What is the minimum concrete strength for epoxy flooring?

Minimum 25 MPa compressive strength (M25 concrete). Weaker concrete will fail under epoxy — the epoxy pull strength exceeds the concrete tensile strength and causes delamination. Test with a pull-off tester — minimum 1.5 MPa adhesion required.

Epoxy vs polyurethane for factory floors — which is better?

Epoxy (HARDFLOOR ERC range) is harder, better for chemical resistance, and more cost-effective for most factories. Polyurethane (HARDFLOOR PU600) is more flexible and resistant to thermal shock — better for food plants with hot water washdowns. For most warehouses and factories, epoxy is the correct choice.

Can I apply epoxy flooring over existing tiles or old epoxy?

Over old epoxy: grind to remove gloss, apply new primer and topcoat. Over tiles: grind tile surface, check for hollow tiles (remove), apply MTP100 primer for compatibility. Fresh concrete is always the best substrate.

How do I prevent epoxy from peeling?

Peeling is almost always caused by: insufficient concrete preparation (laitance not removed), high moisture content, or applying in wrong temperature/humidity. Do not apply when concrete is above 75% RH, below 10°C, or in direct sun above 40°C.

Can the floor be used immediately after application?

Foot traffic after 24 hours. Light vehicle after 72 hours. Do NOT move heavy machinery or fully loaded forklifts onto epoxy before 7 days — premature loading causes indentation and adhesion failure.

Industrial Epoxy Flooring Systems

The Problem: Uncoated Concrete Costs You Every Month

Concrete Dust. Chemical Stains. Forklift Damage. Your Floor Is Failing.

Unprotected concrete generates dust that contaminates products. It absorbs oils and chemicals that can't be cleaned. It cracks under forklift point loads. In food and pharmaceutical facilities, it fails hygiene inspections. The floor isn't a cosmetic issue — it's an operational one.

What Bare Concrete Costs

Concrete dust contamination — In food, pharmaceutical, and electronics manufacturing, concrete dust contamination causes product rejection and regulatory non-compliance.
Chemical absorption — Hydraulic oil, acids, and solvents soak into concrete permanently. Cannot be cleaned. Becomes a slip hazard and environmental liability.
Point load cracking — 3-tonne forklifts concentrate load on small contact patches. Unprotected concrete cracks at joints and weak points within 2–3 years of operation.

Epoxy flooring cost: ₹350–600/m². Replacing a cracked concrete floor: ₹2,000–4,000/m². The maths is straightforward.

Choose Your System

Three performance tiers. Choose based on traffic, chemical exposure, and hygiene requirements. All systems use the same primer — only the topcoat changes.

HARDFLOOR System Selector

ALL SYSTEMS — Primer First
HARDFLOOR EP100 (dry concrete) · HARDFLOOR MTP100 (damp concrete up to 75% RH)
Coverage: 0.15–0.20 kg/m² · Cure: 12–16 hrs

↓

TIER 1 — ERC200 (Light Industrial)
Warehouses, showrooms, commercial spaces · 0.20–0.30 kg/m² per coat · 2 coats
Forklift rated (3T) · Chemical resistant · Semi-gloss finish

↓ step up

TIER 2 — ERC300 (Heavy Industrial)
Factories, automotive, chemical plants · 0.30–0.40 kg/m² per coat · 2–3 coats
Heavy forklift rated (5T+) · Aggressive chemical resistance

↓ step up

TIER 3 — SL1000 Self-Leveling (Precision/Clean Room)
Pharmaceuticals, electronics, clean rooms · 1.2–1.5 kg/m² at 1mm · Seamless
Zero porosity · Dust-free · Glass-smooth finish

System	ERC200	ERC300	SL1000
Best for	Warehouse, showroom	Factory, automotive	Pharma, clean room
Forklift load	3T rated	5T+ rated	3T rated
Chemical resistance	Good	✓ Excellent	Good
Surface finish	Semi-gloss	Matt/Semi-gloss	Glass smooth
Cost per m²	₹350–450	₹450–600	₹600–900
System life	10–15 years	15–20 years	10–15 years

Product Specifications

HARDFLOOR EP100 / MTP100 — Epoxy Primers

0.15–0.20

kg/m² coverage

12–16

hours cure to topcoat

MTP100

for damp concrete (75% RH)

1

coat required

Key difference: MTP100 is moisture-tolerant — apply on concrete that hasn't fully dried (new slab, post-monsoon). EP100 is for fully dry, cured concrete. Wrong primer = delamination within months.

