Code of practice for laying epoxy resin floor toppings
1986 Edition

Overview of Scope & Key Technical Details

Scope (Clause 2.0):
Defines terminology associated with epoxy resin flooring systems, emphasizing chemical resistance, application methods, and maintenance practices.

Highlights:

• Chemical Resistance (Clause 11.1, Table 1):
  Epoxy flooring formulations are classified based on the hardener category:
  • Amine or Amine-Adduct Hardeners
  • Polyamide Hardeners

• Chemical Resistance Ratings:

  • E: Excellent
  • G: Good
  • S: Satisfactory
  • P: Poor
  • X: Not recommended

• Maintenance Reminder (Clause 12.1.4):
  Immediate removal of spills involving strong solvents such as acetone and trichloroethylene is critical.

Rounding Instructions (Clause 0.5):

• Adhere to IS 2-1960 for rounding test and analysis outcomes.
• Maintain consistent significant figures as outlined in the standard.

Visual Summary: Chemical Resistance of Epoxy Flooring

flowchart TD
    A[Epoxy Flooring Mixtures]
    A --> B[Amine Hardeners]
    A --> C[Polyamide Hardeners]

    B --> D{Chemical Resistance}
    C --> E{Chemical Resistance}

    D -->|Acetic Acid| F[Satisfactory to Poor]
    D -->|Caustic Soda| G[Excellent to Satisfactory]
    E -->|Acetic Acid| H[Satisfactory to Poor]
    E -->|Hydrochloric Acid| I[Poor to Not Recommended]

IS 4631 - Clarifications & Definitions

Terminology (Clause 2.0)

• Defines key terms utilized throughout the standard for clarity.
• Example:
  • Accelerator: As referenced in IS 9197-1979, used to expedite epoxy curing.

Rounding of Values (Clause 0.5)

• Test results and analytical data should be rounded following IS 2-1960.
• Maintain the number of significant figures as specified.

Chemical Resistance Table (Clause 11.1)

• Resistance of epoxy flooring to various chemicals at 20°C varies by hardener type:

Legend:

• E = Excellent
• G = Good
• S = Satisfactory
• P = Poor

Diagram: Chemical Resistance Ratings

graph LR
A[Chemical] -->|Amine Hardeners| B(E/G/S/P)
A -->|Polyamide Hardeners| C(E/G/S/P)
B --> D[Rating Scale]
C --> D
D --> E[Excellent]
D --> F[Good]
D --> G[Satisfactory]
D --> H[Poor]

Note: Always reference IS 9197 for accelerator specifications and IS 2 for rounding guidelines to ensure accuracy and compliance.

IS 4631: Material Standards for Epoxy Resin Flooring

Aggregates

• Must meet the requirements of IS 9197:1979.
• Proper grading and cleanliness ensure longevity and performance.

Accelerators

• Should comply with IS 9197:1979.
• Utilized to manage the curing duration of epoxy resins.

Chemical Resistance (Clause 11.1)

Refer to full Table 1 in Clause 11.1 for comprehensive chemical resistance details.

Material Properties

• Epoxy resins, hardeners, and mixtures must adhere to IS 9197 standards.
• Proper selection is essential to withstand chemical exposure and mechanical demands.

flowchart TD
  A[Materials] --> B[Aggregates (IS 9197)]
  A --> C[Accelerators (IS 9197)]
  A --> D[Epoxy Resin Composition]
  D --> E[Chemical Resistance Table]
  E --> F[Amine Hardeners]
  E --> G[Polyamide Hardeners]

Summary: Use aggregates and accelerators conforming to IS 9197. Consult Clause 11.1 Table 1 for chemical resistance to select appropriate resin and hardener combinations based on exposure conditions.

IS 4631: Basic Requirements for Epoxy Resin Flooring

Specifications:

• Aggregates: Should comply with IS 9197-1979 (Clause 3.6).
• Rounding: Testing outcomes must be rounded as per IS 2-1960, preserving significant figures (Clause 0.5).

