Self-levelling resin for industrial floors

The Best Resin for Industry

What is self-levelling resin?

Self-levelling resin, usually epoxy, is a special type of resin capable of levelling itself on horizontal surfaces prepared with primer and already subjected to a processing cycle. It is created by combining resin and hardener, mixed together. The resulting mixture can be applied to wood, cement and tile substrates to create a strong and durable surface.

Once hardened, the self-levelling resin has a glossy appearance, is waterproof and abrasion resistant. Its chemical and mechanical properties remain unaltered throughout its thickness, which is typically 2 to 3 millimetres.

Self-levelling resins are suitable for many environments requiring excellent hygiene and frequent washing; for example, they are often used in mechanical, food, chemical-pharmaceutical industries, laboratories and hospitals. They are also often chosen for the uniformity and regularity of the final surface.

A particular type of self-levelling resins are the transparent ones, which allow various objects to be incorporated, creating original and pleasant effects. In this case, the thickness can reach up to several centimetres.

How should the substrate be? Can it also be uneven, since resin is capable of self-levelling?

As far as the substrate is concerned, this can also have small irregularities or be damaged superficially, as the thickness created by the application cycle (primer + trowel) is able to even out the surface.

Caution, however: the substrate must in any case be free of significant unevenness, which could not be bridged by a material that is 2 - 3 millimetres thick.

In the case of significant differences in level, epoxy mortar can be applied beforehand to create a uniform surface on which the self-levelling resin can be applied.

What advantages does self-levelling resin offer?

Self-levelling resin floors are very popular in both the commercial and industrial sectors.

This is for numerous reasons, briefly described below:

Smooth and planar surface

The characteristic flatness offered by the self-leveling resin, combined with the resistance to loads, is an additional guarantee of safety in environments where forklifts or forklifts frequently pass, often carrying heavy loads. The lack of escape routes, typical of tiles, and the limited presence of joints, make the surface easy to clean and considerably limit the accumulation of dirt and bacteria.

Low thickness

As we said, the thickness is about 2.5 – 3 millimeters: reduced enough to avoid having to modify the fixtures, especially in the event of a renovation.

Remarkable sturdiness

The self-leveling floors in resin do not undergo alterations following frequent washing, chemical agents, continuous passage of people and vehicles. This allows installation in environments with very specific requests, such as food industries, pharmaceutical industries, hospitals or laboratories.

Elasticity

Self-leveling resins have a good degree of elasticity: this also makes them suitable for laying on floors with small surface irregularities.

Reduced times

The characteristic reduced laying and hardening times typical of resin floors are also maintained by self-leveling resins: this minimizes downtime in the work activity.

High aesthetic yield

The surface is aesthetically pleasing: usually opaque, it can be made glossy, with a "glassy" appearance; the joints, despite the classic joints, are minimally visible and make the surface almost linear and uniform: even in industrial and commercial environments the eye wants its part!

Customization

Although it usually has a smooth and glassy appearance, the self-leveling resin can be made non-slip by applying specific finishes, such as to make the surface rough and precisely generate non-slip areas. Furthermore, like other typical resin applications, the self-levelling cycle also allows numerous customization possibilities both, for example, with the insertion of writings, both in terms of colors or with the creation of horizontal signs or other specifications.

In which environments can the self-leveling resin be applied?

Thanks to its versatility and the many advantages it offers, self-leveling resin can be used for various industrial and commercial applications.

For example, realities such as showrooms and shops can take advantage of the glossy finish and the numerous customization possibilities capable of making each individual environment unique and therefore customizable.

The uniform, impact and abrasion resistant surface is ideal for warehouses and depots, where forklifts circulate every day. These same characteristics make self-leveling resin floors a practical choice for manufacturing companies as well.

Thanks to the absence of escape routes and the relative high possibility of cleaning and sanitizing, the self-leveling resins can also be laid in hospitals, laboratories and environments where food is prepared (e.g. industrial kitchens, restaurants, food companies).

Resistance to oil, fuel and other chemicals allows for application inside garages, workshops and garages.

How to lay the self-leveling resin?

Regardless of the type of application cycle, every time a resin floor is created it is important to make sure that the substrate is clean and not contaminated by grease, oil or dust which could compromise the final result.

As far as self-leveling resins are concerned, after careful mechanical preparation and a coat of primer on the substrate, the resin is usually poured, which is then spread with a notched trowel, so as to obtain a uniform result. Immediately after spreading with a spatula, the installer passes the bubble-breaker roller to eliminate the air trapped during the mixing phase.

Sivit offers various self-levelling cycles for numerous applications and for substrates in various conditions.

In this paragraph we describe the application phases of the epoxy self-leveling and transpiring self-levelling cycles; for all other solutions, visit the “ Self-leveling ” page.

Sivit epoxy self-levelling cycle

For concrete substrates without particular problems, we propose the epoxy self-levelling cycle, based on epoxy resins and free of solvents.

If the concrete base ( concrete) has just been completed, wait for the normal curing time (usually about 30 days) before laying the self-levelling resin. In any case, the substrate must be solid, dry, flat, free from contamination by oils, detergents, powders or other substances.

Before starting the work, proceed with the mechanical preparation of the substrate with sanding or shot peening to ensure correct adherence of the products.

The epoxy self-leveling cycle is made up of four phases.

First stage

After having prepared the base, a layer of Fluidepox, a transparent solvent-free epoxy formulation loaded with resin-coated spherical quartz, is applied to skim coat.

While the product itself (Fluidepox) is still fresh, more quartz is sprinkled on the surface.

Second phase

The mortar is prepared by combining the two components of Paviplast, a colored and solvent-free self-leveling epoxy formulation loaded with quartz. The self-leveling mortar is poured, the product is distributed with the toothed doctor blade and the surface is made uniform with a bubble-breaker roller.

Third stage

Depending on the target environment, you may want to tone down the surface gloss and make the surface slightly rough.

In this case, a layer of colored Paviwater can be applied by roller, diluted 10% with water, added with glass microspheres to obtain non-slip surfaces.

Fourth stage

The covering is cut at the concrete joints and sealed with Sigilflex, an elastic and resistant product.

The final thickness of the coating is approximately 2.5 – 3 mm.

Sivit transpiring self-levelling cycle

Funds with rising damp require specific treatment to ensure that the resin layer is not damaged over time. In fact, humidity can cause the formation of condensation, air bubbles, or even force the detachment of the resin from the substrate.

Sivit has therefore developed a transpiring self-levelling cycle designed for these types of substrates, the installation of which takes place in five phases:

First stage

A layer of Ecofondo diluted 15% with water is spread on the suitably prepared substrate with a roller. It is a product that creates a barrier to humidity, and is therefore used as a base layer for damp surfaces.

Second phase

A second coat of Ecofondo is applied, diluted 10% with water and added 10% with quartz.

Third stage

Two coats of Paviwater T68 are applied by roller, each diluted in water.

Fourth stage

It is poured and distributed with Paviplast W toothed blade, a colored epoxy formulation.

The surface is then passed with the bubble breaker roller to create a uniform layer.

Fifth stage

The covering is cut at the concrete joints and sealed with Sigilflex, an elastic and resistant product.

Once the work is finished, the final thickness will be about 2 mm.

Here is a video in which we show step by step the creation of the breathable self-leveling cycle: https://youtu.be/GgplyByYmnQ