Floor & Concrete Coatings — Epoxy, PU & Acrylic Formulation Handbook
About this book
Floor & Concrete Coatings — Epoxy, PU & Acrylic Formulation Handbook is a comprehensive technical reference covering 40 validated starting-point formulations across the full range of industrial floor and concrete coating chemistry — from economy waterborne epoxy primers to premium near-solvent-free systems, 3-component PU-cement hybrids for HACCP environments, MMA reactive coatings curing at −20°C, ESD conductive floor coatings for electronics manufacturing, and crack-bridging elastomeric acrylics for outdoor concrete. Written for industrial coatings formulators, paint manufacturers entering the floor coatings segment, and construction chemicals producers, every formulation is anchored to the concrete substrate science, stoichiometric calculations, and performance standards that define this demanding market.
The technology
The handbook develops the distinct chemistry of each coating family from first principles. Epoxy systems: DGEBA and DGEBF binder selection, EEW/AHEW stoichiometry, WBE dispersion film formation, reactive diluent chemistry (BDDE reduces viscosity while crosslinking into the network), cycloaliphatic vs aromatic curative selection, amine blush prevention and moisture tolerance. Polyurethane systems: aliphatic HDI/IPDI trimer crosslinkers for non-yellowing topcoats, aromatic MDI for PU-cement, NCO:OH ratio, isocyanate moisture sensitivity and supplied-air respirator requirements. PU-cement: interpenetrating polymer-mineral network formation, OPC/CAC cement hydration, PMDI crosslinking, and thermal shock resistance mechanism. MMA reactive coatings: BPO/DMPT redox initiation kinetics, inhibitor (MEHQ) management, gel time control, cold-cure thermodynamics, and ATEX manufacturing requirements. ESD coatings: carbon black DBP absorption as proxy for conductivity, percolation threshold theory, carbon fibre aspect ratio effects, IEC 61340-4-1 resistivity measurement protocol. Waterborne acrylics: coalescence film formation above MFFT, HEUR thickener associative network, UVA+HALS photostabilisation, and crack-bridging elongation mechanics.
Inside the formulations
All 40 formulations are structured across Economy, Mid-range, Premium and Specialty tiers in 10 sub-categories covering both WB and SB chemistry families (MMA excepted). Every block gives IUPAC-named component tables (Part A and Part B for 2-pack systems) with % w/w and sourcing tier, PVC relative to CPVC with film property implications, VOC per EPA Method 24, condensed manufacturing method, QC targets with cited test standards, DFT recommendation, application method, pot life, cure window, stability and shelf life, variants and modifications, and a scientific basis explaining the mechanism behind key formulation decisions.
What you get
- 40 starting-point formulations across 10 floor and concrete coating sub-categories
- Both waterborne (WB) and solventborne (SB) chemistries in every sub-category (MMA excepted)
- All 2-pack systems presented as Part A + Part B with stoichiometric mix ratio verification
- PVC/CPVC analysis, VOC per EPA Method 24, and DFT recommendations for every formulation
- PU-cement 3-component system for HACCP food production and thermal shock environments
- MMA reactive formulations with cold-cure capability to −20°C and ATEX manufacturing notes
- ESD floor coating formulations targeting IEC 61340-4-1 antistatic and conductive zones
- QC targets tied to ASTM D4541, D4060, D523, D2240, ISO 2409, ISO 2812-1, EN 13813, IEC 61340-4-1
- Manufacturing SOPs, isocyanate handling protocols, and batch record template
- 50+ raw materials reference table with sourcing tiers, SVHC flags, and substitution notes
- 40+ failure modes across all 10 system types with root-cause and remediation guidance
Technical details
- Format
- A4 PDF · instant digital download
- Extent
- ~300 pages · 40 formulations · 10 sub-categories
- Chemistry
- Epoxy (WB + SB) · PU 2K (aliphatic + aromatic) · PU-cement hybrid · MMA reactive · ESD · WB acrylic
- Standards
- ASTM D4541/D4060/D523/D2240 · ISO 2409/2812-1 · EN 13813 · EN 1504-2 · EN 1062-7 · IEC 61340-4-1 · ANSI A326.3 · EPA Method 24
- Tiers
- Economy · Mid-range · Premium · Specialty
- Audience
- Industrial coatings formulators · floor coating manufacturers · construction chemicals producers · plant engineers
- Series
- Paints & Coatings Handbook Series · Volume 2 · Industrial Protective Coatings · Book 2.05
Industrial floors fail from the formulation up — get 40 validated starting-point formulations across epoxy, polyurethane, PU-cement, MMA reactive, ESD, and acrylic concrete coating systems, covering every market segment from economy warehouse floor to HACCP-certified food production and ESD electronics environments.
