Long Lasting Alternatives to Epoxy Flooring in Factories and Warehouses

Are you tired of replacing your factory or warehouse flooring every few years due to the limited lifespan of epoxy flooring? You're not alone! Epoxy flooring has been a popular but problematic choice for factories and warehouses. It is used mainly because of its dustless surface, electrostatic properties, chemical resistance, and aesthetics. However, its limited lifespan of only 1-2 years in high-traffic areas has led to the exploration of alternatives by plant managers. This article explores various epoxy alternatives for specific intended jobs of epoxy, including dustless flooring surfaces, electrostatic flooring, and chemical-resistant flooring. The article aims to provide plant managers with alternatives to epoxy to help them make an informed decision.

What is Epoxy?

Epoxy is a thermosetting plastic made of a 2-part epoxy system consisting of hardeners and polymer resins that irreversibly solidify when exposed to heat or certain chemical agents. The resulting chemical bond creates an internal cross linked structure resulting in a stiff plastic material that is resistant to degradation.

Primary Challenge of Epoxy - Limited Lifespan

Epoxy flooring has a limited lifespan in factories and warehouses due to its low abrasion strength (Moh's Scale < 2). Typically, the lifespan of an epoxy flooring ranges between 1-2 years in manufacturing companies and warehouses.However, in high traffic areas, areas with humidity or lubricant usage, it may not last even for 9 months. Due to the limited lifespan, plant managers nowadays are considering alternative flooring solutions. 

Before searching for “Alternatives of Epoxy” on Google, it is important to first understand the intended “Job to be Done" (JTBD) of Epoxy in a factory or warehouse. The major objectives why Epoxy is used are as follows:

• To get a Dustless Flooring Surface
• To get a Electrostatic Flooring Surface
• To get a Flooring surface that is Chemically resistant
• To block concrete pores to prevent mould formation.
• To have a VOC free flooring surface
• To have an aesthetic floor with markings in different colours

Below, we have suggested various alternatives to Epoxy for each of these intended jobs of Epoxy in a factory/ warehouse.

Epoxy Alternatives for Dustless Flooring Surface

Odus Flooring

Unlike traditional Epoxy flooring that simply forms coatings above the surface, Odus takes a unique approach to strengthen the floor from within. In this process, concrete regenerating chemicals are adsorbed by concrete to increase its surface strength. This process can increase the Moh’s scale of a normal concrete floor from 3/10 to up-to 7/10 (To add some context, Diamond is 10/10). Thus making it hard enough to withstand heavy forklifts and other machinery commonly used in factories and warehouses. Since it acts inside the floor, it is unaffected by moisture or lubricant usage also. Odus is a long-lasting solution that can keep floors dust-free for at least 10 years. It can be applied to both new and old floor surfaces. The only requirement is that the concrete base must be finished with Trimex/VDF and have a minimum grade of M25.

Min Life: 10 Years | Forklift Proof | Moisture Proof | Lubricant Proof | Needs at least M25 grade, VDF/ Trimex finished concrete floor as Base.

Concrete Polished Floors

Concrete polishing is a process that mechanically grinds, hones, and polishes concrete floors using abrasives to create a smooth and glossy finish. It uses Sodium silicate as a bonding agent with concrete dust (Calcium Carbonate), resulting in a dust-free surface. Polished concrete is considered a superior dustless flooring option when compared to epoxy. The lifespan of polished concrete is typically 3-4 years, but it is not suitable for forklifts and welding activities. It is essential to hire an experienced contractor for concrete polishing to prevent problems. If not done correctly, sodium released from sodium silicate can harm concrete, causing early symptoms such as rough white patches, crazing, and white lines within 2-3 months of implementation. Regular maintenance and re-polishing are necessary to ensure the longevity and appearance of polished concrete.

