Epoxy Mortar Floor Systems
Ultimate Strength for the Most Demanding Industrial Environments
Why Choose Epoxy Mortar for Extreme Industrial Conditions?
When conventional flooring fails within months, epoxy mortar stands strong for decades. We're talking about floors that survive steel wheel forklifts, chemical resistant flooring challenges that would dissolve concrete, and impact loads that shatter tiles. Our epoxy mortar systems combine the strength of concrete with the chemical resistance of epoxy flooring, creating an indestructible hybrid.
The numbers speak volumes: compressive strength exceeding 100 N/mm², flexural strength over 40 N/mm², and tensile strength above 15 N/mm². These aren't just statistics—they translate to floors that handle 50-tonne vehicles, resist 98% sulfuric acid, and withstand dropped steel beams without cracking. This is industrial epoxy flooring at its absolute peak.
Traditional concrete repairs fail because they don't bond properly to existing substrates. Epoxy mortar chemically fuses with the base concrete, becoming one monolithic structure. This eliminates the delamination problems that plague other heavy-duty systems. Once installed, our mortar floors become permanent fixtures, outlasting the buildings they're in.
Epoxy Mortar System Investment
How Is Epoxy Mortar Engineered for Maximum Strength?
The secret lies in the aggregate-to-resin ratio. We use graded quartz aggregates from 0.1mm to 4mm, creating optimal particle packing. Smaller particles fill voids between larger ones, maximizing density. The epoxy binder completely encapsulates each grain, creating a matrix stronger than either component alone.
Installation precision determines performance. We begin with shot-blasting to achieve CSP 5-6 surface profile, ensuring maximum mechanical adhesion. The primer penetrates deep into concrete pores, creating an unbreakable bond. Mortar application uses specialized troweling techniques achieving perfect compaction without air voids.
Curing chemistry transforms the material. Exothermic reactions during polymerization create molecular cross-linking throughout the thickness. This three-dimensional polymer network resists everything—chemicals can't penetrate it, impacts can't fracture it, and thermal cycles can't degrade it. The result is a floor that genuinely lasts forever.
What Extreme Conditions Can Epoxy Mortar Withstand?
Chemical plants throw everything at floors—concentrated acids, caustic alkalis, aggressive solvents. Our chemical-resistant mortar formulations use novolac or vinyl ester resins providing protection across the entire pH spectrum. Spillages that would destroy concrete in hours have zero effect on properly specified epoxy mortar.
Temperature extremes test flooring limits. Epoxy mortar handles thermal shock from -40°C blast freezers to +90°C steam cleaning without cracking. The coefficient of thermal expansion closely matches concrete, preventing differential movement. This stability maintains performance through decades of temperature cycling.
Impact resistance surpasses all alternatives. Drop tests with 20kg weights from 2 meters show no damage—not even surface marking. This toughness handles everything from dropped tools to pallet impacts. In steel mills where white-hot slag occasionally hits floors, specialized heat-resistant mortars prevent damage that would destroy other systems.
Which Industries Require Epoxy Mortar's Extreme Performance?
Power generation facilities cannot tolerate floor failure. Turbine halls with massive equipment loads, chemical treatment areas with corrosive materials, and transformer bays with oil spill risks all demand epoxy mortar's reliability. The 30-year design life matches plant operational cycles, eliminating mid-life refurbishment costs.
Mining and mineral processing operations destroy standard floors. Ore handling areas face constant impact from rocks and equipment. Processing plants deal with acidic slurries and alkaline flotation chemicals. Our mining-spec mortars incorporate steel fibers and ceramic aggregates, creating floors that match the toughness of the industry they serve.
Waste treatment plants present unique challenges. Constantly wet conditions, biological attack, and aggressive leachates create a perfect storm for floor degradation. Epoxy mortar's impermeable structure prevents contamination penetration while antimicrobial additives inhibit bacterial growth. These floors maintain integrity in conditions that dissolve concrete within years.
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Frequently Asked Questions
Thickness depends on service conditions. Light industrial needs 6-8mm, heavy manufacturing requires 10-12mm, and extreme conditions benefit from 15-20mm. We analyze your specific loads, chemical exposure, and thermal conditions to specify optimal thickness. Over-specification wastes money, but under-specification risks premature failure. Our 30 years' experience ensures perfect specification.
Epoxy mortar excels at concrete rehabilitation. We rebuild spalled areas, fill deep gouges, and resurface deteriorated slabs. The superior bonding means repairs become stronger than the original concrete. Large patches, complete overlays, or localized repairs all achieve permanent results. This rehabilitation approach costs 60% less than replacement while providing superior performance.
Standard installations of 500m² take 5-7 days including preparation, priming, mortar application, and topcoating. Large projects are phased to maintain partial operation. Rapid-cure formulations reduce downtime—returning areas to service in 48 hours. We work nights and weekends to minimize disruption. Proper planning ensures your operations continue during installation.
Joint design is critical for mortar floor success. We honor existing expansion joints using flexible sealants that accommodate movement while maintaining chemical resistance. New saw-cuts relieve stress in large areas. Isolation joints around columns and equipment prevent telegraphing cracks. This systematic approach ensures long-term performance without random cracking.
Life-cycle analysis proves epoxy mortar's value. Initial investment is higher, but 30-year life with minimal maintenance delivers lowest total cost. Avoided production losses from floor failures save millions. Reduced equipment damage from smooth, level surfaces cuts maintenance costs. Insurance premiums often decrease due to improved safety. Most clients see ROI within 3-5 years.
Build Floors That Last a Lifetime
Invest in epoxy mortar for permanent industrial flooring solutions.