Epoxy flooring thickness ranges from thin coatings at 0.3-1mm for light protection, self-levelling screeds at 2-6mm for moderate wear, to heavy-duty mortars exceeding 6mm for extreme conditions. Each thickness category serves specific purposes: coatings cost £11-15 per m²-35/m² for dust-proofing, screeds £11-15 per m²-55/m² for commercial use, and mortars £11-15 per m²-85/m² for industrial applications requiring maximum durability.
Thickness Categories Overview
Epoxy flooring thickness directly correlates to durability, performance characteristics, and cost. Understanding the three main categories helps specify the right system for your facility's operational demands and budget constraints.
The thickness you choose affects not just the initial cost but also the floor's lifespan, maintenance requirements, and ability to withstand your specific operational stresses. Thinner systems suit light-duty environments with minimal mechanical wear, while thicker installations handle heavy impacts, thermal shock, and aggressive chemicals.
Key Thickness Categories
- Thin Film Coatings (0.3-1mm): Protective seal for concrete, dust-proofing, light chemical resistance
- Self-Levelling Screeds (2-6mm): Smooth finish, moderate durability, ideal for commercial/industrial use
- Heavy-Duty Mortars (6-12mm+): Maximum durability, impact resistance, suitable for extreme conditions
Thin Film Coatings (0.3-1mm)
Thin film epoxy coatings provide cost-effective protection for concrete substrates in light to medium-duty environments. Applied in 2-3 coats, these systems transform dusty concrete into cleanable, chemical-resistant surfaces suitable for warehouses, retail spaces, and light manufacturing.
Coating System Components
A typical thin coating system consists of primer (100-150 microns), body coat (200-400 microns), and optional topcoat (50-100 microns). Total dry film thickness ranges from 350-650 microns (0.35-0.65mm), though high-build variants can reach 1mm.
Application Areas
- Warehouse flooring with pedestrian and light forklift traffic
- Retail flooring stockrooms and back-of-house areas
- Car park decks requiring basic protection
- Clean rooms where seamless surfaces are essential
- Electronics assembly areas needing ESD protection
Performance Characteristics
Thin coatings offer excellent adhesion to prepared concrete, typically achieving 2-3 N/mm² pull-off strength. They provide good chemical resistance to oils, fuels, and mild acids, though concentrated chemicals may cause staining or softening. Abrasion resistance reaches 60-80mg loss (Taber CS17/1kg/1000 cycles), sufficient for foot traffic and rubber-wheeled vehicles.
The main limitation of thin coatings is their inability to level uneven substrates or repair damaged concrete. Surface imperfections telegraph through, making thorough preparation essential. Expected lifespan ranges from 5-10 years depending on traffic intensity and maintenance.
Self-Levelling Screeds (2-6mm)
Self-levelling epoxy screeds create smooth, durable surfaces ideal for commercial and industrial facilities. These systems flow and level naturally, producing flat floors suitable for high-speed traffic and automated guided vehicles (AGVs). Our self-levelling flooring installations transform uneven substrates into perfectly flat surfaces.
Screed System Build-Up
Installation begins with primer application, followed by the self-levelling layer poured at 2-6mm thickness. The resin and aggregate blend flows to create a smooth surface, eliminating trowel marks and ridges. A seal coat locks the surface, providing additional chemical resistance and colour stability.
Technical Specifications
- Compressive strength: 50-70 N/mm² (higher than concrete substrate)
- Flexural strength: 15-25 N/mm² (accommodates minor substrate movement)
- Abrasion resistance: 40-60mg loss (superior to thin coatings)
- Chemical resistance: Excellent against acids, alkalis, and solvents
- Temperature resistance: -20°C to +60°C continuous exposure
Optimal Applications
Self-levelling screeds excel in pharmaceutical production areas requiring GMP compliance, food processing facilities needing HACCP-compliant surfaces, and laboratories demanding chemical resistance. The smooth finish facilitates cleaning while the thickness provides durability for 10-15 year service life.
These systems also suit retail showrooms, commercial kitchens, and healthcare facilities where aesthetics matter. Decorative options include solid colours, flake broadcasts, and metallic effects, combining functionality with visual appeal.
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Get Expert GuidanceHeavy-Duty Mortars (6mm+)
Epoxy mortar systems provide maximum durability for extreme industrial environments. These trowel-applied systems combine epoxy resin with graded aggregates, creating floors capable of withstanding severe mechanical and chemical attack. Our heavy-duty mortar installations deliver 20+ year service life in demanding applications.
Mortar System Composition
Heavy-duty mortars blend epoxy resin with kiln-dried aggregates at 1:4 to 1:7 ratios. Multiple aggregate grades create dense matrices resistant to impact and abrasion. Thickness ranges from 6-12mm standard, with repairs and overlays possible up to 50mm.
Performance Advantages
- Impact resistance: Withstands dropped tools and heavy equipment
- Thermal shock resistance: Handles steam cleaning and temperature cycling
- Load bearing: Supports 40-tonne vehicles and point loads
- Chemical immunity: Resists 98% sulphuric acid and caustic solutions
- Longevity: 20-30 year lifespan with minimal maintenance
Industrial Applications
Mortar systems suit heavy engineering workshops where metal components drop frequently, chemical processing plants with spillage risks, and waste transfer stations experiencing extreme abrasion. The thickness accommodates substrate irregularities while providing superior protection.
Installation requires skilled applicators to achieve correct profiles and finishes. Cove bases integrated into mortar systems eliminate wall/floor joints where contamination accumulates, essential for hygiene-critical environments.
