Epoxy VS Other Products

• Slow curing time/ longer Pot Life (allows for deeper penetration into the substrate)
• Exceptional substrate adhesion
• Exceptional strong impact resistance – 10,000+ PSI pushing on surface (Compressive Strength)
• Higher tolerance to permanently bond to wet concrete with high MVER (Moisture Vapor Emissions) from 3 lbs to 20 lbs.

• Requires extensive surface abrasion to allow for 3-6 mils of penetration into the Substrate.
• Longer back-to-service time
• Less chemical resistance than some other polymers
• Lower uV Resistance – May amber, fade, or yellow over time (unless protected)

Polyureas are considered to be the new kids on the block when it comes to polymer coatings. However, they have been around; in other capacities, for more than 20 years. Because of their chemical resistance, polyureas were initially developed for corrosion protection in metal pipelines, water towers, and liquid storage tanks. Historically, they have been applied through specialized spray guns, due to their thinner viscosity and extremely fast (almost immediate) curing times. This makes polyureas ideal for coating vertical and rounded surfaces. Over the years, large chemical companies have reformulated polyureas to allow for easier use by
extending their working times, which has enabled them to be used in other industries, such as concrete floors. Eventually, using a molecular alteration, manufacturers recently created a different type of polyurea known as polyaspartic.

Both products, regardless of nomenclature, have nearly identical attributes, including fast curing and exceptional elongation rates. Polyaspartics generally contain higher solid content than polyureas and, as previously mentioned, are widely accepted as a premier, protective top coat in many industrial coating systems (because of their increased chemical resistance, abrasion
resistance and uV stability).

Additionally, polyureas have an extremely low tolerance for any moisture (as you might recall their roots were designed for applying to metal – NOT concrete). This can make polyureas more vulnerable to delamination or adhesion failures when applied to concrete when compared to industrial-strength epoxy

• Chemical resistance superior to other polymers
• uV Stable – less likely to amber, stain, or discolor
• Shorter back-to-service time
• Excellent abrasion resistance and flexibility

• Fast cure times (allows for minimal penetration into the substrate)
• Vulnerable to delamination and a low tolerance for any substrate moisture if utilized as the base coat.
• Must be applied thin, not allowing for maximum system build when broadcasting flake into it.
• Generally higher VOC’s and odor due to containing more solvents than industrial-strength epoxies.

Anyone considering a full broadcast system for their garage floor, basement or commercial location will likely encounter many claims regarding the aforementioned products. Below, we will summarize and clarify many of those claims to assist you in making an educated decision, based on factual and accurate information.

Industrial epoxy is indeed an older technology, making it tried and true. Though some of these environments may appear to be casual environments, residential garages, and basements are some of the most abusive environments around and require coatings that can withstand the weight of vehicles and resist delamination from contact with hot tires, which can reach temperatures as low as 30 degrees in the winter and 150 degrees in the summer. Industrial-strength epoxy, while older than some other polymers, remains the preferred product to connect a coating system directly to concrete. Industrial epoxy’s ability to cure slowly and wick into the prepared concrete surface allows it to integrate into the concrete (3-6 mils) and create a tenacious and permanent bond.

Quicker-curing polyurea base coats are renowned for not bonding as well to bare concrete and also lacking moisture tolerance, both of which could make them susceptible to delamination over time. Regardless of the recent technology improvements made with polyureas, the time-tested effectiveness of utilizing high solids, and industrial epoxies as the base coat is proven and trusted by the coatings industry. This is why industrial epoxies continue to be the product of choice by coating manufacturers, industrial-coating supply houses, and commercial coating contractors alike. The bottom line is that there is no one-size-fits-all approach to coatings. So,  when selecting the correct coating system for a specific application, the decision should be driven by which products will deliver the highest-quality system to the consumer and not what is easiest and fastest.

There are undisputed attributes of polyureas and polyaspartics that are superior to industrial epoxies, as discussed above. Some of these attributes include abrasion resistance, chemical resistance, uV resistance and back-to-service times. However, none of these benefits pertain to what remains the lowest common denominator in coating systems: The durability and longevity achieved through permanent adhesion to the concrete. Without a permanent bond, all of the other ancillary benefits of the garage floor coating system are negated.

Polyureas were not originally engineered for bonding strength to concrete. They were developed to be applied at a thin mil to achieve a quick bond to non-porous metals, with a focus on their superior chemical resistance and uV stability. More recently, One-Day installers have touted polyurea’s greater elasticity. While this may be true when laboratory tested independent of other products, most manufacturers agree that a polyurea having greater flexibility is more of a marketing point and not an important product characteristic when coating concrete in a residential garage or more casual location.

