What is Epoxy Flooring? Benefits, Uses & Costs

UltraSyntec has installed industrial epoxy flooring across the UK since 1996. This guide covers what epoxy flooring does well and where it is the right choice, written from what we see on site, not from a brochure. If you are specifying a floor for a working building, our industrial resin flooring systems outline what we install and where each system is best suited.

Epoxy flooring is a durable, seamless coating system applied over concrete surfaces, commonly used in commercial and industrial environments for its strength, hygiene, and chemical resistance.

The importance of flooring can sometimes be overlooked in commercial and industrial buildings. But for optimal productivity and safety, you need floors that keep your business running efficiently.

A popular option for many businesses is epoxy finish concrete, thanks to its reliability and durability.

Here, we reveal some of the incredible benefits of epoxy flooring, as well as its downsides.

What is Epoxy Flooring?

The term epoxy refers to a combination of hardeners and resins. When mixed, these substances cause a chemical reaction. When hard, this reaction results in the formation of a rigid plastic material, comprising tightly linked cross-polymer structures. This material bonds well to most base layers, creating a resistant and durable floor surface.

Epoxy coating professionals apply the epoxy as a liquid to concrete floor surfaces. This liquid then hardens to form a smooth and hard-wearing floor. As concrete is porous, the epoxy coating bonds to the base layer, creating a strong and seamless epoxy finish on the concrete surface.

But only experienced professionals can apply the epoxy coating. These experts can also ensure that the original surface is suitable and that the appropriate epoxy coating is used.

The Installation Cost of Epoxy Resin Flooring Per m²

Typical installation costs for areas up to 500 m2 range from £25 to £45 per square metre. The price will vary depending on the size of the floor in question. Furthermore, the amount of preparation and/or repair required by the substrate before the flooring material can be applied.

For epoxy resin floor areas above 500m2, this cost per square metre will reduce to between £12 and £25, again depending upon the total area in question and the preparation works required.

9 Benefits of Epoxy Flooring

There are many benefits associated with using concrete floor epoxies. Here are the top nine:

1. Durable and Resistant

Epoxy coating bonds seamlessly to existing floor surfaces, creating durable, high-quality surfaces that are sure to last for years.

Epoxy flooring is also very strong and resistant to wear and tear. This makes it an ideal choice for commercial and industrial spaces. Epoxy coating can withstand the constant flow of transport vehicles, heavy machinery, and forklifts, as well as foot traffic from customers and workers.

And, as epoxy flooring is resistant to sudden impact, any accidents, such as dropped cargo or spillages, will not cause any damage to your floor surfaces.

2. Reduces Damage to Machinery

As well as being resistant enough to bear the weight of a steady stream of traffic, the smooth and seamless surface created by epoxy coating is more forgiving than other types of flooring on the machinery that travels over it.

This means less wear and tear for transport machinery, which results in lower maintenance costs for the business.

3. Resistant to Chemicals

Thanks to its resistant and highly durable structure, epoxy flooring can withstand continued exposure to chemicals without becoming less effective or damaged in any way.

For this reason, epoxy coating is ideal for the floors of pharmaceutical manufacturing facilities, warehouse facilities, and industrial plants, all of which may be regularly exposed to these kinds of harsh elements.

4. Attractive Floor Surface

Many business owners choose epoxy flooring for its aesthetic appeal. An epoxy coating gives new life to old and tired floors, creating a gleaming and highly attractive floor surface.

Plus, there are many different textures and colours to choose from. So, you can match your flooring to the rest of your facility, or even to your company’s colour scheme.

5. Safe Working Environment

This range of colour options means that it’s also possible to use different colours and designs on certain sections of the floor to create designated zones.

This makes epoxy floor coating ideal for large spaces, where loading bays, forklift paths, and walkways need to be marked to ensure the safe movement of vehicles and workers.

Epoxy coating is also resistant to extreme and sudden impact, slippages, high temperatures, and even fire.

Plus, epoxy floor coating boosts brightness by up to 300 per cent. This is due to the way light reflects off the smooth epoxy surface. As a result, your workers and customers will benefit from improved visibility and a safer working environment. And you avoid the cost of installing extra lighting.

6. Fast Application

Another benefit of epoxy flooring is its relatively quick and easy installation. This means you won’t need to shut down your business or stall production for long, saving you time and money. Ultrasyntec can also work out of hours to minimise disruption for your business.

7. Easy to Clean

The crevices and pores in other flooring surfaces attract a lot of bacteria and dirt, making them difficult to clean.

In contrast, epoxy flooring provides a smooth and completely sealed surface. As epoxy flooring is free from crevices and pores, it’s much easier to clean and maintain.

In fact, warm soapy water is all you need to clean epoxy flooring and keep it looking like new.

8. Environmentally Friendly

As well as being an ideal option for your business and your workers, epoxy floor coatings are good for the environment in several ways.

The manufacturing process of epoxy coating is minimal, and the materials used are free from harmful substances. You also don’t need to use harsh and harmful chemicals to keep your epoxy flooring clean and dirt-free.

