Self – Leveling Tree-Layer Industrial Flooring

Introducing Self-Leveling Three-Layer Industrial Flooring:

Self-leveling three-layer epoxy flooring is an extremely durable and robust flooring system with unique properties. It is widely used in high-traffic areas such as industrial environments, warehouses, storage facilities, hospitals, and sports venues. These seamless polymeric three-layer self-leveling floorings not only enhance aesthetics, but also provide high resistance to pressure and impact, along with easy and quick cleaning. This product is available in various designs and is used across industrial, commercial, hygienic, sports, and residential applications.

For a high-quality installation of self-leveling three-layer flooring, proper surface preparation and a smooth substrate are essential. The material consumption of self-leveling epoxy must not be less than the calculated amount; otherwise, it will result in poor quality execution. Unfortunately, many contractors overlook this aspect, leading to unpleasent final results.

Mandana Polymer Engineering Company, a knowledge-based and research-driven enterprise, has developed the technical expertise to manufacture various polymeric products through years of research and innovation. The seamless polymeric self-leveling flooring is produced industrially, commercially, and residentially at the Mandana Polymer Industrial Complex. In addition to manufacturing products, Mandana Polymer provides specialized consultancy services for epoxy flooring installation and supervision.

Key Features of Self-Leveling Three-Layer Industrial Flooring:

• Waterproof and moisture-resistant
• Impact and abrasion-resistant
• Seamless and impermeable surface
• Antibacterial properties
• Chemical-resistant
• Long lifespan
• Customizable color options (RAL color collection)
• Easy to clean
• Lightweight, reducing overall structural weight

How to apply Self-Leveling Three-Layer Flooring?

Step 1: Pre-Installation Checks and Recommendations

• The surface must be completely clean, free of dust, moisture, or contaminants.
• The seams and unevenness of the surface must be leveled.
• If the surface is greasy, it should be cleaned with a degreasing solution and dried before flooring application.
• All tools and containers used for mixing should be entirely clean and free from contamination.
• The flooring materials should be placed at the project site one day before installation.

Step 2: Ensuring Proper Temperature Conditions

• Before installation, measure the surface and material temperatures using a digital thermometer.
• The surface temperature should be between 20°C and 30°C during application. Do not allow the material to freeze. 
• A laser thermometer should be used for surface temperature measurement, as room temperature may differ significantly from the actual surface temperature.

Step 3: Surface Preparation

• Self-leveling epoxy flooring should only be applied over a surface that has been primed with EF10 primer and EF20 undercoat.
• The epoxy application should be performed while maintaining the proper time intervals between layers.

Implementation Process for Self-Leveling Three-Layer Epoxy Flooring:

Materials Required:

Epoxy flooring coating consists of two components: resin and hardener, which are mixed and used in a specific ratio. For detailed information on the mixing ratio and application method, please contact the technical support and consultants of Mandana Polymer Company.

Necessary Tools:

• Surface preparation equipment including shot blasting machine, floor grinding equipment (suitable grinding machine and sander) and industrial vacuum cleaner for concrete preparation
• Electric and manual mixer for precise mixing of epoxy with hardener
• Electric blowers such as hot air blower
• Handheld floor coater (spike roller) for adjusting the thickness and better penetration of epoxy on the surface
• Compressor and airless sprayer for uniform spraying in large-area projects
• Troller and squeegee, comb squeegee (toothed) and applicator rollers (Trowel, bubble roller and wool roller)
• Precise scale for precise measurement of epoxy resin and hardener
• Industrial heater for adjusting ambient temperature in cold weather
• Safety and protective equipment: mask, goggles, work clothes, gloves for chemicals and shoes for epoxy 
• Accessory equipment: anti-foam spray and UV lamp or local light

Steps for Applying Three-Layer Self-Leveling Epoxy Flooring:

1. Treating the surface with primer and undercoating materials

• Surface Preparation: Leveling the floor through grinding or surface preparation techniques following standard protocols.
• Chemical Cleaning: Degreasing oily and greasy surfaces using OP30 degreasing solution.
• Primer Application: Applying EF10 primer with hardener 2260, following the primer application guide. This step is crucial for increasing adhesion to concrete, eliminating dust effects, neutralizing concrete vapor emissions.
• Crack and Gap Filling: Repairing damaged and cracked surfaces using a specialized sealant.
• Undercoat Application: Applying EF20 undercoat with hardener 2225, following the undercoat application guide.
  Sanding & Defect Correction: Addressing imperfections and smoothing out the undercoat layer.