Chemical Resistance (Clause 11.1, Table 1):

Epoxy flooring formulations exhibit different resistance levels to chemicals at 20°C, categorized as:

• E: Excellent
• G: Good
• S: Satisfactory
• P: Poor

Notes:

• Choose epoxy type based on anticipated chemical exposure.
• Use aggregates and materials as per referenced Indian Standards for durability.
• Ensure testing precision following IS 2-1960.

flowchart TD
    A[Epoxy Flooring] --> B{Hardener Type}
    B --> C[Amine Hardeners]
    B --> D[Polyamide Hardeners]
    C --> E[Chemical Resistance: E, G, S, P]
    D --> F[Chemical Resistance: E, G, S, P]
    E --> G[Select mix according to chemical exposure]
    F --> G

This ensures adherence to general requirements and chemical durability as per IS 4631.

IS 4631: Varieties of Epoxy Resin Floor Coverings

Important Points from IS 4631 and IS 9197-1979:

• The nature of epoxy resin floor toppings depends on the resin and hardener composition (Clause 0.3).
• Properties must comply with IS 9197-1979 (Clause 4.1).
• Two primary categories of epoxy resin floor toppings (Clause 5.0):

Types:

1. Self-Leveling Epoxy Floors

   • Feature a smooth, glossy surface.
   • Ideal for areas requiring chemical resistance and ease of cleaning.
   • Typical thickness ranges from 1.5 to 3 mm.

2. Epoxy Mortar Floors

   • Contain high aggregate content.
   • Offer superior mechanical strength and abrasion resistance.
   • Thickness generally from 6 to 12 mm.
   • Suitable for industrial floors subjected to heavy traffic.

Additional Points:

• Special finishes are available for unique requirements.
• For heavily filled toppings, applying a seal coat with unfilled resin is recommended to improve adhesion.

Typical Composition Example:

flowchart LR
    A[Epoxy Resin Floor Coverings] --> B[Self-Leveling]
    A --> C[Epoxy Mortar]
    B --> D[Thin, smooth surface]
    C --> E[Thick, aggregate-rich]
    D --> F[Chemical resistance]
    E --> G[High abrasion resistance]

For detailed mix designs and mechanical properties, consult IS 9197-1979 and resin manufacturer specifications.

IS 4631 - Recommended Thickness for Epoxy Resin Floor Layers (Clauses 6.1 & 6.5)

Important Notes:

• Thickness directly influences durability, chemical resistance, and mechanical strength.
• Non-slip surfaces can be created by scattering grit onto the epoxy surface while still tacky (Clause 5.4).
• Thickness choice depends on traffic load, thermal conditions, and chemical exposure.

Chemical Resistance Summary (Clause 11.1 Table 1)

• Epoxy systems cured with Amine or Polyamide Hardeners exhibit different resistance levels.
• Refer to the full chemical resistance table for specific chemicals.
• Resistance ratings: E (Excellent), G (Good), S (Satisfactory), P (Poor).

flowchart TD
    A[Epoxy Resin Flooring] --> B[Trowel Type]
    A --> C[Flow Type]
    A --> D[Terrazzo Floors]

    B --> B1[4 mm - Standard Use]
    B --> B2[6.5 mm - Heavy Traffic/Thermal Shock]

    C --> C1[2 mm - Thin Application]

    D --> D1[10 mm - Heavy Duty]

    style B1 fill:#a2d5f2,stroke:#000,stroke-width:1px
    style B2 fill:#f9d5e5,stroke:#000,stroke-width:1px
    style C1 fill:#a2f2a2,stroke:#000,stroke-width:1px
    style D1 fill:#f2dba2,stroke:#000,stroke-width:1px

Summary: Apply minimum thicknesses based on usage and environmental conditions: 4-6.5 mm for trowel finishes, 2 mm for flow types, and 10 mm for terrazzo floors to achieve optimal performance.

IS 4631: Guidelines for Mixing and Applying Epoxy Resin Flooring

Mixing Process (Clauses 7.1 & 9.1)

• Components: Combine resin, hardener, and aggregates (if applicable) in specified ratios.
• Sequence: Add resin first, then hardener, followed by dry aggregate.
• Mixing Methods:
  • Prefer power mixers with effective shearing action.
  • Hand mixing permissible for small-scale work.
  • Continuous mixers allowed for flowable mixes.
• Mixing Duration: Long enough to ensure homogeneity but within the pot-life limit.
• Aggregate Condition: Must be dry to prevent moisture contamination.

