Chemical resistance varies significantly between flooring systems: standard epoxy resists mild acids and alkalis, polyurethane handles organic acids and oils, polyurethane concrete withstands 98% sulphuric acid, while vinyl ester systems resist the broadest chemical range. Selection depends on specific chemicals, concentrations, temperatures, and exposure duration in your facility.
Chemical Resistance Overview
Industrial flooring faces constant chemical attack from production processes, cleaning agents, and accidental spillage. Understanding how different resin systems respond to chemical exposure ensures specification of appropriate protection, preventing costly failures and safety hazards.
Chemical resistance depends on multiple factors beyond the resin type. Concentration, temperature, exposure duration, and mechanical stress during contact all influence performance. A system resisting 10% sulphuric acid at 20°C may fail rapidly with 50% concentration at 60°C.
Key Resistance Factors
- Polymer structure: Cross-link density determines chemical penetration resistance
- System thickness: Thicker applications provide longer resistance times
- Temperature: Every 10°C increase doubles chemical reaction rates
- Mechanical stress: Movement and impact accelerate chemical penetration
- Joint integrity: Failures often initiate at joints and terminations
Our experience with pharmaceutical flooring and laboratory flooring demonstrates that proper system selection prevents 95% of chemical-related failures.
Acid Resistance Comparison
Acid resistance varies dramatically between flooring systems, with concentration and type determining suitability. Understanding these differences ensures appropriate selection for your specific acid exposure risks.
Organic Acids
Food processing facilities commonly encounter organic acids including citric, acetic, and lactic acids. Standard epoxy systems handle these acids well at typical concentrations (5-20%), showing minimal degradation over years of exposure. Polyurethane systems excel with organic acids, particularly in dairy environments where lactic acid concentrations reach 85%.
Mineral Acids
Mineral acids present greater challenges, requiring specialised systems for reliable protection. Sulphuric acid, the most common industrial acid, attacks standard epoxy above 20% concentration. Hydrochloric acid causes rapid degradation above 10% unless using vinyl ester or novolac epoxy formulations.
| Acid Type | Standard Epoxy | Novolac Epoxy | PU Concrete | Vinyl Ester |
|---|---|---|---|---|
| Sulphuric (10%) | Good | Excellent | Excellent | Excellent |
| Sulphuric (50%) | Poor | Good | Excellent | Excellent |
| Sulphuric (98%) | Fail | Fair | Good | Excellent |
| Hydrochloric (20%) | Fair | Good | Excellent | Excellent |
| Nitric (10%) | Fair | Good | Good | Excellent |
| Phosphoric (85%) | Poor | Good | Excellent | Excellent |
| Acetic (10%) | Excellent | Excellent | Excellent | Excellent |
| Citric (50%) | Good | Excellent | Excellent | Excellent |
Alkali & Base Resistance
Alkaline chemicals, while generally less aggressive than acids, still require careful system selection. Food processing, breweries, and chemical plants regularly use caustic cleaning solutions demanding appropriate resistance.
Caustic Solutions
Sodium hydroxide (caustic soda) represents the primary alkaline threat in industrial environments. Standard epoxy tolerates 20% solutions indefinitely, while 50% concentrations require novolac or vinyl ester systems. Temperature proves critical—hot caustic solutions dramatically accelerate degradation.
Polyurethane concrete excels in alkaline environments, withstanding 50% sodium hydroxide at 60°C without degradation. This makes it ideal for CIP (clean-in-place) areas in food processing where hot caustic cleaning occurs daily.
Ammonia & Amines
Ammonia and organic amines present unique challenges, penetrating standard epoxy systems and causing softening. Cold storage facilities using ammonia refrigeration require special consideration, as leaks create highly concentrated exposure zones.
- Standard epoxy: Suitable for <5% ammonia at ambient temperature
- Novolac epoxy: Handles 10-15% ammonia with good longevity
- Polyurethane: Resists ammonia vapours but softens with liquid contact
- Vinyl ester: Excellent resistance to all concentrations
Chemical Resistance Testing Available
Free chemical resistance assessment for your specific chemical exposure requirements
Request TestingSolvent & Oil Resistance
Solvents and oils penetrate polymer networks differently than acids or bases, causing swelling rather than chemical breakdown. This swelling weakens the polymer matrix, leading to softening, blistering, and eventual failure.