The extra illumination an epoxy surface provides means that large industrial and commercial spaces don’t have to resort to extra lighting, saving energy.

Since the epoxy coating is long-lasting, you won’t have to consider replacing it for many years, meaning less waste. And, finally, since it also helps to avoid the usual wear and tear on your vehicles, you won’t have to replace tyres and various mechanical parts as often, also resulting in less waste.

9. Cost Effective

Epoxy floor coating can be expensive. But, its durability alone makes it an extremely cost-effective option, as you won’t need to replace it for many years.

And, when you consider the savings on vehicle repairs, lighting, cleaning, and installation, it’s clear that epoxy flooring will continue to save you money in the long term too.

The Downside of Epoxy Flooring

In the interests of providing balanced and informative detail, we must also look carefully at the potential downsides of epoxy flooring systems, as well as the benefits of epoxy floor coatings, in certain applications.

For epoxy flooring to provide the best possible performance, the underlying floor, concrete surfaces or substrate must be prepared correctly before the material is applied. Reputable epoxy flooring installers will use techniques such as diamond grinding with specialist equipment to ensure the substrate is suitable, and will carry out remedial works, such as filling cracks with appropriate materials.

Achieving a clean finish free of solvents, oil and dirt is also an essential part of the preparatory process, adding to the time and eventual cost of the project.

In addition, epoxy floors must be laid following the individual manufacturer’s guidelines. Each coat must be allowed to cure before proceeding to the next step; otherwise, performance will be affected, and this level of downtime may be too costly for your business. This is a job best carried out by specialists who understand the material specifications and are qualified to advise on the best material for the job.

Maintenance is an important consideration too – epoxy floors need to be properly maintained to avoid damage, which can lead to delamination and floor failure.

Finally, be sure you want epoxy floors and that they are suitable for the proposed processes and activities they will be subjected to. These surfaces are designed to last, and removing an epoxy floor once it has been laid is expensive and time-consuming.

That’s why it’s always worth consulting with the experts. The team at UltraSyntec has decades of experience advising on the appropriate choice of epoxy flooring for various industrial, manufacturing, and commercial applications. They will assess your current and future requirements and provide an epoxy floor finish specification tailored to your specific needs.   

It’s Important to Properly Prepare the Substrate

We’ve touched on just how important correct substrate preparation is when laying an epoxy floor, so let’s explain why it’s also vital to fill in any existing cracks or damage before the material is laid. If the substrate is uneven or cracked in places, it can affect the look and feel of the finished floor surface, with ripples appearing in damaged areas where the epoxy cannot bridge the cracks. Specialist flooring contractors can prepare your existing floor with purpose-designed materials and compounds to prevent this from happening.

Correct Application is Vital for a Long-Lasting Solution

If you’re looking for a long-lasting, durable solution, installing epoxy resin flooring is a specialist task. Qualified flooring contractors will understand the issues, know how to handle the materials and understand exactly what is required before the process begins. Downtime is a costly issue for your business, and they will minimise the time required to ensure you have the best possible finished product to serve your business for years to come.

Maintenance & Cleaning is Important

It’s important to have a good cleaning and maintenance regime for an epoxy floor. Regular work, keeping it free from dirt and grit, will pay off, as over time these can damage the floor surface. Pay attention when moving machinery and equipment to avoid impact damage, which can weaken the structure.

Epoxy floors are tough and durable, but attention to detail will extend their lifespan. Remove spillages promptly, particularly if they are oils or solvents which can attack the surface. Immediate treatment will mitigate the possibility of damage. In many cases, a neutralising agent can be used; consult with your specialist installer. If you are removing stains, avoid harsh agents and use a specialist cleaner designed for this purpose.  

It’s Labour Intensive to Remove

Removing a large area of epoxy flooring is a specialist task, as it may require chemicals and equipment best applied by a qualified team who understands how to manage the risks and hazards involved.

It’s a labour-intensive and time-consuming task which will impact your business processes, and the resultant waste materials must be disposed of correctly as they can be hazardous to health.

Consulting specialist flooring installers before you lay an epoxy floor is a must; they will understand and advise on the best solutions for your application and help eliminate the possibility of having to remove the floor once it has been installed.   

The Resulting Surface is Cold

Epoxy floor coating can feel cold, particularly in cooler weather, but it will typically be the same temperature as other hard flooring surfaces. They will, however, offer significantly greater durability and resistance to wear and tear.

Install Epoxy Flooring Today

As this list shows, there are many different benefits of epoxy flooring. And, these benefits cover a wide range of considerations, from financial to aesthetic.

Balancing the pros and cons of epoxy flooring will help to make the right decision, particularly if performance and longevity are important considerations.

This is why warehouses, industrial workshops, and even RAF bases know that epoxy coating is the best choice for their floors, providing a cost-effective flooring solution.

If you’re interested in installing epoxy flooring, contact us today for more information.