Installing an epoxy resin floor requires strict adherence to technical rules. As a flooring expert with many years of experience and a manufacturer of high-grade resins for constructing floor systems tailored to various project requirements, we share with you the most essential guidelines on this subject.
How to install an epoxy resin floor
Above all, it is never worth rushing the works or “cutting corners” by ignoring defects in the base concrete.
The correct sequence of work must be strictly followed, paying careful attention to every single step. In this process, there are no minor or less important tasks.
The quality of the selected products is also crucial. Technologically proven resin quality directly translates into the durability and performance characteristics of the finished floor system. It is safest to choose resins from reputable manufacturers who do not compromise on product quality. In the BAUTECH range, these are our BAUPOX resins.
Finally, and equally as important, is selecting the right floor system to match the specific needs of the project. After all, not all epoxy resin floors are created equal!
As an investor or contractor, you know which flooring characteristics are key to your project: the required level of chemical resistance (including resistance to animal waste), whether it needs anti-slip properties or a decorative finish, or if it must be perfectly smooth. You also know the intended loads it will face—whether pedestrian or vehicular traffic, and at what intensity. Unsure? Speak with one of our Technical Sales Advisors!
Step-by-step guide to installing an epoxy resin floor
Before you begin installing a resin floor, you face the crucial decision of choosing the right resin system whose characteristics match the specific needs of your project. This decision is essential, as only then can you be guided through the stages of constructing an epoxy floor for THAT SPECIFIC system.
Only then can you be confident that you are in the right place: indeed at the start of the journey, but equipped with the right product, the right instructions, and expert support should the need arise!
The right system is one that has been specified precisely for your project requirements.
Resin flooring for various project requirements
At BAUTECH, we offer ready-made, proven systems for constructing epoxy resin floors tailored to diverse project requirements: car park flooring, chemical-resistant flooring, resin floors for manufacturing facilities, clubs, hospitals, and rooms for countless other applications too numerous to list. Within these systems, we offer specific solutions designed for varying concrete moisture levels (<4%, <6%, <8%).
Bautech BAUPOX resins have been manufactured at our production facility for 30 years. They pack POWER and make zero compromises! Are you a Professional? Work with professional products.
- BAUPOX COLOR QUARTZ 8 SYSTEM™ - Dekoracyjny system posadzkowy na bazie żywic epoksydowych o najwyższej odporności chemicznej - SPRAWDŹ
- BAUPOX PARKING SYSTEM™ - Antypoślizgowy system posadzkowy na bazie żywic epoksydowych - SPRAWDŹ
- BAUPOX SR SYSTEM™ - System posadzkowy na bazie żywic epoksydowych o rozwiniętej, wyraźnej strukturze antypoślizgowej - SPRAWDŹ
- BAUPOX SL SYSTEM™ - Samorozlewny system posadzkowy na bazie żywic epoksydowych o idealnie gładkim efekcie - SPRAWDŹ
- BAUTECH BAUPOX TL SYSTEM™ - Cienkopowłokowy system posadzkowy na bazie żywic epoksydowych - SPRAWDŹ
- BAUPOX COLORID SYSTEM™ - Dekoracyjny system posadzkowy na bazie żywic epoksydowych i kolorowych płatków akrylowych - SPRAWDŹ
General Contractor Instructions Step by Step
Why a general one? Because detailed instructions for each of the BAUPOX resin floor systems can be found in their Individual Technical Data Sheets. The systems differ from one another, meaning there is no single universal instruction set for installing a resin floor. However, certain steps are common across all systems, which we outline below:
APPLICATION CONDITIONS: Substrate temperature: min. +10°C; Relative air humidity: max. 75%; Product temperature prior to application: +10°C to +25°C. NOTE! Special care must be taken to ensure that the substrate temperature is at least 3°C above the dew point temperature. Work areas must be well-ventilated.
GENERAL NOTES: Each applied layer must be left to cure for approx. 24 hours before applying the next one. NOTE! Contact of freshly applied surfaces with moisture (high air humidity) will disrupt the curing process. Over time, the surface may remain tacky with a tendency to develop milky discolouration.
The concrete substrate must be stable and possess adequate load-bearing capacity for the intended static and dynamic loads—concrete with a minimum pull-off strength of 1.5 N/mm². Any defects or surface voids must be filled using a repair mortar made from resin and sand.
The substrate must feature an effective damp-proof membrane (horizontal insulation) to protect against capillary rising damp.
Surfaces intended for epoxy coating protection must be clean and absorbent. Laitance, all types of contamination, and old protective coatings must be removed mechanically by grinding, shot-blasting, or scarifying.
When restoring old epoxy floors, it is imperative to verify their adhesion to the substrate (min. 1.5 N/mm²), and the surface must be degreased and mechanically abraded.
Reinforcing coat: In the case of weaker substrates (pull-off strength below the minimum 1.5 N/mm²), it is recommended to apply BAUTECH BAUPOX 100 GP™ to strengthen the surface before proceeding with the priming layer.
Priming coat: The choice of primer should depend on the parameters of the concrete on which the floor system is to be constructed. Depending on the concrete moisture content (<4%, <6%, <8%), apply one of the primers specified in the Technical Data Sheet:
BAUTECH BAUPOX 100 STX™, BAUTECH BAUPOX 100 ST™ – Concrete with elevated moisture levels; up to a maximum of 8%.
BAUTECH BAUPOX 100 K™ – Economical 2-in-1 formula (primer + colour), designed for use on concrete with moisture levels up to 4%.
The correctly mixed material must be spread onto the concrete substrate in a single coat using a rubber squeegee and then a resin roller until complete saturation is achieved.
In certain systems, the freshly applied priming resin must be broadcast evenly with quartz aggregate of the grain size specified in the technical data sheet. Once cured, sweep off the excess aggregate, lightly sand the surface with a mechanical sander using sandpaper, and thoroughly vacuum the entire area.
The correctly mixed material must be spread evenly over the substrate using a steel trowel or a resin roller, leaving a uniform layer on the surface to fill pores and smooth out minor imperfections.
In some systems, this is the stage to broadcast the resin with another layer of aggregate or decorative acrylic flakes.
Always install a 5 mm perimeter expansion joint along the walls (using expansion joint foam).
For systems incorporating a glass fibre mesh or matting, there is no need to recreate construction joints.
In all other cases, recreate the original expansion joints prior to sanding.
Decorative flakes: Broadcast decorative flakes onto the wet base resin coat.
Quartz sand: Broadcasting with quartz sand creates an anti-slip coating.
The seal coat depends on the specific system. For this purpose, use transparent resin BAUTECH BAUPOX 400™ or polyurethane lacquer BAUTECH BAUPUR 800 HP TOPLINE™. The correctly mixed material must be spread evenly over the prepared layer using a steel notched squeegee or a resin/lacquer roller.
Commissioning / Ready for Use
At a temperature of 20°C and a relative air humidity of 60–70%:
Pedestrian traffic: after 24 hours
Mechanical loading: after 72 hoursFull chemical resistance: after 7 days
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