Hydrocarbon Resistance
Petroleum products including petrol, diesel, and hydraulic oils require careful system selection. Standard epoxy provides good resistance to occasional spillage but fails under continuous immersion. Aircraft hangars, vehicle workshops, and oil terminals need enhanced protection.
| Chemical | Standard Epoxy | Novolac Epoxy | Polyurethane | MMA Resin |
|---|---|---|---|---|
| Petrol | Fair | Good | Fair | Poor |
| Diesel/Gas Oil | Good | Excellent | Good | Fair |
| Motor Oil | Excellent | Excellent | Excellent | Good |
| Hydraulic Fluid | Good | Excellent | Excellent | Fair |
| Skydrol | Poor | Fair | Poor | Poor |
| Brake Fluid | Poor | Fair | Good | Poor |
Solvent Categories
Aromatic solvents (xylene, toluene) aggressively attack most resin systems, requiring vinyl ester or specially formulated novolac epoxies. Ketones (MEK, acetone) cause rapid swelling in standard systems but novolac formulations provide adequate resistance for splash and spillage.
Alcohols present minimal risk to properly formulated systems, though methanol requires consideration in pharmaceutical environments. Chlorinated solvents demand extreme caution—only vinyl ester systems provide reliable long-term resistance.
System-by-System Analysis
Each flooring system offers distinct chemical resistance profiles suited to specific applications. Understanding these characteristics enables optimal selection for your facility's unique requirements.
Standard Epoxy Systems
Standard bisphenol-A epoxy provides economical chemical protection for moderate exposure. These systems excel in environments with occasional spillage of mild chemicals, offering good resistance to oils, dilute acids, and cleaning chemicals.
- Strengths: Oils, dilute acids/alkalis, detergents
- Weaknesses: Concentrated acids, solvents, oxidising agents
- Temperature limit: 60°C continuous, 80°C intermittent
- Typical thickness: 2-3mm self-levelling application
- Cost: £11-15 per m²-50/m² installed
Novolac Epoxy Systems
Novolac epoxy formulations provide enhanced chemical resistance through increased cross-link density. These systems suit chemical processing, pharmaceutical production, and laboratories handling aggressive chemicals.
- Strengths: Wide chemical resistance, high temperature tolerance
- Weaknesses: Oxidising acids, some chlorinated solvents
- Temperature limit: 90°C continuous, 120°C intermittent
- Typical thickness: 3-6mm trowelled application
- Cost: £11-15 per m²-75/m² installed
Polyurethane Concrete
Polyurethane concrete combines chemical resistance with thermal shock tolerance, making it ideal for food processing and brewing. The system's ability to withstand steam cleaning while resisting organic acids proves invaluable.
- Strengths: Thermal shock, organic acids, caustic solutions
- Weaknesses: Some solvents, oxidising agents
- Temperature limit: 120°C continuous, 150°C steam cleaning
- Typical thickness: 6-9mm trowelled application
- Cost: £11-15 per m²-85/m² installed
Vinyl Ester Systems
Vinyl ester represents the ultimate chemical resistance, handling virtually all acids, alkalis, and solvents. These systems suit the most demanding chemical environments including battery rooms, plating shops, and chemical storage.
- Strengths: Exceptional broad-spectrum resistance
- Weaknesses: Higher cost, strong odour during installation
- Temperature limit: 100°C continuous, 140°C intermittent
- Typical thickness: 3-5mm with glass reinforcement
- Cost: £11-15 per m²-100/m² installed
Industry-Specific Solutions
Different industries face unique chemical exposure profiles requiring tailored flooring solutions. Our recommendations reflect decades of experience across diverse sectors.
Pharmaceutical Manufacturing
Pharmaceutical facilities require resistance to solvents, acids, and cleaning agents while maintaining cleanroom standards. We recommend novolac epoxy for production areas handling APIs and solvents, with polyurethane concrete in washdown zones.