Life: 3-4 Years | Dust Proof | Needs to be done by an experienced contractor

Epoxy Alternatives for Electrostatic Flooring

Electrostatic Dissipative (ESD) Flooring

ESD flooring is a specialized flooring designed to protect sensitive electronic equipment from static electricity damage. It is made using an injection molding process with evenly distributed metal fibers to ensure long-term ESD performance. ESD flooring includes materials that transfer electrostatic charge to the flooring and has a low electrical resistance allowing static charges to safely dissipate to the ground. It has an electrical resistance ranging from 2.5 x 10^4 to 1.0 x 10^9 Ohms compared to epoxy flooring, which has a static dissipative range of 10^6 to 10^7 Ohms. Thus, ESD flooring is a better option for electrostatic flooring needs, particularly in industries where protecting electronic equipment is essential. The average lifespan of ESD flooring is 3-4 years but can vary based on factors such as foot and vehicle traffic. The installation and maintenance costs are high.

Life: 3-4 Years | Better Electrostatic dissipation| High Installation and Maintenance Cost

Epoxy Alternatives for Chemical Resistant Flooring

Odus Flooring

Although Concrete is a chemically inert compound, it still gets damaged by chemicals. The sponge like - porous structure of concrete makes it absorb chemicals. Corrosive chemicals react with the reinforcements in RCC, weakening the floor over time. 

Odus Flooring makes concrete resistant to chemicals by protecting it from 2 ways. First,  Odus uses concrete regeneration to  block 80% of the pores on the top floor layer. Thus creating a barrier to prevent the absorption of chemicals. Second, it blocks all reactive compounds like Calcium Carbonate from the concrete surface. This process makes the concrete floor resistant to mild chemical substances like alkaline liquids and mild acids, and increases its resistance to chemicals with a pH level ranging from 4 to 9. 

Min Life: 10 Years | Resistant to pH 4 to 9 | Not recommended for stronger acids 

Polyurethane Concrete (PU)

Polyurethane (PU) concrete is a composite material that combines the properties of plastic or synthetic resin with those of traditional concrete. Unlike epoxy resins, PU systems offer superior resistance to corrosion, inorganic and organic alkalis, solvents, and a broader range and concentrations of chemicals, making it a more reliable and cost-effective choice for plant managers. Although the initial cost of PU systems may be higher than that of epoxy, their lifespan is roughly double, lasting up to 5 years compared to epoxy. Furthermore, PU offers superior heat, cold, and thermal shock tolerance, making it an ideal flooring solution for industrial facilities where extreme temperature changes often occur. PU systems can tolerate up to 120°C compared to epoxy's 65°C heat resistance. PU flooring may release potentially harmful VOCs into the air during the drying and curing process. Additionally, it can be susceptible to UV radiation, leading to fading over time. Also, running of Forklifts may damage PU because of moderate abrasion resistance (Mohs 2 to 3).  Furthermore, if there is moisture or high humidity during application, the top surface may develop bubbles, blisters, pinholes, and wrinkles, leading to debonding issues from the concrete substrate. Despite these drawbacks, PU systems remain a better choice than epoxy for plant managers due to their superior chemical resistance, longer lifespan, and thermal shock tolerance.

Life: 3 to 5 Years | Resistant to a broad range of Chemicals | Good for extreme Heat | Can get damaged by UV exposure, Forklifts and improper application

Epoxy Alternatives for mould resistant non porous Flooring

Odus Flooring

As explained above, Odus treatment blocks the top most layer of concrete thus blocking 80% of pores. Due to blocking of pores internally, there is no possibility of any kind of mould/ bacterial growth on Odus Floors. Thus Odus floors can be used as an alternative to Epoxy for hygienic floors while giving a better lifespan of 10+ years.

Min Life: 10 Years | Resistant to mould/ bacterial formation

Polyurethane Concrete (PU)

As explained above (section: Epoxy Alternatives to Chemical Resistant Flooring), PU forms a thick and strong coating on top of concrete floors to block all its pores. Protecting the floor for 3-5 years. However, PU is susceptible to damage from Forklifts, UV radiations, moisture and improper installation.

