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How to Install Super Wear-Resistant Epoxy Flooring

Created on 02.27
Super wear-resistant epoxy flooring is widely used in industrial plants, warehouses, pharmaceutical facilities, electronics factories, and cleanroom environments where durability, abrasion resistance, and easy maintenance are critical. Compared with standard epoxy coatings, this system offers enhanced hardness, scratch resistance, and long-term performance under heavy traffic.
This guide explains the complete installation process of a super wear-resistant epoxy flooring system, from surface preparation to final coating.
Empty underground parking garage with marked parking spaces and bright overhead lighting.

1. Understanding the Floor System Structure

A typical super wear-resistant epoxy flooring system consists of the following layers:
Concrete substrate
Epoxy primer (sealer)
Epoxy mortar layer (if thickness required)
Epoxy putty layer (leveling)
Epoxy intermediate coat
Super wear-resistant epoxy topcoat
Total thickness typically ranges from 0.5 mm to 3 mm, depending on traffic load and design requirements.

2. Step 1 – Surface Preparation

Surface preparation is the most critical step for long-term performance.

Key Requirements:

Substrate must be dry (moisture content within acceptable limits)
Surface must be clean, smooth, and free of oil, dust, or loose particles
No hollow areas, cracks, or laitance
Concrete compressive strength must meet project specifications

Preparation Process:

Mechanical grinding or shot blasting
Repair cracks and damaged areas
Vacuum cleaning to remove dust
Proper surface preparation ensures strong adhesion and prevents delamination.

3. Step 2 – Apply Epoxy Primer

The epoxy primer serves to:
Seal the concrete pores
Improve adhesion between substrate and coating
Strengthen surface integrity
Application method:
Roll or scrape evenly across the surface
Ensure full penetration into the substrate
Allow proper curing time before next step

4. Step 3 – Epoxy Mortar Layer (If Required)

For heavy-duty or thicker systems (1–3 mm), an epoxy mortar layer is applied.

Purpose:

Increase mechanical strength
Improve impact resistance
Enhance load-bearing capacity
The mortar is mixed with quartz sand and applied evenly, then leveled.
After curing:
Grind the surface
Vacuum clean thoroughly

5. Step 4 – Epoxy Putty / Leveling Layer

This layer ensures a smooth and flat surface.

Functions:

Fill minor pores and imperfections
Improve surface uniformity
Prepare for topcoat application
After curing:
Light sanding
Remove dust completely

6. Step 5 – Super Wear-Resistant Epoxy Topcoat

This is the core functional layer of the system.

Performance Features:

High hardness and excellent toughness
Superior abrasion and scratch resistance
Anti-skid texture (optional)
Mold-resistant performance
Metallic matte or fine textured finish
Uniform, high-end appearance
Application method:
Roller or trowel application
Ensure even thickness
Avoid bubbles and roller marks
Final thickness typically ranges from 0.5–3 mm depending on design.

7. Curing and Inspection

After final coating:
Restrict traffic for at least 24–48 hours
Allow full curing (typically 5–7 days for heavy load use)
Conduct inspection for:
Surface smoothness
Adhesion
Thickness
Appearance uniformity
Only after full curing should heavy equipment be installed.

8. Environmental Conditions for Installation

For best results:
Temperature: 10–30°C
Relative humidity: <75%
Good ventilation
Avoid installation in high-moisture environments
Improper environmental conditions may cause bubbling, poor curing, or surface defects.

9. Applications of Super Wear-Resistant Epoxy Flooring

This flooring system is ideal for:
Industrial manufacturing plants
Warehouses and logistics centers
Pharmaceutical production areas
Electronics and semiconductor facilities
Cleanrooms and GMP workshops
Hospitals and operating support areas

Conclusion

Installing super wear-resistant epoxy flooring requires careful preparation, precise layering, and strict environmental control. When properly applied, the system delivers exceptional durability, aesthetic appeal, and long-term cost efficiency.
For cleanroom engineering projects, selecting the correct thickness and surface finish is especially important to ensure compliance with cleanliness standards and operational safety.
If you need help selecting the right flooring specification for your facility, a professional assessment of traffic load, chemical exposure, and environmental conditions is recommended.
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