- Production areas: Novolac epoxy with coved skirting
- Cleanrooms: Static-dissipative epoxy with chemical modification
- Laboratories: Vinyl ester for maximum resistance
- Utilities: Standard epoxy with local protection
Food & Beverage Processing
Food facilities face organic acids, caustic cleaning, and thermal shock from steam cleaning. Polyurethane concrete provides optimal performance, combining chemical resistance with thermal tolerance and slip resistance.
- Wet processing: 9mm polyurethane concrete
- Dry processing: 6mm polyurethane concrete
- Cold storage: Flexible polyurethane systems
- Packaging: Standard epoxy with enhanced durability
Chemical Processing
Chemical plants require system selection based on specific chemical exposure. Primary containment areas need vinyl ester, while secondary containment may use novolac epoxy. Bunding requires careful joint design to prevent leakage.
- Storage areas: Vinyl ester with secondary containment
- Production: Novolac epoxy or vinyl ester per chemicals
- Loading bays: Chemical-resistant with impact tolerance
- Laboratories: Vinyl ester with bench protection
Automotive Industry
Automotive facilities encounter oils, fuels, battery acid, and brake fluid. Standard epoxy suits most areas, with enhanced protection in battery charging and paint shops.
- Assembly areas: Standard epoxy with oil resistance
- Paint shops: Solvent-resistant novolac epoxy
- Battery charging: Acid-resistant with ESD properties
- Workshops: Standard epoxy with local protection mats
Testing Standards & Certification
Chemical resistance claims require validation through recognised testing standards. Understanding these standards ensures specified systems meet regulatory and insurance requirements.
ASTM Testing Methods
ASTM C581 provides standard test methods for chemical resistance of thermosetting resins. Testing involves immersion in specific chemicals at defined temperatures, measuring weight change, hardness variation, and visual degradation over time.
- ASTM C581: Chemical resistance of thermosetting resins
- ASTM D543: Resistance to chemical reagents
- ASTM D1308: Effect of household chemicals
- ASTM D4060: Abrasion resistance (Taber test)
Performance Classifications
Chemical resistance ratings follow standard classifications enabling comparison between systems:
- Excellent: No visible effect, <1% property change
- Good: Slight surface change, <5% property change
- Fair: Moderate effect, 5-15% property change
- Poor: Significant degradation, >15% property change
- Not Recommended: Rapid failure expected
Selection Guidelines
Selecting appropriate chemical-resistant flooring requires systematic evaluation of exposure conditions and operational requirements. This structured approach ensures optimal system specification.
Assessment Checklist
Document all chemicals present including cleaning agents often overlooked in initial assessments. Record maximum concentrations even if typical exposure involves diluted solutions. Note temperature extremes during processing and cleaning cycles.
Decision Matrix
| Factor | Low Risk | Medium Risk | High Risk | Extreme Risk |
|---|---|---|---|---|
| Chemical Type | Oils, detergents | Dilute acids/alkalis | Concentrated chemicals | Mixed aggressive chemicals |
| Exposure | Occasional splash | Regular spillage | Frequent contact | Continuous immersion |
| Temperature | <40°C | 40-60°C | 60-80°C | >80°C |
| Recommendation | Standard epoxy | Novolac epoxy | PU concrete | Vinyl ester |
Safety Factors
Always specify one level higher resistance than minimum requirements. Chemical concentrations may increase unexpectedly, temperatures fluctuate, and new chemicals introduce unforeseen challenges. This safety margin prevents premature failure and extends service life.
Expert Chemical Resistance Specification
Professional assessment and system recommendation for your specific chemical exposure
Get Specification HelpConclusion
Chemical resistance requirements vary dramatically across industries and applications. Standard epoxy suits mild exposure, novolac epoxy handles moderate chemicals, polyurethane concrete excels in food processing, while vinyl ester provides ultimate protection for aggressive chemicals. Proper selection based on specific exposure conditions ensures long-term performance and safety.
Professional assessment identifies optimal systems for your unique chemical exposure profile. Our technical team combines laboratory testing with field experience, specifying chemical-resistant flooring that protects your facility, employees, and investment. Contact us for expert guidance on achieving reliable chemical protection tailored to your operational requirements.