Resinous Flooring
Summary
Resinous flooring is a seamless system of primers, body coats or mortars, broadcast aggregate, and topcoats built from epoxy, polyurethane, urethane cement, or MMA resins over prepared concrete. It resists chemicals, water, and wear with integral cove base, but resin type, thickness, slab moisture, and surface profile must match the exposure.
Cols
Terminology
- Epoxy: two-part resin; strong adhesion and chemical resistance; slower cure
- Polyurethane / aliphatic urethane: topcoats with UV stability and abrasion resistance
- Urethane cement: cement-modified polyurethane mortar; tolerates thermal shock and moisture; for kitchens and food plants
- MMA: methyl methacrylate; cures in about 1 to 2 hours, even in cold; strong odor
- Self-leveling / slurry: flowable body coat
- Broadcast: aggregate or colored quartz scattered into wet resin for texture and slip resistance
- Troweled mortar: heavy resin-aggregate mix for impact and thermal shock
- Integral cove base: resin base turned up the wall for sanitary joints
- CSP: concrete surface profile created by shot blasting or grinding
- Moisture mitigation primer: epoxy primer for slabs above standard moisture limits
Standards
Thicknesses
- Thin film coatings: mils; for light duty
- Self-leveling and broadcast systems: about 1/16 in. to 1/8 in.
- Urethane cement and troweled mortars: about 1/4 in. and thicker for heavy duty and thermal shock
Ratings
- Slab moisture: common limits 3 lb/1,000 sq ft/24 hr (ASTM F1869) or 75 percent RH (ASTM F2170), or as the manufacturer states
- Application conditions: substrate and material typically held between 65 and 85 degrees F during and after application
- Concrete age: 28 to 30 days minimum cure common unless moisture-tolerant primers are used
Test standards
- ASTM F2170 and F1869: slab moisture
- ICRI 310.2R: concrete surface profiles
Materials
- Epoxy: labs, warehouses, garages, and general commercial
- Urethane cement: commercial kitchens, food and beverage, freezers
- MMA: fast-return projects and cold rooms
- Decorative quartz and flake broadcasts: restrooms, locker rooms, and retail
- Topcoats: urethane or polyaspartic for UV and wear
Detailing
- Specify substrate preparation (shot blasting or grinding) to the manufacturer's surface profile
- Test moisture; specify mitigation primers where needed
- Slope floors to drains in wet areas; build integral cove base with metal or resin terminations
- Detail joints: honor slab moving joints, fill control joints
- Plan ventilation and odor control for MMA and solvent-based products in occupied buildings
Uses
Specific uses
- Commercial kitchens and food processing
- Laboratories and cleanrooms
- Healthcare operating rooms and sterile processing
- Warehouses, garages, and manufacturing
- Restrooms and locker rooms
Pros and cons
Pros
- Seamless and sanitary with integral cove base
- Chemical, water, and wear resistance
- Wide range of textures for slip resistance
- Durable over concrete with proper preparation
Cons
- Sensitive to slab moisture and preparation
- Odor and cure times disrupt occupied buildings
- Hard underfoot
- Epoxy topcoats yellow in UV without urethane topcoats
Manufacturing and cost
Construction
- Concrete prepared by shot blasting or grinding; cracks and joints repaired
- Primer, body coat or mortar, broadcast, and topcoats applied in sequence
Main manufacturers and suppliers
Trade association: American Society of Concrete Contractors.
Typical costs
- Epoxy broadcast system, installed: $3.50 to $7 per sq ft
- Heavier epoxy and resinous systems, installed: up to $12 per sq ft and more
Sources
- WBDG: VA 09 67 23.20 resinous flooring specification, https://www.wbdg.org/FFC/VA/VAASC/VA 09 67 23.20.pdf
- Hawaii DOD: resinous flooring specification (moisture limits), https://dev-dod.hawaii.gov/hieng/files/2022/08/A2-3-09672-Resinous-Flooring.pdf
- Plastic Ranger: types of resinous flooring, https://plasticranger.com/what-is-resinous-flooring/
- Arcat: Sherwin-Williams 09 67 23 resinous flooring specification, https://www.arcat.com/spec-doc/sherwin-williams-35477/09_67_23gen/doc
- Terrapin Construction Group: commercial flooring cost per sq ft, 2026, https://terrapincg.com/news/commercial-flooring-costs-per-sf-2026
- Wikimedia Commons: Installation of epoxy and screen mesh to fix cracks on the existing concrete floor at the southern end of the future LIRR passenger concourse. (49363293063).jpg, by MTA Capital Construction Mega Projects (CC BY 2.0), https://commons.wikimedia.org/wiki/File:Installation_of_epoxy_and_screen_mesh_to_fix_cracks_on_the_existing_concrete_floor_at_the_southern_end_of_the_future_LIRR_passenger_concourse._(49363293063).jpg