Who is this book for?
Industrial Coatings Formulator
You develop or adapt floor and concrete coating systems — epoxy self-levelling, 2-pack PU topcoats, PU-cement, MMA reactive, ESD and waterborne acrylic — and need complete starting-point formulations with EEW/AHEW stoichiometry, PVC/CPVC analysis, VOC calculations, and QC specifications already worked out.
Paint Manufacturer Entering Floor Coatings
You manufacture industrial paints and want to extend into the high-value floor coatings segment — from economy WB epoxy primers through premium near-solvent-free systems to specialty MMA reactive and ESD grades — with manufacturing SOPs, isocyanate handling protocols, and raw material sourcing tiers.
Construction Chemicals Producer
You produce construction chemicals and want to add PU-cement hybrid floor systems, epoxy penetrating concrete primers and crack-bridging elastomeric acrylics to your range with the correct EN 13813, EN 1504-2 and ANSI A326.3 DCOF compliance frameworks built in from the outset.
Table of Contents
- Concrete substrate science: CSP preparation, MVER moisture testing, adhesion mechanisms
- Epoxy chemistry: DGEBA, DGEBF, EPN novolac; EEW/AHEW stoichiometry; WB dispersions
- Polyurethane chemistry: aliphatic (IPDI, HDI) vs aromatic (MDI); NCO:OH ratio; pot life
- PU-cement 3-component chemistry: interpenetrating polymer-mineral network; OPC/CAC binder
- MMA reactive coatings: free-radical BPO/DMPT initiation; gel time; cold-cure to −20°C; ATEX requirements
- WB acrylic floor coatings: coalescence film formation; MFFT; crack-bridging EN 1062-7
- ESD coatings: carbon black percolation theory; IEC 61340-4-1 surface resistivity 10⁵–10⁹ Ω
- Sub-cat 01: WB Epoxy Floor Primer — F1–F4 (Economy WBE → Specialty ESD-compatible)
- Sub-cat 02: WB Epoxy Self-Levelling Topcoat — F5–F8 (Economy → Specialty chemical-resistant)
- Sub-cat 03: SB Epoxy-PU Floor Topcoat — F9–F12 (Economy → Specialty DIN 18032-2 sports floor)
- Sub-cat 04: PU-Cement Hybrid Floor System — F13–F16 (Economy → Specialty HACCP thermal-shock)
- Sub-cat 05: SB Epoxy Self-Levelling Floor Coat — F17–F20 (Economy → Specialty chemical containment)
- Sub-cat 06: WB Acrylic Floor Coating — F21–F24 (Economy → Specialty elastomeric crack-bridging)
- Sub-cat 07: MMA Reactive Floor Coating — F25–F28 (Economy → Specialty cold-cure −20°C)
- Sub-cat 08: ESD Floor Coating — F29–F32 (Economy WB → Specialty conductive IEC Zone 0)
- Sub-cat 09: WB Acrylic Concrete Sealer/Primer — F33–F36 (Economy sealer → Specialty EN 1504-2)
- Sub-cat 10: SB Epoxy Penetrating Concrete Primer — F37–F40 (Economy → Specialty novolac chemical-resistant)
- Equipment and plant requirements for 2-pack epoxy, PU, PU-cement, MMA and WB acrylic systems
- Isocyanate handling and nitrogen-purge protocols for NCO-containing Part B components
- MMA reactive coating manufacture: ATEX Zone 1, BPO segregation, temperature control
- Manufacturing sequence SOPs for all five chemistry families
- Scale-up considerations: HSD tip speed, heat management, HEUR thickener sensitivity, pot life variability
- Batch record template with in-process QC checkpoints
- Master ingredient table for 50+ materials: IUPAC name, role, formulation codes, cost tier, key specification
- Supplier selection and qualification: CoA requirements, REACH SVHC compliance, dual-sourcing
- Indicative cost-tier guide (commodity / mid / speciality) with substitution notes
- Critical inputs: DGEBF vs DGEBA selection, EPN novolac for chemical resistance, MDA-free aromatic amines