HARDFLOOR ERC300 — Heavy Duty Topcoat

0.30–0.40

kg/m² per coat

2–3

coats required

8–12

hours between coats

15–20

year system life

Cost Breakdown — 1,000 m² Warehouse (ERC200 System)

Material Costs

EP100 Primer (1,000 m² × 0.18 kg)₹22,000–28,000

ERC200 Topcoat (1,000 m² × 0.50 kg, 2 coats)₹1,20,000–1,50,000

Total — Materials₹1,42,000–1,78,000

Labour & Application

Surface grinding, preparation, cleaning₹40,000–60,000

Primer + 2 coats application₹30,000–40,000

Total — Labour₹70,000–1,00,000

All-in: ₹2,12,000–2,78,000 for 1,000 m² (₹212–278/m²)

10–15 year life. Eliminates dust contamination from day one. Reduces cleaning time by 60–70%.

Application Timeline — 1,000 m² Floor

Day 1

Concrete Preparation

Shot blast or grind to CSP 3 profile. Remove laitance, existing coatings, oil. Fill cracks and joints. Test moisture — must be below 75% RH (CM test).

⏱ Full day · Most critical step — determines lifespan

Day 2

Primer Application

Apply EP100 (dry) or MTP100 (damp) by roller. Even coverage — no missed areas. Primer should penetrate visibly into concrete surface.

⏱ 4–6 hrs · Cure: 12–16 hrs overnight

Day 3

Topcoat — Coat 1

Apply ERC200 or ERC300 by roller. Work in sections. Non-slip aggregate broadcast into wet coat if required. Allow 8–12 hours.

⏱ 6–8 hrs for 1,000 m² · Cure: 8–12 hrs

Day 4

Topcoat — Coat 2

Second coat perpendicular to first. Uniform colour and gloss. No missed areas or holidays (bare spots).

⏱ 6–8 hrs · Foot traffic: 24 hrs

Day 5–7

✓ Cure and Handover

Foot traffic after 24 hrs. Light vehicles Day 5. Full forklift traffic and chemical exposure after Day 7 (full cure).

Total: 4 days application + 3 days cure

Frequently Asked Questions

My concrete is new — how long before I can apply epoxy?

Minimum 28 days after concrete pour. 45 days is better for high-performance systems. Young concrete releases moisture that causes epoxy to blister. If schedule requires earlier, use HARDFLOOR MTP100 moisture-tolerant primer — but concrete must still be minimum 14 days old.

ERC200 vs ERC300 — how do I choose?

ERC200 for warehouses storing goods, showrooms, and light manufacturing. ERC300 for environments with heavy forklifts (5T+), chemical spills, continuous traffic, or temperature extremes. If in doubt, specify ERC300 — the cost difference is 20–25% and the performance difference is significant.

My floor is oily and has been for years. Can I still apply epoxy?

Degrease thoroughly — hot water, degreaser, and scrubbing. Allow to dry. Shot blast. Test adhesion on a 300mm patch before full application. Deep oil contamination may require multiple degreasing cycles. Do not apply epoxy over contaminated concrete — adhesion will fail.

Can I do the work myself?

Surface preparation requires shot blasting or grinding equipment — this typically requires a contractor. Primer and topcoat application is DIY-possible for smaller areas. For industrial-scale work (500+ m²), use a trained applicator — the preparation stage is where most failures occur.