Epoxy is a versatile material that can be used as a coating, adhesive or composite. It offers high tensile and compressive strength as well as great chemical resistance to a variety of acids, bases, solvents and oils.
Epoxy resins can be further modified with curing agents or hardeners that influence factors like moisture resistance, viscosity and elasticity. They are commonly used for corrosion protection of steel or concrete structures in harsh environments.
Water-Based
Epoxy floor coatings provide an attractive, glossy finish to concrete floors that are also highly durable against machine and vehicle traffic and chemical spills. However, not all epoxy products are created equal, and understanding the difference between various formulations will help you choose the right solution for your project.
There are two types of epoxies, water-based and solvent based. Water-based epoxies contain additives like water and a surfactant that allow them to spread more easily, while still providing excellent adhesion and self-leveling properties. In addition, these epoxies generally have a longer pot life than their solvent based counterparts. This is important for projects that require multiple coats, as it allows the application of additional coats without having to wait for the first one to cure.
As the name implies, solvent based epoxies contain volatile organic compounds, or VOCs, which evaporate during curing and produce harmful fumes that must be ventilated properly to prevent them from affecting workers’ health. As a result, most building code requirements prohibit the use of solvent-based epoxies, unless proper ventilation is installed.
In the past, solvent-based epoxies were the preferred product for several reasons. They can be applied in cooler temperatures, can tolerate petroleum contaminates in the concrete, and are more durable than their water-based counterparts. Despite these advantages, their high VOC content is becoming increasingly less acceptable and has led to the creation of water-based epoxies that perform just as well and emit significantly fewer harmful fumes during and after installation.
The biggest disadvantage to using solvent based epoxies is that they must be applied very quickly. Once the epoxy is mixed, it begins to harden within a short amount of time known as the “pot life.” The pot life can vary depending on the quality of the product; for example, a high-quality product may have a pot life of up to an hour while a low-quality product might offer less than an hour of work time. When the pot life expires, high-quality epoxies will reactivate to continue the curing process and form rock hard monolithic sheets with exceptional gloss.
Solvent-Based
A mixture of different chemicals, epoxies are a go-to material for creating a strong bond between materials and are used in everything from flooring to aerospace. They’re formulated for specific surfaces and materials to ensure that the coating created will have the best durability for that particular surface or part. Depending on the application and environmental conditions, epoxy can be cured in a range of times.
While there are many different types of epoxies, the two most common are solvent-based and water-based. Both have their pros and cons, with each having a specific use. Water-based epoxies are known to be easy to work with and dry much faster than their solvent counterparts. However, they tend to have a lower film strength than other types of epoxies and are more susceptible to solvent entrapment, which can lead to divots or thicker regions in the final coating.
On the other hand, solvent-based epoxies are typically more expensive than their water-based counterparts, but they offer greater durability and can be applied in a wider range of temperatures. They also feature a higher film thickness than their water-based counterparts, with some having up to 10 mils or more of a dry film coating. These epoxies can be applied in a variety of ways, such as spraying or dipping. Dip coating can be done through either an automated or manual process, with the device being lowered into a tank of material and then drained of any excess.
These epoxies are commonly found in the automotive and marine industries, as they can provide resistance to corrosion from acidic or caustic cleaners. They are also able to withstand the corrosive effects of salt water and have excellent UV protection, as well as color stability. They are often used to coat steel and concrete, including in the fabrication of chemical, food, or marine equipment.
Similar to cycloaliphatic epoxies, these feature a ring-like structure within their chemical makeup and are more rigid than their water-based counterparts. However, they can also flex more than the cycloaliphatic epoxies and are therefore more useful for applications that require flexibility. They are frequently used in the manufacturing of composites, coatings, and adhesives, as they have a good balance between rigidity, chemical resistance, and flex.
Solids-Based
100% solids epoxy floor coating is the best and most durable option, but also the most expensive. This type of epoxy does not contain any water or solvents which could evaporate during curing, which gives it a much thicker dry film coating of about 10 mils or more. This type of epoxy also contains no VOCs and cures solely through chemical catalization.
One of the biggest advantages of using this type of epoxy is its rapid drying time. This is great for environments where the floor must be back in service in a short amount of time and is a big reason why contractors like it. Another advantage is that this type of epoxy does not have any VOCs which means that it does not produce any harmful fumes during application, which can be a problem in smaller areas or confined spaces.
Another disadvantage of this type of epoxy is that it has a much shorter pot life than other types. This means that the contractor must work quickly to apply the coats before the mixture starts to harden. This can be a big challenge for someone who is not used to working with epoxy and may lead to mistakes which could cause problems down the road.
This type of epoxy has a number of other benefits which make it a popular choice as well. It does not require any special equipment to mix or use and is available from many different manufacturers. It is also less prone to petroleum contamination and can be used in a variety of environments, from your garage to an industrial setting.
The key to finding the right epoxy for your project is reading the technical data sheets which are provided by each manufacturer. This will give you a good idea of how the various products compare and which one may be better for your specific needs. Be sure to check the VOC level of each product as well, since this is an important consideration for most people. If you have any questions or concerns about the type of epoxy that would be best for your project, it is always a good idea to consult an expert.
Hybrid
The base resin and solidifier components play a crucial role in the tribological performance of epoxy coating. A variety of fillers can be incorporated into the pristine epoxy resin to enhance its tribological properties. The use of different types of fillers such as primary, secondary or tertiary amine compounds resulted in an increase in fracture toughness and impact resistance of the cured epoxy system. Other than tribological enhancement, the incorporation of these fillers also improves the chemical and corrosion resistance of the epoxy system.
The carboxyl functional polyester and epoxy binder systems are commonly used as the hybrid powder coatings. These are characterized by their lower cost and curing agent compared to traditional thermosets. However, these powders tend to have softer surface than hard and chemically resistant epoxy coatings. The chemists can adjust the ratio of these two resins to provide a coating that meets the application requirements such as hardness, scratch resistance and chemical resistance.
Coating epoxy resin is a type of thermoset coating that is used to provide a strong, durable and chip-resistant surface. It is often applied to concrete floors in areas that receive heavy forklift and truck traffic as it has very good mechanical strength and a non-slip surface. It is also frequently used for kitchen and dining rooms, storage places and garages as it is easy to clean and has excellent stain and acid resistance.
There are several types of hybrid epoxy flooring systems that are available. These include self-dispersing epoxy with quartz sand, methyl methacrylate, and polyurea/polyaspartic hybrids. Each type of system has its own unique advantages. Epoxy flooring systems offer exceptional versatility, allowing homeowners and businesses to customize their spaces to their exact needs. Whether you’re aiming for durability or a sleek appearance, you can achieve a modern look with their flooring options, tailored to fit any aesthetic or functional requirement. While these systems can be used for a wide range of applications, it is important to select the appropriate type of coating for your specific project. In addition to evaluating the condition of the substrate, it is also important to consider the application technique and the budget.
The tribological performance of epoxy composite coatings is influenced by the choice of resin, fillers, and the curing conditions. Barletta et al. [87] evaluated the wear and scratch resistance of epoxy coatings fabricated using varying base and solidifier resins, aluminum fillers, and alumina fillers. The results showed that the friction coefficient and wear rate of the cured film increased with increasing baking temperature, while the coatings fabricated using alumina fillers had the lowest wear rates.