Sealing Industrial Concrete Floors: Options and Benefits

Understanding Concrete Sealing

Sealed concrete is a very common and generic term used in construction and architectural specifications. It is almost as generic as the term polished concrete. All these phrases have different meanings for the customer, contractor, and client. Seeing a floor in one facility does not guarantee the same results in another. Resinous flooring materials, application methods, and the chemistry of the concrete can produce a wide range of results. Today we are going to dive into common ways to seal industrial concrete floors and how each can benefit your facility.

Basic Concrete Sealers

Concrete is a porous and often dusty product if left unsealed. Its porous nature makes it very susceptible to staining and spalling in wet environments. The most basic way to seal up concrete is with Ashford Formula or Prosoco LS Guard. These products require minimal experience or equipment to be applied. They penetrate the concrete and work to chemically fill the voids of the concrete floor. They offer stain protection and can be burnished to give the surface a reflective sheen. These products are often applied by concrete companies and help aid in the curing process by accelerating hydration of Portland cement. If the surface is not going to be epoxy coated in the future, this can serve as a basic and functional concrete sealer. For areas that will be epoxy coated, this process can impact grinding or shot blasting methods for your epoxy coatings contractor. It can also change recommended specifications or additional epoxy primer requirements. Neither of these pose a problem if the floor coating professional asks the correct questions or is familiar with the concrete specifications.

Acrylic Concrete Sealers

Acrylic concrete sealers are also a low-cost way to topically seal a concrete slab. These products are water-based or solvent-based and are typically installed at 300-500 square feet per gallon. Both sealers will typically have shorter life spans than industrial epoxy floor coatings. You will often see these products used to coat acid-stained floors, stamped concrete floors, or even concrete driveways. They offer some UV stability against yellowing but often need to be reapplied to protect the surface. Acrylic concrete sealers normally need to be recoated every 1 to 3 years to provide specified levels of concrete protection. While these concrete sealers have a place in the market, they are not long-lasting sealer options.

Epoxy Floor Coatings

One of the most used concrete sealers is epoxy floor coatings. Epoxy water emulsion primer/sealer or high solids epoxy are two common products used to seal concrete floors. Both can be used as standalone finishes to protect concrete floors. These products can also be used to hide imperfections or cracks when thickening agents like cabosil are used. These epoxy concrete sealers work well to provide a non-porous and easily cleanable surface but do have limitations. These epoxy concrete sealers are not light stable and will yellow/amber over time. If the epoxy floor sealer is pigmented, multiple coats will be needed to achieve a uniform appearance.

Epoxy and Urethane Coatings

For protection of industrial concrete floors, epoxy and urethane coatings offer a more permanent solution. These products offer chemical resistance and a more robust Taber Abrasion value than concrete densifiers or acrylic concrete sealers. The process is also more involved in scope, making a professional floor coatings company a must. Surface preparation such as diamond grinding or shot blasting is required to provide the proper surface profile. Epoxy primers or solvent-based urethane are used as the base layer to bond to the concrete floor. This is followed by a chemical-resistant topcoat. These products can be applied in a clear or pigmented finish. With the popularity of polished concrete growing globally, clear concrete sealers are often used to mimic or match the look of natural polished concrete. In areas where slip resistance is a concern, epoxy and urethane floor coatings can also incorporate non-slip additives like aluminum oxide or glass beads.

Common Areas for Epoxy and Urethane Floor Coatings

• Aircraft Hangars
• Industrial Manufacturing Facilities
• Warehouses and Distribution Facilities
• Battery Manufacturing Floors
• Charging Station Flooring
• Food and Beverage Manufacturing

Conclusion

No matter what type of facility your business occupies, protecting your concrete floor should not be overlooked. People often consider concrete a durable and maintenance-free option, leading them to overlook protecting their floors. When these surfaces are neglected for too long, major spalling, cracking, and erosion will lead to more costly repairs. Even choosing and maintaining a basic concrete sealer will prevent costly repairs and downtime in the future. The team at Liquid Floors has been preserving and protecting concrete in industrial facilities for over 20 years. Schedule a site visit with a team member to see how our services can make a big impact in your facility.

Contributed by James Eller – Sales Manager at Liquid Floors