Epoxy Floor Coating Calculator — Resin, Primer & Aggregate

For domestic garages, a total dry film thickness (DFT) of 200-300 microns is sufficient. Light industrial floors need 300-500 microns. Heavy industrial or forklift areas need 500-1000+ microns. The primer coat is typically 50 microns, with build coats at 100-250 microns each. The DFT is roughly 50-60% of the wet film thickness due to solvent evaporation.

Most 2-part epoxy floor coatings use a 2:1 or 3:1 base-to-hardener ratio by volume. Always follow the manufacturer's instructions exactly — incorrect ratios will cause soft spots, poor adhesion, or failure to cure. Mix thoroughly for 3-4 minutes, scraping the sides and bottom of the container. The mixed product typically has a pot life of 20-40 minutes.

Yes, an epoxy primer is essential. It penetrates the concrete pores, improves adhesion, and reduces bubble formation (outgassing) in the build coat. On new concrete, allow 28 days curing before priming. On existing concrete, degrease and etch with acid or diamond grind for best results. The primer typically covers 6-8 m²/L.

Epoxy floor coatings are typically touch-dry in 12-16 hours at 20°C, light foot traffic after 24 hours, and full cure in 7 days. Do not apply at temperatures below 10°C as curing will be very slow. Above 30°C, the pot life is significantly reduced. Vehicle traffic should wait at least 72 hours, ideally 7 days.

Quartz sand (0.3-0.8mm grade) is the most common anti-slip aggregate for epoxy floors. For a light or standard anti-slip texture, broadcast at around 1.5 kg/m² into the wet build coat; a full broadcast 'to refusal' (where you keep scattering until no more aggregate sticks) uses around 3 kg/m². After curing, vacuum or sweep off the loose excess and apply a seal coat. For heavy-duty anti-slip, aluminium oxide aggregate gives superior grip. Coloured quartz flakes are used for decorative finishes in showrooms and retail spaces.