Application (Clause 7.2)

• Employ standard tools such as trowels, notched spreaders, and screeds.
• Avoid using water or detergents on tools since epoxy is sensitive to moisture.
• Ensure all equipment is dry when contacting the epoxy mix.

Special Preparation for Heavy Fills (Clause 9.2.2)

• For heavily filled trowel compounds, first apply a tack coat of unfilled resin-hardener mixture.
• Allow the tack coat to reach a tacky state before topping.

Mixing & Application Summary

flowchart TD
    A[Begin Mixing] --> B[Add Resin]
    B --> C[Add Hardener]
    C --> D{Add Aggregate?}
    D -- Yes --> E[Add Dry Aggregate]
    D -- No --> F[Mix Thoroughly]
    E --> F
    F --> G[Apply Within Pot Life]
    G --> H[Spread Using Dry Tools]
    H --> I{Heavy Aggregate?}
    I -- Yes --> J[Apply Tack Coat and Cure to Tacky]
    J --> K[Apply Trowel Mix]
    I -- No --> K

IS 4631 – Guidelines for Preparing Floor Surfaces Prior to Epoxy Flooring

Essential Procedures

• Concrete Surface Preparation (Clause 8.2):

  • Base concrete must be fully cured and dry.
  • Surface roughness achieved through sand blasting or hacking.
  • Remove surface laitance by washing with 10-15% dilute hydrochloric acid for about 15 minutes until bubbling ceases.
  • Thoroughly rinse the surface using water or dilute ammonia; verify pH with litmus paper.
  • Ensure complete drying before applying epoxy.
  • Remove any grease or oils using solvents like acetone or detergents.
  • Repair any cracks or damaged areas with fresh concrete and allow full curing before topping.
  • In case of heavy contamination, perform scarification or wire brushing.

• Non-Skid Floor Preparation (Clause 5.4):

  • Distribute appropriate grit on the epoxy surface while it remains tacky to enhance slip resistance.

• Application Equipment (Clause 7.2):

  • Use conventional tools such as trowels, notched spreaders, and screeds.
  • Do not wet tools with water or detergents, as epoxy is moisture-sensitive.

Surface Preparation Summary Table

flowchart TD
    A[Existing Concrete Floor] --> B[Assess Structural Integrity]
    B --> C{Are Cracks or Damage Present?}
    C -- Yes --> D[Repair and Cure Concrete]
    C -- No --> E[Clean Surface]
    E --> F[Remove Laitance with Dilute HCl]
    F --> G[Roughen Surface by Sandblasting/Hacking]
    G --> H[Dry Surface Thoroughly]
    H --> I[Apply Epoxy Resin Floor Topping]

IS 4631: Procedures for Applying Epoxy Resin Floor Toppings

Material Requirements

• Epoxy resins and hardeners should comply with IS 9197:1979.
• Proper mix proportions are critical to achieve desired mechanical and chemical performance.
• Consult resin manufacturers for exact formulation details.

Types of Epoxy Toppings

• Different types exist depending on filler content and intended use.
• Heavily filled epoxy compounds might require an initial seal coat of unfilled resin.

Application Steps (Clause 9.2)

• Prepare the surface to be clean, dry, and free from dust or oils.
• Apply primer coat if recommended.
• Mix resin and hardener thoroughly following manufacturer instructions.
• Evenly spread the epoxy topping using trowels or rollers.
• Allow adequate curing time under specified environmental conditions.

Typical Properties (per IS 9197)

Application Workflow Diagram:

flowchart TD
    A[Surface Preparation] --> B[Primer Application]
    B --> C[Mix Resin & Hardener]
    C --> D[Apply Epoxy Coating]
    D --> E[Curing and Finishing]

Note: Always follow detailed instructions from manufacturers and IS clauses.