System Comparison Table
| System Type | Thickness | Cost/m² | Durability | Installation Time | Service Life |
|---|---|---|---|---|---|
| Thin Coating | 0.3-1mm | £11-15 | Light-Medium | 2-3 days/1000m² | 5-10 years |
| High-Build Coating | 1-2mm | £11-15 | Medium | 3-4 days/1000m² | 7-12 years |
| Self-Levelling | 2-4mm | £11-15 | Medium-Heavy | 3-5 days/1000m² | 10-15 years |
| Flow-Applied Screed | 4-6mm | £11-15 | Heavy | 4-6 days/1000m² | 12-18 years |
| Trowelled Mortar | 6-9mm | £11-15 | Very Heavy | 5-7 days/1000m² | 15-25 years |
| Heavy Mortar | 9-12mm | £11-15 | Extreme | 7-10 days/1000m² | 20-30 years |
When to Use Each Thickness
Selecting appropriate thickness requires evaluating operational demands, substrate condition, and budget constraints. Each thickness category suits specific applications based on wear patterns, chemical exposure, and structural requirements.
Thin Coatings (0.3-1mm) Are Ideal When:
- Concrete is structurally sound with minimal defects
- Traffic limited to pedestrians and light vehicles
- Chemical exposure involves occasional spillage only
- Budget constraints prevent thicker systems
- Downtime must be minimised (24-48 hour return to service)
Self-Levelling Screeds (2-6mm) Excel When:
- Substrate has minor undulations requiring levelling
- Moderate to heavy wheeled traffic operates
- Hygiene standards demand seamless, cleanable surfaces
- Decorative finish enhances brand image
- 10+ year service life justifies investment
Mortar Systems (6mm+) Become Essential When:
- Substrate damage requires structural repair
- Heavy impacts from dropped objects occur
- Aggressive chemicals contact floors regularly
- Thermal shock from steam cleaning happens daily
- 20+ year service life provides best lifecycle value
Cost Implications of Thickness
Understanding cost drivers helps optimise specifications within budget constraints. Material costs increase linearly with thickness, but labour costs don't scale proportionally, making thicker systems more economical per millimetre.
Direct Cost Factors
Material consumption drives primary costs. Thin coatings require 0.3-0.5kg/m² per coat, while self-levelling screeds consume 1.8-2.2kg/m² per millimetre thickness. Mortar systems use 2.0-2.4kg/m² per millimetre due to aggregate content.
Labour intensity varies significantly. Thin coatings apply quickly using rollers, requiring 2-3 operatives per 1000m²/day. Self-levelling screeds need 4-5 operatives for mixing, pouring, and spiking. Mortar systems demand 5-7 skilled operatives for trowelling and finishing.
Lifecycle Cost Analysis
Thicker systems offer superior lifecycle value despite higher initial costs. A 0.5mm coating lasting 7 years costs £4.29/m²/year, while a 6mm screed lasting 15 years costs £3.33/m²/year. Factor in reduced maintenance and downtime for comprehensive evaluation.
Hidden Cost Considerations
- Preparation costs: Thicker systems tolerate poorer substrates, reducing prep work
- Downtime impact: Mortar systems take longer but last decades
- Maintenance frequency: Thin coatings need recoating every 5-7 years
- Repair costs: Damage to thin coatings often requires complete renewal
- Cleaning efficiency: Smooth screeds reduce cleaning labour by 30%
Installation Considerations
Successful installation depends on understanding how thickness affects application methods, curing requirements, and quality control. Each system demands specific environmental conditions and substrate preparation standards.
Substrate Requirements by Thickness
Thin coatings demand near-perfect substrates. Surface regularity must achieve SR1 classification (3mm under 2m straightedge), with concrete strength minimum 25N/mm². Any laitance, contamination, or previous coatings require complete removal through diamond grinding or shot blasting.
Self-levelling screeds tolerate SR2 surfaces (5mm variance), using their flow characteristics to achieve SR1 finish. Primers bridge minor cracks and provide adhesion to variable substrates. Moisture content below 5% prevents osmotic blistering.
Mortar systems accommodate damaged substrates, filling holes to 50mm depth. Their thickness allows incorporation of repairs during installation. Mechanical preparation creates adequate key regardless of surface condition.
Environmental Conditions
Temperature affects all thicknesses but impacts thin coatings most severely. Substrate temperature must exceed dew point by 3°C minimum, with ambient temperature between 10-30°C. Thin coatings applied outside these parameters may never cure properly.
Humidity control becomes critical for self-levelling screeds. High humidity extends flow time but may cause surface defects. Dehumidification equipment maintains 40-60% relative humidity for optimal results.
Quality Control Measures
- Wet film thickness gauges verify application rates every 100m²
- Flow testing for screeds ensures consistent viscosity between mixes
- Holiday detection on thin coatings identifies pinholes requiring repair
- Core samples from mortar systems confirm thickness and density
- Adhesion testing validates bond strength before full application
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Request ConsultationConclusion
Epoxy flooring thickness selection balances performance requirements with budget reality. Thin coatings provide economical protection for light-duty areas, self-levelling screeds deliver optimal price/performance for commercial applications, while heavy-duty mortars ensure decades of service in extreme conditions.
Professional specification considers not just current requirements but anticipated changes in use, ensuring selected thickness accommodates future demands. Our technical team evaluates substrate condition, operational stresses, and lifecycle costs to recommend optimal thickness for your specific application. Contact us for expert guidance on achieving maximum value from your flooring investment.