Epoxy flooring has revolutionized industrial and commercial surfaces with its exceptional durability, chemical resistance, and aesthetic appeal. GLI Epoxy Flooring specializes in the installation of epoxy flooring. But behind every seamless, high-performance epoxy floor lies a sophisticated manufacturing process that transforms basic chemical compounds into specialized flooring systems. Understanding how epoxy is made for flooring applications reveals the intricate science and engineering that creates these remarkable surfaces.

The Foundation: Basic Epoxy Chemistry

The journey of epoxy flooring begins with fundamental chemistry involving two primary components: epoxy resin and hardener. Epoxy is a thermosetting polymer created through a chemical reaction between these components, forming cross-linked networks that deliver exceptional strength and durability. Epoxy is a type of polymer comprised of two components, typically called resin and hardener, mixed into specific proportions. When these components are combined, a chemical reaction happens and creates a hardened material with a myriad of useful applications.

The base epoxy resin serves as the foundation for all epoxy flooring systems. The most common epoxy resins are based on reacting epichlorohydrin (ECH) with bisphenol A, resulting in a different chemical substance known as bisphenol A diglycidyl ether (commonly known as BADGE or DGEBA). This fundamental reaction creates the molecular backbone that gives epoxy its remarkable properties.

Manufacturing Base Epoxy Resins

The production of epoxy resins for flooring begins in specialized chemical manufacturing facilities where precise control over temperature, pressure, and chemical ratios ensures consistent quality. The preparation method comprises dissolving bisphenol A and epichlorohydrin, and under the conditions of 45-65 DEG C, adding a cocatalyst and NaOH solution to perform etherification for 1-3h; under the conditions of 55-70 DEG C and absolute pressure of 15-25KPa, adding the NaOH solution dropwise.

The manufacturing process involves several critical stages. Initially, bisphenol A and epichlorohydrin are combined in carefully controlled ratios within large reaction vessels. In this two-stage reaction, epichlorohydrin is first added to bisphenol A (bis(3-chloro-2-hydroxy-propoxy)bisphenol A is formed), then a bisepoxide is formed in a condensation reaction with a stoichiometric amount of sodium hydroxide. The chlorine atom is released as sodium chloride (NaCl) and the hydrogen atom as water.

The reaction generates heat and requires precise temperature control to ensure proper molecular formation. During this process, manufacturers monitor viscosity, molecular weight, and epoxide content to maintain consistent product specifications. Higher molecular weight diglycidyl ethers (n ≥ 1) are formed by the reaction of the bisphenol A diglycidyl ether formed with further bisphenol A, this is called prepolymerization.

Creating Flooring-Specific Formulations

Raw epoxy resin must be transformed into specialized flooring formulations to meet the demanding requirements of industrial and commercial applications. These commodity epoxy manufacturers mentioned above typically do not sell epoxy resins in a form usable to smaller end users, so there is another group of companies that purchases epoxy raw materials from the major producers and then compounds (blends, modifies, or otherwise customizes) epoxy systems from these raw materials. These companies are known as “formulators”.

Formulators play a crucial role in adapting base epoxy resins for specific flooring applications. There are hundreds of ways that these formulators can modify epoxies—by adding mineral fillers (talc, silica, alumina, etc.), by adding flexibilizers, viscosity reducers, colorants, thickeners, accelerators, adhesion promoters, etc. These modifications are made to reduce costs, to improve performance, and to improve processing convenience.

Additives and Fillers for Enhanced Performance

Modern epoxy flooring systems incorporate numerous additives and fillers to achieve specific performance characteristics. Coatings are typically pure resins without any fillers, except for possible texture additives used to improve wear or increase slip resistance. Slurries incorporate a blend of aggregates to bulk up a resin, while still allowing for good flow and levelling during installation. Mortars utilize a high aggregate-to-resin ratio (5:1).

The selection and incorporation of fillers significantly impact the final product’s properties. Quartz aggregates provide exceptional durability and slip resistance, while decorative aggregates create aesthetic appeal. Dur-A-Gard™ MR is a solid color seamless pigmented flooring system consisting of 100% solids epoxy and natural quartz aggregates with a chemical and wear-resistant urethane topcoat. These aggregates are carefully sized, cleaned, and dried before incorporation into the epoxy matrix.

Specialized additives address specific performance requirements. Anti-static additives create conductive pathways for static dissipation in electronics manufacturing. UV stabilizers prevent yellowing and degradation in areas exposed to sunlight. Chemical resistance modifiers enhance protection against acids, solvents, and other aggressive substances commonly found in industrial environments.

