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FL510
CNMI
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Epoxy Self-Leveling Flooring System
For Heavy-Duty Industrial & Hygienic Environments
Where to Use
This system is engineered for industrial and commercial environments requiring extreme flatness, seamless sanitation, and chemical resistance:
Pharmaceutical / Food GMP workshops – eliminates dust and bacterial breeding points
Chemical / Electroplating plants – resists acid, alkali, and solvent spills
Electronics / Precision assembly lines – dust-free, ESD variants available
Warehouses with forklift traffic – withstands point loading and wheel abrasion
Hospital operating rooms / Cleanrooms – seamless, easy to sterilize
High-end parking garages & showrooms – aesthetic mirror finish
This system delivers measurable performance advantages over standard floor paints or single-layer coatings.
Chemical resistance
Resists immersion of 10% sulfuric acid, 20% sodium hydroxide, diesel, hydraulic oil, and common industrial solvents for more than 72 hours without surface degradation.
Compressive strength
Achieves minimum 85 MPa (ASTM D695). Capable of supporting fully loaded forklifts, racking posts, and heavy machinery without cracking or indentation.
Adhesion to concrete
Bond strength exceeds 2.5 MPa (ASTM D4541). Failure always occurs within the concrete substrate – not at the coating interface – guaranteeing no delamination when properly installed.
Abrasion resistance
Wear loss ≤0.03 grams using CS17 wheel, 1000g load, 1000 cycles (ASTM D4060). Withstands daily forklift turning, pallet dragging, and steel wheeled trolleys.
Seamless and hygienic
Zero joints or cracks. No places for dust, bacteria, or liquids to accumulate. Fully compliant with GMP, FDA, and HACCP sanitary requirements.
Self-leveling flatness
Achieves floor flatness within 2 mm over a 3-meter straight edge. Ideal for high-rack warehouses, automated guided vehicles (AGVs), and precision assembly lines.
Proper installation is as critical as the material itself. Each step must be executed to the specified standard.
Step 1 – Substrate preparation
Shot blasting or diamond grinding to remove laitance, open the concrete pores, and create a CSP (Concrete Surface Profile) of 3-5. All loose concrete, oil stains, and old coatings must be removed.
Step 2 – Vacuum cleaning
Industrial vacuum cleaner to achieve a completely dust-free surface. No dust, no debris, no moisture droplets.
Step 3 – Primer application
Roller apply high-penetration epoxy primer at 0.15-0.25 kg/m². Ensure full coverage and absorption. Allow to dry to a tack-free state (typically 8-12 hours at 25°C).
Step 4 – Mortar layer
Mix epoxy mortar with graded quartz sand. Apply by toothed trowel to a thickness of 1-3 mm. Fill all low spots and cracks. Allow full cure (minimum 12 hours).
Step 5 – Grinding and putty layer
Grind the mortar layer to remove any ridges. Apply epoxy putty by scraper to seal pinholes and air voids. Allow to cure and sand smooth.
Step 6 – Self-leveling topcoat
Mix self-leveling epoxy (precisely 4:1 or 5:1 ratio by weight). Pour onto floor and spread with a notched trowel. Immediately run a spike roller in both directions to release trapped air. The material will self-level to a mirror finish.
Step 7 – Curing
Protect from dust, water, and traffic. Light foot traffic allowed after 24-48 hours. Forklift traffic only after 7 days at 25°C. Full chemical resistance develops after 10 days.
Text description of material consumption per layer:
Primer consumption: 0.15 to 0.25 kilograms per square meter, depending on concrete porosity. Highly absorbent substrates require more.
Mortar layer consumption: 0.3 to 0.4 kilograms per square meter per millimeter of thickness. Typical total mortar thickness is 0.5-1 millimeters.
Putty layer consumption: 0.2 to 0.3 kilograms per square meter. This is a thin sealing coat applied after grinding the mortar layer.
Self-leveling topcoat consumption: 0.8 to 1 kilograms per square meter per millimeter of thickness. The final topcoat is typically applied at 1.0 to 2.0 millimeters total thickness.
Total system consumption for a 2 mm final system: Approximately 1.5to 2kilograms per square meter. Add 10 to 15 percent for site losses, spillage, and uneven substrate absorption.
All values are typical at 25°C and 50% relative humidity unless noted.
Mix ratio (by weight): 4 parts resin (Part A) to 1 part hardener (Part B), or 5:1 depending on formulation. Consult product data sheet.
Pot life at 25°C: 20 to 30 minutes. Material must be applied within this window before viscosity increases.
Tack-free time: 8 to 12 hours. Light foot traffic possible after 24 to 48 hours.
Full cure time: 7 days at 25°C. Lower temperatures extend curing proportionally. No forklift traffic before full cure.
Hardness (Shore D): 80 or higher (ASTM D2240)
Compressive strength: 85 MPa minimum (ASTM D695)
Flexural strength: 30 MPa minimum (ASTM D790)
Pull-off adhesion strength: 2.5 MPa minimum (ASTM D4541). Failure occurs in concrete substrate, not at bond line.
Abrasion resistance (Taber): Weight loss ≤0.03 grams (CS17 wheel, 1000 g load, 1000 cycles – ASTM D4060)
Temperature resistance (dry heat): -40°C to +80°C continuous. Short-term exposure up to 120°C.
Chemical resistance (immersion, 72 hours at 25°C): No softening, blistering, or color change for 10% sulfuric acid, 20% sodium hydroxide, diesel, motor oil, and 5% sodium hypochlorite (bleach).
Q1: Can this system be used outdoors?
No. Standard epoxy yellows and chalks under UV. For outdoors, use a polyurethane or polyaspartic topcoat over epoxy, or switch to UV-stable polyurea.
Q2: How long does it last under forklift traffic?
8-12 years with proper installation (mortar layer + topcoat ≥1.5mm). Heavy multi-shift traffic reduces lifespan. Thicker systems (2.5-3mm total) last longer.
Q3: Is the standard finish slip-resistant?
No. The mirror finish is slippery when wet. Add anti-slip aggregate (silica or aluminum oxide) to the topcoat – this creates a textured matte finish.
Q4: How soon can forklifts drive on it?
Light foot traffic: 24-48 hours. Forklift traffic: 7 days minimum at 25°C (77°F). Lower temperatures extend curing time. Full cure takes 10 days.
Q5: Can it be applied over old epoxy or existing paint?
No. Old coatings must be completely removed by shot blasting to expose bare concrete. Epoxy needs mechanical bond into porous concrete – coating over coating will delaminate.
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