IS 4631 – Guidelines on Curing Epoxy Resin Flooring

Although the standard does not provide detailed curing formulas, it includes important instructions and considerations:

Key Curing Aspects (from IS 4631):

• Surface Preparation: For heavily filled trowel compounds, apply a tack coat of unfilled resin-hardener mix by brushing, allowing it to cure to a tacky consistency before applying the topping (Clause 9.2.2).
• Expansion Joints: These must align with joints in the base concrete and be filled with flexible, chemically resistant material (Clause 9.4).
• Chemical Resistance: Proper curing influences chemical resistance; see Table 1 (Clause 11.1) for ratings at 20°C.

General Industry Practices:

• Temperature: Maintain ambient conditions between 20°C and 30°C for optimal curing.
• Duration: Full cure typically requires 7 days; initial tackiness occurs within 4-6 hours.
• Humidity: Keep humidity low to avoid moisture interference.
• Mix Ratios: Follow exact resin-to-hardener ratios to ensure proper reaction.

Chemical Reaction Representation:

[ \text{Epoxy Resin} + \text{Hardener} \xrightarrow{time, temperature} \text{Cross-linked Polymer (Cured Epoxy)} ]

Chemical Resistance Summary (Excerpt)

flowchart LR
    A[Mix Resin & Hardener] --> B{Apply Tack Coat?}
    B -- Yes --> C[Tack Coat Cures to Tacky Stage]
    C --> D[Apply Filled Trowel Compound]
    B -- No --> D
    D --> E[Allow Full Cure (7 Days)]
    E --> F[Achieve Required Chemical Resistance & Strength]

Note: Always consult resin manufacturers for specific curing instructions.

IS 4631: Assessment of Chemical Resistance in Epoxy Flooring (Clauses 10.1 & 11.1)

Key Information:

• The chemical resistance depends on the hardener category:
  • Amine or Amine-Adduct Hardeners: Offer superior chemical resistance.
  • Polyamide Hardeners: Provide enhanced impact and temperature resistance but somewhat lower chemical resistance.

Chemical Resistance Ratings at 20°C:

Notes:

• Ratings explained: E = Excellent, G = Good, S = Satisfactory, P = Poor, X = Unsatisfactory.
• Performance varies with chemical concentration, combined chemical/mechanical stresses, and temperature.
• Polyamide hardeners are recommended for floors exposed to impact and temperature variations despite slightly lower chemical resistance.

Chemical Resistance Visualization:

flowchart LR
    A[Epoxy Resin Flooring] --> B{Hardener Type}
    B --> C[Amine Hardeners]
    B --> D[Polyamide Hardeners]
    C --> E[Higher Chemical Resistance]
    D --> F[Better Impact and Temperature Tolerance]
    E --> G[Ideal for High Chemical Exposure]
    F --> H[Ideal for Mechanical Stress and Temperature Variations]

Refer to Table 1 in Clause 11.1 for detailed chemical resistance data.

IS 4631 – Upkeep of Epoxy Resin Floor Surfaces

Maintenance Essentials (Clauses 12.1 & 12.1.4)

• Epoxy resin floors require minimal maintenance.
• Important: Promptly clean spills of strong solvents such as acetone and trichloroethylene to avoid surface damage.

Chemical Resistance Summary (Clause 11.1 - Table 1)

• Epoxy floors cured with amine hardeners generally have superior chemical resistance compared to those cured with polyamide hardeners.
• Polyamide-cured floors are better suited for conditions involving impact and temperature fluctuations.
• Chemical resistance depends on:
  • Chemical type
  • Concentration
  • Mechanical stresses
  • Temperature variations

E = Excellent, G = Good, S = Satisfactory, P = Poor

Maintenance Tips:

• Immediately clean solvent spills.
• Choose polyamide-cured epoxy for floors exposed to mechanical and thermal stresses.
• Conduct periodic inspections to detect any damage early.

flowchart TD
    A[Solvent Spill] --> B{Type of Solvent?}
    B -->|Acetone or Trichloroethylene| C[Immediate Removal]
    B -->|Other Solvents| D[Clean per Resistance Guidelines]
    C --> E[Protect Flooring]
    D --> E

For comprehensive chemical resistance information, consult Table 1, Clause 11.1 of IS 4631.