Life: 3 to 5 Years | Resistant to a broad range of Chemicals | Good for extreme Heat | Can get damaged by UV exposure, Forklifts and improper application

Polyspartic Flooring

Polyaspartic coatings, made of two components - resin and aliphatic isocyanate, can prevent mold formation by forming a coating on top that blocks pores. Polyurea coatings, on the other hand, use aromatic isocyanate. Polyaspartic coatings have a wide range of application temperatures from -30°F to 140°F, are thermally stable up to 350°F, and have high humidity resistance. They have UV resistance, protecting underlying layers from yellowing and polymer breakdown. The coating dries fast, allowing large areas to be back in service within 2 to 6 hours. However, there are some disadvantages of Polyspartic Flooings. The lack of texture in the smooth and glossy surface makes it slippery when wet, but non-slip additives can be added. Also, they are vulnerable to acid corrosion and weakly bonded amino acid molecules make them susceptible to break down when exposed to highly acidic compounds, leading to corrosion, staining, and weakening of the structure. It is very important to have a completely dry atmosphere while the application is going on. High moisture content during application delays the curing time and thus affects quality of the finished product.

Life: 5 to 6 Years | Resistant to a broad range of Temperature| Fast Curing | UV Resistant |Slippery when wet | Gets corroded by Acids | Cannot be applied in the presence of moisture

Epoxy Alternatives for a VOC free Flooring

Odus Flooring

Odus Flooring essentially transforms concrete into high-density concrete, resulting in a final product with zero VOC emissions, much like concrete. Additionally, the chemicals used in the process are non-emitting, making Odus completely emission-free during and after application. The VOC-free nature makes it a more healthier and eco friendly flooring option. Also, it is a suitable flooring solution for food and beverage factories that require a VOC-free environment to maintain product quality and can contribute to improving the building's LEED score. Moreover, the high-density concrete composition of Odus ensures durability and resistance to wear and tear, making it a long-lasting flooring option for commercial spaces.

Min Life: 10 years | Zero VOC Emissions | Forklift Proof | Healthier for workers | Eco Friendly

Epoxy Alternatives for Aesthetic Floors with Varied Coloured Markings

Polyurethane Concrete (PU)

Polyurethane Concrete (PU) is an alternative to epoxy for differentiated colour markings on factory floors. PU can be pigmented with different colours to create distinct patterns or demarcate areas. It is also highly resistant to chemical exposure, moderate abrasion, and impact, making it an ideal choice for industrial environments. PU is also more flexible than epoxy, allowing it to withstand thermal expansion and contraction without cracking. On average, PU flooring can last up to 3-5 years with proper maintenance, making it a cost-effective solution for factories and warehouses. Overall, PU flooring offers an aesthetically pleasing solution with superior durability and longevity compared to traditional epoxy flooring.

Life: 3 to 5 Years | Available in colours | Can be applied on Old and New Floors | Gets Damaged by Forklifts | 

Coloured Concrete or Coloured Hardeners with Odus

It is advisable to plan factory markings and floor layout during the construction phase.In this case, colored concrete can be used at the time of floor laying itself. With Odus on top, such floors are practically immortal! Other than longevity, colored concrete is more cost-effective than any other flooring option. Also, it is more eco-friendly. Nowadays, there are also colored hardeners that can be done on the top 5 mm layer of concrete to give a variety of colors. Another good part is that the number of color options available with concrete is vast! You could even get complex shades like mint green or baby pink on floors. These floors will be there forever, eliminating the need to re-do the floor markings every time there is an important visit/audit. Such floors can be treated with Odus to increase its life and give it a dustless nature with good chemical resistance and VOC-free nature. The only limitation with this approach is that it can only be done during floor construction and not in old factories.

Min Life: 10 Years | Eco Friendly | Vast variety of shades | Can only be done during construction of new floors |

To sum up, epoxy flooring has been a popular choice for factory and warehouse managers due to its dustless, electrostatic, and chemical-resistant properties. However, its limited lifespan has left plant managers searching for alternatives that can meet their specific requirements. By understanding the intended job to be done, various alternatives such as Odus flooring, concrete polished floors, and ESD flooring can provide superior results that are durable and cost-effective. It is crucial to carefully evaluate the alternatives and choose the one that best fits your needs and conditions to ensure a long-lasting and efficient flooring solution.