressure to reopen early, the solution is not to shorten waiting times arbitrarily, but to consider phased work and suitable system selection from the outset. Whether adjacent work will generate dust, water or impact should also be included in the schedule.

Maintenance planning and handover records complete the cost assessment

Comparing a flooring investment only by its initial application cost can conceal important items such as cleaning, local repairs and production downtime. Including product names, batch information, application dates, an area plan and maintenance recommendations in the handover file makes later decisions easier. Detergent compatibility, brush selection and spill removal methods should be determined from the manufacturer's maintenance instructions. The Sikafloor maintenance guide explains the role of cleaning and regular inspection during service.

If a transparent finishing coat is being considered, review the epoxy clear coating product information separately and confirm system compatibility with the existing coloured coat. Do not assume that a new coat can be applied directly to every old floor. Tracking small wear spots with dated photographs helps identify recurring operational effects and plan maintenance over more limited areas.

What information is needed for comparable quotations?

Consider, for example, a dry spare-parts warehouse and a frequently washed filling area within the same project. Wheel movements and rack layout take priority in the warehouse, while chemical contact, drainage and cleaning must be considered together in the filling area. Pricing the two zones only by total square metres can conceal their different needs. Adding a simple layout showing each area's function to the quotation request makes assessment easier.

Condition of the existing concrete or coating, previous repairs and known moisture problems.
Vehicles, wheels, loading points and heavily used turning routes.
Chemical list, spill contact duration, cleaning method and temperature effects.
Maximum production downtime, need for phased work and criteria to be checked at acceptance.

Including this information in a quotation request provides a more meaningful starting point than a request consisting only of a product name and square metres. Missing measurements and application constraints can be shared through the Versan Boya contact channel. Final application should be planned by a specialist team in accordance with the selected products' current technical and safety documentation.

Frequently asked questions about epoxy factory floors

Can epoxy be applied immediately over new concrete?

The casting date alone cannot determine this. Moisture, surface strength, preparation condition and the requirements of the selected system must be assessed. An application schedule should not be committed to for a floor whose suitability has not been verified.

Is thicker epoxy always more durable?

Layer thickness alone is not a sufficient criterion. The substrate, system composition, adhesion, exposure and application quality all influence performance. The project's target thickness should be based on the system's technical documentation.

Is a glossy floor necessarily slippery?

Appearance and slip resistance in actual use are not the same assessment. Wetness, contamination, texture and footwear should be considered together, and the required performance verified by an appropriate method.

Must an old epoxy coating be completely removed?

There is no single answer for every project. The soundness and contamination of the existing coat and its compatibility with the new system must be examined. The extent of areas to be retained, preparation method and sample application result are determined through technical assessment.

Technical sources

This article is an editorial technical assessment prepared on 24 September 2026. The sources explain general principles; in practice, the current technical data sheet for the selected product and the project specification take precedence.

TopicsIndustrial coatings Technical information Project consultation

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