Types of Epoxy Systems for Flooring

Manufacturers produce several distinct types of epoxy systems to meet diverse flooring requirements. Water-based epoxy systems offer low VOC content and easier application but provide limited durability for heavy-duty applications. Water-based epoxy coatings are a popular choice due to their ease of application and lower levels of volatile organic compounds (VOCs). They consist of epoxy resin and a water-based hardener.

Solvent-based systems provide improved chemical resistance and mechanical properties compared to water-based alternatives. However, 100% solids epoxy represents the premium choice for demanding commercial and industrial applications. Two-part epoxy floor coatings with 100 percent solids offer a thick, hard, and visually appealing finish for concrete floors. These coatings do not contain traditional solvents, making them a durable and attractive option.

Self-leveling epoxy systems incorporate special flow additives and rheology modifiers that enable the material to spread evenly and eliminate application marks. Generally, self-levelling systems are applied between 1 to 3mm and applied in liquid form for fast installation, resulting in a smooth, seamless finish. The resin-rich formulations of epoxy SL provide a very strong durable finish for heavy-duty demanding environments.

Quality Control and Testing

Manufacturing epoxy for flooring applications requires rigorous quality control throughout the production process. Manufacturers test viscosity, gel time, pot life, adhesion strength, and chemical resistance to ensure consistent performance. This is expressed as the “epoxide equivalent weight”, which is the ratio between the molecular weight of the monomer and the number of epoxide groups. This parameter is used to calculate the mass of co-reactant (hardener) to use when curing epoxy resins.

Temperature and humidity control during manufacturing prevents premature curing and ensures proper shelf life. Raw materials undergo incoming inspection to verify purity and specifications. Batch testing validates that each production run meets established performance criteria before packaging and shipment.

Hardener Manufacturing and Matching

Epoxy hardeners require separate manufacturing processes tailored to specific applications and cure characteristics. Amine hardeners provide fast cure and excellent mechanical properties, while polyamide hardeners offer greater flexibility and moisture tolerance. Reaction of polyepoxides with themselves or with polyfunctional hardeners forms a thermosetting polymer, often with favorable mechanical properties and high thermal and chemical resistance.

Manufacturers carefully match hardener chemistry to resin formulations, ensuring optimal cross-linking and performance. Stoichiometric ratios must be precisely calculated and communicated to end users to achieve proper cure and maximum properties.

Environmental and Safety Considerations

Modern epoxy manufacturing incorporates environmental sustainability and worker safety measures. As a world-leading manufacturer of resin flooring, many solutions produced by Flowcrete are formulated to be solvent-free, contain low quantities of VOCs (Volatile Organic Compounds) and do not present environmental hazards.

Manufacturers implement closed-loop systems to capture and recycle solvents, while waste treatment facilities neutralize and dispose of byproducts safely. Worker exposure to chemicals is minimized through engineering controls, personal protective equipment, and comprehensive training programs.

Packaging and Distribution

Final packaging preserves product integrity during storage and transportation. Epoxy resins require protection from moisture, temperature extremes, and contamination. The raw materials required for manufacturing epoxy resin include epoxy resin, curing agents, fillers, and other additives. Multi-component systems require careful labeling and color coding to prevent mixing errors in the field.

Manufacturers provide detailed technical data sheets, safety information, and application guidelines to ensure proper use. Temperature-sensitive products may require refrigerated storage and special handling during shipment.

Innovation and Future Developments

The epoxy flooring industry continues evolving with bio-based raw materials, improved performance characteristics, and enhanced sustainability. At Nerpa Polymers, we work on developing formulations where 20-50% of the BPA-based molecules are replaced with resin made from bioglycerol. These innovations reduce environmental impact while maintaining or improving performance.

Research focuses on developing faster-curing systems, improved chemical resistance, and enhanced aesthetic options. Smart additives that provide self-healing properties or color-changing capabilities represent emerging technologies that may transform future flooring applications.

Conclusion

The manufacturing of epoxy for flooring applications represents a sophisticated blend of chemistry, engineering, and quality control. From the initial reaction of basic chemical building blocks to the final formulated products, each step requires precise control and expertise. Understanding this complex process helps specifiers and users appreciate the technology behind high-performance epoxy flooring systems and make informed decisions for their specific applications. As the industry continues advancing, new manufacturing techniques and formulations will further expand the capabilities and applications of epoxy flooring technology.