Types of Epoxy Self-Leveling Floors
| System | Thickness | Filler Loading | Best For |
|---|---|---|---|
| Thin-film coating | 0.3–0.5 mm | None | Light-duty, decorative |
| Self-leveling floor | 2–3 mm | 30–40% BaSO₄ | Warehouses, food plants, hospitals |
| Heavy-duty screed | 4–6 mm | 40–60% quartz/BaSO₄ | Forklift traffic, heavy industry |
| Anti-static floor | 2–3 mm | Conductive fillers | Electronics, explosive zones |
Standard Formulation for 2–3 mm Self-Leveling Floor
The following formulation is based on Global Optimals materials. All percentages are by weight of total mixed system:
| Component | Product | % by weight | Function |
|---|---|---|---|
| Epoxy resin | KER 828 or CYD-128 | 28–32% | Film former, adhesion |
| Hardener | KH-816 | 8–10% | Crosslinker |
| Filler | Blanc fixe L or N | 50–58% | Body, hardness, shrinkage control |
| Reactive diluent | Benzyl alcohol | 2–4% | Viscosity reduction, wetting |
| Defoamer | TEGO AIREX 900 | 0.2–0.4% | Eliminates bubbles |
| Leveling agent | GLIDE B 1484 | 0.1–0.2% | Mirror finish |
| Pigment paste | Universal paste | 1–3% | Color |
| Dispersant | TEGO Dispers 670 | 0.3–0.5% | Pigment distribution |
Step-by-Step Application Guide
Step 1 — Surface Preparation (Critical)
Surface prep determines 80% of the floor's success. The concrete substrate must:
- Be structurally sound with compressive strength ≥ 25 MPa
- Be mechanically abraded to CSP 3–4 (shot-blasted or diamond-ground)
- Have moisture content below 4% (measured by CM-method / carbide bomb)
- Be free of oil, grease, dust, and laitance (acid-etching or grinding required)
- Ambient and substrate temperature: +10°C to +30°C
- Substrate temp must be ≥ 3°C above dew point
Step 2 — Primer Application
Mix KER 828 + KH-816 at 100:27 ratio without any filler. Thin with up to 5% benzyl alcohol if needed. Apply by roller or squeegee at 200–300 g/m². The primer seals the concrete and ensures adhesion of the screed. Cure time: 12–16 h at 20°C. The surface must be tacky but not wet when the screed is applied (overcoat window: 12–24 h).
Step 3 — Mixing the Screed
- Weigh all components accurately (±2% tolerance)
- Mix Part A (resin + additives + pigment) with slow-speed mixer (300–400 rpm) for 2 minutes
- Add Part B (hardener). Mix for 2 more minutes, scraping sides
- Add Blanc fixe gradually while mixing. Avoid adding all at once
- Total pot life at 25°C: 30–40 minutes. Work in batches accordingly
⚠️ Never mix partial ratios by eye. Always weigh. A 10% error in hardener causes permanent cure failure.
Step 4 — Pouring and Spreading
Pour the mixed screed onto the primed surface. Spread with a notched squeegee (notch depth = target thickness + 20% for leveling). The self-leveling properties will flatten the surface within 20–30 minutes. Work in strips, maintaining a wet edge to prevent lap marks.
Step 5 — De-aeration
Within 10 minutes of pouring, roll the surface with a spiked roller (nadelwalze / spike roller). This releases trapped air bubbles that would otherwise form pinholes. Roll in two perpendicular directions. This step is mandatory — TEGO AIREX 900 reduces but does not fully eliminate bubbles from mixing.
Step 6 — Curing and Protection
- 0–24 h: No foot traffic. Protect from dust with polyethylene sheeting (do not lay directly — use tent effect)
- 24 h: Light foot traffic permitted
- 72 h: Light wheeled traffic
- 7 days: Full mechanical and chemical resistance. Heavy loads and forklift traffic permitted
Material Consumption Calculator
| Layer | Thickness | Consumption (kg/m²) | Coverage per 25 kg pail |
|---|---|---|---|
| Primer (resin only) | — | 0.25–0.30 | ~85 m² |
| Self-leveling screed | 2 mm | 3.5–4.0 | ~6.5 m² |
| Self-leveling screed | 3 mm | 5.0–5.5 | ~4.7 m² |
| Topcoat (optional) | 0.2–0.3 mm | 0.35–0.45 | ~60 m² |
Add 10–15% to all figures for substrate roughness, waste and overlaps.
Common Mistakes and How to Avoid Them
| Defect | Cause | Prevention |
|---|---|---|
| Pinholes / craters | Trapped air, damp substrate, skipped spike rolling | Spike roll within 10 min; check moisture; use AIREX 900 |
| Tacky / soft surface | Wrong mix ratio, low temperature, moisture inhibition | Weigh components; ensure T > +10°C; check dew point |
| Poor adhesion / delamination | Contaminated substrate, skipped primer, over-cured primer | CSP 3–4 prep; primer within 24 h overcoat window |
| Colour variation / lap marks | Slow working, dried edges, inconsistent batch mixing | Work in strips; maintain wet edge; consistent batch sizes |
| Yellowing | UV exposure (normal for aromatic epoxy) | Apply UV-stable aliphatic PU topcoat for outdoor / daylit areas |
| Bubbles (large) | Mixing too fast, hot substrate, delayed spike roll | Mix at 300–400 rpm; substrate T < 30°C; spike roll immediately |