In contrast, industrial epoxies have been proven for decades to be the best polymer for bonding directly to concrete and remain as the best option for experienced, commercial coatings installation companies to use as the base coat in garage-floor coating systems. The reality is that systems using a polyurea base coat are easier and less time-consuming to install, as they only require one day for installation. One-day floor coating companies often state that they provide warranties ranging from 15 years and up to limited lifetime warranties. How are such warranty and longevity claims substantiated when the products used for One-Day floor coating systems are new to the market and untested for such extensive longevity claims???

Countless companies that install One-Day garage floor systems publish claims that their systems using polyurea base coats are up to 20 times stronger than systems using epoxy base coats while presenting no factual data to support their statements. These claims are misleading, as there are many variables in play when comparing the strength of any polymer’s bond to concrete. Which type of epoxy do these claims refer to – – industrial-strength epoxy, which is widely used in factories, airplane hangers, and warehouses, or DIY epoxy kits, purchased at local home improvement or paint stores? Epoxies in DIY kits, which may be water or solvent-based, often have lower solids content than industrial-strength epoxies, resulting in a limited mechanical and chemical bond with concrete. This makes them more user-friendly for homeowners and house painters who install the products themselves, but it reduces their durability and longevity. The inferior attributes of DIY epoxy kits can lead to delamination, coating failures, and costly reinstallations in the future.

So, applying a blanket statement that any polyurea is stronger than epoxy is not true and would require facts to support such a claim. It is not an apples-to-apples comparison. The strength of any polymer is measured in several areas:

Bond strength, Compressive strength, Flexural strength, and Tensile strength. The Bonding strength, which is the measurement of how well a polymer bonds to the substrate, is considered the most important “strength” attribute. No other strength-related traits have any merit if the coating’s bond to the substrate is not permanent. For example, if the bond strength of the polymer is greater than the tensile strength of the concrete itself, then the strength limitations will cause the concrete to fail prior to any polymer failing, be it polyurea or epoxy.

Many of the One-Day garage floor companies state that their total system build is equal to that of the Industrial-strength epoxy systems, and others omit this system characteristic. The thickness of the floor coating system is extremely important. If a coating is too thin, it will not provide sufficient protection during the day-to-day rigors of garage use. In contrast, if the coating is too thick, it can become brittle. Polyureas can be prone to outgassing if applied too thick and are normally installed at 250-375 square feet per gallon (4-6 mils per coat). This creates an extremely thin base coat, in comparison to the industrial-strength epoxy coats that are (10-16mils). Potential issues of a base coat being too thin are:

• Inconsistent coverage: Without enough base coat material to receive the broadcast Medium (flake), the base coat may be visible following the application.
• Reduced impact resistance: If less broadcast medium adheres to the base coat, it results in less of a protective top-coat material being applied to encapsulate the flakes.
• Less long-term durability: Using a thinner polyurea base coat can lead to the overall system thickness being up to 50% less than a hybrid system utilizing an industrial epoxy base coat.

Higher Compressive Strength, Tensile Strength and Elongation numbers alone do not translate to a better quality system. Professional companies must understand the solids content and spread rates for each product and how it translates to the coating’s final DFT (Dry Film Thickness). Consequently, they use mathematical formulas to determine how much product needs to be applied per square foot, given the type of material used. This specific calculation allows for an accurate coating thickness and predictable long-term performance

One-Day garage floor companies proclaim that their products can be installed in extreme temperature conditions. While this may be true, it is not relative to semi-exterior industrial epoxy installations, particularly on garage floors.

It is common sense that there is a significant difference between the temperature of the concrete substrate and the ambient temperature. The main focus during a quality coating installation is the temperature of the concrete itself. Since garages are not typically directly exposed to the elements, the concrete temperature in garages stays relatively constant (between 35 – 75 degrees) throughout all seasons in most parts of the country. These temperatures are well within the installation parameters of industrial epoxy. Additionally, all polymer coatings manufacturers offer cold or warm-weather hardeners, to allow contractors to adjust the speed of the curing process, without jeopardizing the quality of the bond between resin and concrete.

Science and chemistry suggest that using the best attributes of each specific product within a coating system will deliver the best overall results for the customer. Industrial-strength epoxy is a better all-around product for the base coat within a full broadcast garage/basement floor system, due to its proven ability to form a permanent mechanical AND chemical bond directly to the concrete substrate.

Likewise, the attributes of polyaspartics are better suited to be applied as a top coat, in order to utilize their abrasion, chemical, and uV resistance as the system’s protective coat. Therefore, using a hybrid system of industrial-strength epoxy as a base coat and polyaspartic as a top or clear coat is the preferred industrial methodology for installing a full-broadcast flake system, these systems provide the best characteristics of both industrial-strength epoxy and polyaspartic, providing a best-in-class system that is durable, chemical resistant, abrasion resistant and uV stable and is why they have been the favored system of industrial, commercial and residential contractors for decades!