2. Self-Leveling Epoxy Topcoat Application

• Using EF30 topcoat with hardener 2239
• Stirring the topcoat for 2 minutes before adding the hardener
• Mixing hardener with topcoat for 3 minutes
• Allowing the mixture to rest for 1 to 5 minutes before application

Important Considerations:

• Even 10 grams of incorrect hardener proportion can ruin the result.
• All calculations for the correct hardener quantity must be performed using an industrial-grade precision scale.
• Avoid mixing excessive amounts of topcoat and hardener beyond immediate application needs.
• If decorative flakes (flicks) are to be used, they should be sprinkled 15-30 minutes after the topcoat application by tossing them evenly over the surface.
• Curing Time:

Initial drying time per layer: 8 hours
Final curing time per layer: 24 hours

Technical Specifications of Self-Leveling Three-Layer Industrial Flooring:

Abrasion and Scratch Resistance: Fully resistant
Water and Moisture Resistance: Completely waterproof
Chemical Resistance: Highly resistant
Fire Resistance: Non-flammable

Applications and Suitable Surfaces for Self-Leveling Three-Layer Epoxy Flooring:

• Industrial and factory floors, warehouses, and storage facilities
• Hospitals, clinics, and healthcare centers
• Residential applications
• Children’s rooms and kindergartens
• Kitchens, living rooms, and bedrooms
• Bathrooms and sanitary facilities
• Parking ramps and garages
• Sports halls
• Banquet halls, restaurants, and hotels
• Studios and photography/recording spaces
• Elevator floors
• Pharmacies, laboratories, and medical clinics

Physical and Chemical Properties of Self-Leveling Three-Layer Industrial Flooring:

• Application temperature range: 20°C – 30°C
• Final thickness: Approximately 3 mm
• Color: Customizable (Order according to RAL color collection)
• Solvent Content: None
• Application Tool: Trowel
• Initial drying time per layer: 8 hours
• Final curing time per layer: 24 hours

Storage and Considerations for Self-Leveling Three-Layer Epoxy Flooring:

• Packaging: Available in 1 kg containers
• Shelf Life: 12 months in original packaging
• Optimal Storage Temperature: 10-30°C
• Store in a dry place, away from direct sunlight, water, and rain.
• Avoid storing materials at temperatures below 5°C.
• Ensure materials do not freeze inside containers.

Safety and Protection for Self-Leveling Three-Layer Industrial Flooring:

• Protective Equipment: It is recommended to wear Gloves and a mask should be used during installation.
• Health & Environmental Impact: Although epoxy materials do not fall under hazardous classifications, direct contact with skin or eyes should be washed with water immediately.

Standards and Certifications for Self-Leveling Three-Layer Industrial Flooring:

• Certified operating license from the Ministry of Industry, Mine, and Trade
• Knowledge-based enterprise certification
• ISO Certifications: 9001, 14001, 18001, IMS
• BS EN14891 Standard (UK)
• AS/NZS 4858 Standard (Australia & New Zealand)
• Certified by the Research Center for Building and Housing
• The only company in Iran with a factory-specific standard

Self-Leveling Three-Layer Industrial Flooring– Purchase and Warranty:

Epoxy flooring is one of the best options for industrial, commercial, and residential environments, known for its high resistance, long durability, and attractive appearance. This type of flooring, with its seamless and uniform coating, is resistant to moisture, chemicals, and impact, making it an ideal choice for different environments such based on their application. These products are provided with a factory-certified technical approval, operating license, and a 5-year guarantee.

Epoxy Adhesive is manufactured with advanced technologies and offers the best price-to-performance ratio. For purchasing or inquiries about prices, please contact Mandana Polymer’s sales or technical support team.