- Epoxy failures: delamination, osmotic blistering, amine blush, yellowing, pinholing, wrong mix ratio
- PU failures: CO₂ foaming, soft film, delamination from primer, isocyanate health incidents
- PU-cement failures: surface dusting, delamination, thermal cracking
- MMA failures: no-cure, entrapped bubbles, residual odour, BPO fire incidents
- WB acrylic failures: map cracking, efflorescence, microbial growth, gloss loss
- ESD failures: resistivity out of range, inhomogeneity, too-low resistivity
- Appendix A — Glossary of 40+ technical terms (AHEW, CPVC, CSP, DCOF, EEW, HALS, MFFT, MVER, RCS, SVHC…)
- Appendix B — Test Method References (25 standards: ASTM D4541, D4060, D523, D2240, ISO 2409, ISO 2812-1, EN 13813, EN 1504-2, IEC 61340-4-1, ANSI A326.3…)
- Appendix C — Formulation Index F1–F40 with sub-category, WB/SB, tier, and system chemistry
See what's inside
Frequently asked questions
They are validated starting points. You will need to bench-test and adapt treat rates to your specific raw material lots, but you start from a working formulation — not a blank sheet.
The handbook is a PDF — high-resolution A4, printable, with bookmarks and a linked table of contents. You receive an instant download link and it is also available in your library indefinitely.
Up to 5 downloads are included with your purchase. If you need more, contact us and we will reset your download limit.
Yes. The handbook opens with a fundamentals section that explains the underlying chemistry and ingredient functions before presenting formulations — so beginners can follow the rationale, not just the recipe.
Yes — with one confirmed exception. Every sub-category has both WB and SB formulations except MMA reactive coatings, where no commercial waterborne equivalent exists. The handbook explicitly notes this as a well-established industry constraint, not an omission.
Yes. All 2-pack epoxy and PU formulations are presented as Part A (resin/base) and Part B (hardener/crosslinker) with % w/w component tables for each part, weight mix ratio, stoichiometric verification (NH:epoxide or NCO:OH ratio), pot life at 25°C, and cure schedule.
PU-cement is a 3-component system (liquid PU dispersion + MDI crosslinker + dry cement/aggregate blend) that forms an interpenetrating polymer-mineral network. It delivers 60–90°C thermal shock resistance, pH resistance for HACCP food production environments, and moisture tolerance for wet concrete — properties that standard 2-pack epoxy cannot match. Four formulations are provided across Economy through Specialty (HACCP) tiers.
ESD (electrostatic discharge) floor coatings control static charge accumulation to protect sensitive electronics from discharge damage. IEC 61340-4-1 defines two performance zones: antistatic (10⁶–10⁹ Ω surface resistivity) and conductive (10⁴–10⁶ Ω). The handbook provides four formulations from economy WB epoxy antistatic through specialty solventborne conductive grade, with carbon black loading, percolation theory, and carbon fibre co-conductor design all explained.
Yes. Sub-category 07 (MMA Reactive) includes F28 — Specialty Cold-Cure MMA Floor Coating designed for application and cure down to −20°C, using boosted DMPT accelerator and a co-monomer system that maintains gel time and full cure at sub-zero temperatures. The handbook also notes that most epoxy systems can be adapted for application at ≥5°C using DMP-30 accelerator dosage adjustment, with guidance provided.
