Self-Leveling Resin for Industrial Floors

In recent years, self-leveling resins have garnered significant attention from industry professionals and the general public alike. This is due to their versatility, the ability to be applied in various industrial environments, short curing times, and appealing aesthetic effects with numerous customization possibilities. In this article, we will explore what self-leveling resin is, its characteristics, suitable environments, and the application process.

What is Self-Leveling Resin?

Self-leveling resin, usually epoxy, is a special type of resin capable of leveling itself on horizontal surfaces prepared with primer and pre-treated with a processing cycle. It is created by mixing resin and hardener. The resulting mixture can be applied on substrates such as wood, concrete, tiles, to create a robust and durable surface.

Once hardened, self-leveling resin has a glossy appearance, is waterproof, and abrasion-resistant. Its chemical and mechanical properties remain consistent throughout its thickness, which generally ranges from 2 to 3 millimeters.

Suitable Environments

Self-leveling resins are ideal for environments requiring excellent hygiene and frequent cleaning, such as mechanical, food, chemical-pharmaceutical industries, laboratories, and hospitals. They are often chosen for the uniformity and regularity of the final surface. Transparent self-leveling resins, which allow various objects to be embedded, creating original and pleasant effects, can achieve thicknesses of several centimeters.

Substrate Requirements

The substrate can have minor irregularities or surface damage, as the thickness created by the application cycle (primer + spatula) can level the surface. However, the substrate must be free of significant level differences, which cannot be filled by a material with a thickness of 2-3 millimeters. For major discrepancies, epoxy mortar can be applied beforehand to create a uniform surface for the self-leveling resin.

Advantages of Self-Leveling Resin

Self-leveling resin floors are highly popular in both commercial and industrial settings for several reasons:

• Smooth and Even Surface: The characteristic evenness and load resistance provide added safety in environments where forklifts and pallet trucks frequently operate, transporting heavy loads.
• Low Thickness: With a thickness of about 2.5-3 millimeters, it is thin enough to avoid modifying fixtures, especially during renovations.
• High Durability: Resistant to frequent washing, chemicals, and constant foot and vehicle traffic, making it suitable for specific environments like food industries, pharmaceuticals, hospitals, and laboratories.
• Elasticity: Good elasticity allows for application on floors with minor surface irregularities.
• Reduced Application Times: Quick installation and curing times minimize downtime for work activities.
• High Aesthetic Appeal: Usually matte, it can be made glossy with a "glassy" appearance, providing a nearly seamless and uniform surface.
• Customization: Self-leveling resin can be made non-slip with specific finishes and offers various customization possibilities, such as inserting texts or creating horizontal signage.

Application Environments

Due to its versatility and numerous benefits, self-leveling resin can be used in various industrial and commercial applications. Showrooms and stores can benefit from its glossy finish and customization options, making each space unique. The uniform, impact- and abrasion-resistant surface is ideal for warehouses and storage areas with frequent forklift traffic. These features also make self-leveling resin floors practical for manufacturing companies.

Hospitals, laboratories, and food preparation areas (e.g., industrial kitchens, restaurants, food companies) can benefit from the ease of cleaning and sanitization due to the absence of grout lines. The resistance to oil, fuel, and other chemicals makes it suitable for garages, workshops, and car parks.

Application Process

Regardless of the application cycle type, it is crucial to ensure the substrate is clean and free of contaminants such as grease, oils, and dust. For self-leveling resins, after thorough mechanical preparation and applying a primer, the resin is usually poured and spread with a notched trowel to achieve an even result. Immediately after troweling, a spiked roller is used to eliminate air bubbles trapped during mixing.

Sivit offers various self-leveling cycles for numerous applications and substrates in different conditions. Below, we describe the application phases of the epoxy self-leveling and breathable self-leveling cycles. For other solutions, visit the "Self-Leveling" page.

Sivit Epoxy Self-Leveling Cycle

For concrete substrates without significant issues, we recommend the Epoxy Self-Leveling Cycle, based on solvent-free epoxy resins. If the concrete substrate is newly created, wait for the normal curing time (about 30 days) before applying the self-leveling resin. The substrate must be solid, dry, level, and free of contaminants such as oils, detergents, dust, or other substances.

The application cycle consists of four phases:

1. Primer Application: Apply a layer of Fluidepox, a transparent, solvent-free epoxy formulation loaded with spherical quartz, onto the prepared substrate.
2. Quartz Dusting: While Fluidepox is still fresh, sprinkle additional quartz on the surface.
3. Mortar Application: Prepare the mortar by mixing the two components of Paviplast, a colored, solvent-free, self-leveling epoxy formulation loaded with quartz. Pour the self-leveling mortar, distribute it with a notched squeegee, and level the surface with a spiked roller.
4. Final Surface Treatment: If desired, apply a layer of colored Paviwater diluted with 10% water and add glass microspheres to achieve a non-slip surface. The coating is cut at the concrete joints and sealed with Sigilflex, an elastic and resistant product. The final thickness of the coating is about 2.5-3 millimeters.

Sivit Breathable Self-Leveling Cycle

For substrates with rising humidity, a specific treatment is required to ensure the resin layer remains undamaged over time. Humidity can cause condensation, air bubbles, or even force the resin to detach from the substrate.

Sivit has developed a breathable self-leveling cycle for these types of substrates, consisting of five phases:

1. Ecofondo Application: Apply a roller layer of Ecofondo diluted with 15% water to the prepared substrate. This product creates a moisture barrier and is used as a base layer for damp surfaces.
2. Second Layer of Ecofondo: Apply a second layer of Ecofondo diluted with 10% water and loaded with 10% quartz.
3. Paviwater T68 Application: Apply two roller layers of Paviwater T68, each diluted in water.
4. Paviplast W Application: Pour and distribute Paviplast W, a colored epoxy formulation, with a notched squeegee.
5. Spiked Roller Treatment: Use a spiked roller to create a uniform layer.

The coating is cut at the concrete joints and sealed with Sigilflex, an elastic and resistant product. The final thickness after the process is about 2 millimeters.

For more information on our self-leveling solutions, contact us at +39 011 2730033 or email commerciale@sivit.it.