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The Top 3 Coatings for Industrial Floors to Consider

Selecting the ideal industrial floor coating for your facility can be a challenging task. Epoxy coatings are popular for their versatility and durability, but they have their limitations. Other options, such as polyurethane and polyaspartic coatings, also have their pros and cons.

The reality is, there is no one-size-fits-all coating for industrial floors. The right choice for your facility will depend on your specific needs and requirements. The most important questions to ask are:

Does the floor have to hold up heavy equipment and withstand vibrations and abrasions?
Do your operations involve harsh chemicals?
What’s the risk of slipping on your facility floor?
How much traffic (vehicular and human) does the floor have to handle?

The answers to these will dictate the kind of industrial floor coating best suited to your facility; however, coatings for industrial floors should aim to require minimal maintenance (which reduces costly downtime), improve worker safety, and maximise durability.

At Ascoat, we have worked with clients across a wide range of industries, including food and beverage manufacturing, mechanical workshops, factories, and pharmaceutical companies, to install industrial floor coatings that meet their specific operational and safety needs.

Armed with over three decades of experience, we generally recommend three coatings for industrial floors: polyurethane cement, self-levelling epoxy, and roll-on epoxy coating.

1. Polyurethane Cement

Polyurethane cement, or poly-cement, coating is made by combining polyurethane resin with modified cement. It’s one of the toughest industrial floor coatings on the market, with high resistance against abrasions, chemicals, thermal shocks, and moisture.

It is a suitable choice for heavy-duty industries, like manufacturing and mechanical, where it holds up well and lasts a long time, even in the most demanding environments.

The ability of poly-cement to withstand extreme hot and cold temperatures also makes it a good industrial floor coating for facilities handling foods and beverages, including commercial kitchens, cold storage areas, and food production factories.

Non-Slip Protection

Poly-cement floor coating is one of the best when it comes to slip protection. Its finish can range from completely smooth to P5, the highest non-slip rating. It’s the best type of coating for areas, like wet kitchens and food processing zones, where moisture and grease present a very high risk of slipping. These areas typically require a floor with a P4 or P5 non-slip rating.

Polyurethane Cement Installation

Polyurethane cement can be applied using a rake and roller or with a trowel. At Ascoat, most of our industrial floor coatings are trowel-applied. In contrast to rollers, trowelling allows thicker floor coatings (between 4mm and 9mm), which improves the floor’s durability and resistance to damage from abrasion, shock, and chemicals.

The finishing of poly-cement coating can range from matte to semi-gloss, depending on your preferences.

2. Self-levelling Epoxy

Self-levelling (SL) epoxy gets its name as it naturally flows to create an even, smooth, and seamless floor.

The two-part coating system (resin + curing agent) hardens into a tough, hard-wearing, and impact-resistant surface suitable for light and medium-duty industrial applications, such as garages, workshops, pharmaceutical facilities, printing and packaging, and warehouses.

Self-levelling epoxy is also resistant to solvents, oils, and other chemicals.

Non-Slip Protection

We can install a self-levelling epoxy floor coating with up to a P3 non-slip finish, which improves safety in areas with a moderate risk of slipping.

Self-levelling Epoxy Installation & Appearance

SL epoxy is installed on a concrete floor that has been prepped and primed to ensure maximum adhesion and durability.

It’s applied to a thickness of between 2-3mm and has a glossy appearance. Depending on your particular needs, additional coats can be applied over the epoxy to provide additional protection and longevity.

For example, a urethane topcoat can be applied to enhance UV protection, improve resilience to wear (especially in high-traffic areas), and increase chemical resistance.

Other overcoat options include an aggregate anti-slip coating, an anti-bacterial coating, and an antistatic and ESD coating.

3. Roll-on Epoxy Coating

Roll-on epoxy is the go-to flooring system for general-purpose light and medium-duty industrial applications. It is thinner than self-levelling epoxy, with a standard thickness of 0.4mm to 0.6mm.

Roll-on epoxy creates an impervious barrier on concrete, which provides moisture, chemical, and wear protection in garages, light industrial facilities (such as component assembly areas), warehouses, and commercial spaces with low to medium traffic.

Roll-on epoxy coating is commonly used to improve aesthetics in commercial areas thanks to its glossy finish and availability in a wide range of colours.

We also use roll-on epoxy in our floor zoning projects. Its glossy high-visibility finish, durability, and customisability make it ideal for zone and line marking on commercial and industrial floors.

Non-Slip Protection

The finish of a roll-on epoxy coating can range from smooth to a P3 non-slip finish, making it suitable for kitchens, labs, garages, stairways, ramps, and other areas where there’s a moderate slip risk.

Application of Roll-on Industrial Epoxy Flooring

Similar to other industrial concrete floor coatings, application begins with prepping and priming the concrete surface. The epoxy coating is then applied as a 2 or 3 coat system using a roller with a curing time of 24-72 hours.

Why Choose Ascoat for Industrial Floor Coatings

We have over 30 years of experience designing, installing, and maintaining floor coatings for industrial floors. We understand the unique technical needs of various industries and can help you select the ideal floor coating for your facility.

To make sure work is finished on time with minimal disruptions to your operations, we handle all projects ourselves (no subcontractors involved), and come with our own equipment and materials. Additionally, we have a dedicated operations manager and technical manager assigned to each project to ensure the delivery of high-quality results.

Testimonials

Ascoat have recently completed a large floor coating project in a new formulating and filling facility. The total area of around 2400 m2 included both epoxy and urethane flooring, including stairways with variations on non-slip finish to suit the environment. The work was staged and included specific timing for access to work in existing operational areas. All work was completed to specification and to a high standard. The cooperation and flexibility from Ascoat was vital as access dates varied with both the construction schedule and our production schedule.

We were impressed by the responsiveness, professionalism and technical knowledge of the Ascoat team. I would be pleased to recommend Ascoat Industrial Floor Surfacing as a contractor that delivers what they promise, to a high standard, in a professional manner.

Mick and the fantastic team get the job done on time and on budget

Known Mick and the boys for a while now, they are willing to do anything for you, great and friendly staff

Ascoat were great to work with on a complex project in the middle of other construction work. Quality of work and anti-static end result were excellent.

Ascoat meticulously, and with much finesse, completed the tasks on time and within nominated budget, totally in line with all company policies, permits, SWMS, etc. Would not hesitate to utilise their services on any other project in future requiring their expertise. Well done guys.

Good morning Laurence As you are aware, the work has been completed here. We are quick to complain but not so with praise. I would like to register my appreciation for the site team lead by Brandon. The quality of the finished product and the way the Ascoat staff conducted themselves was exemplary. I can’t speak highly enough of all those that attended site, particularly your foreman. It was a pleasure having your company here.