Heavy Tonnage Industrial Epoxy Floor System
The Toughest Epoxy Floor Coating on Earth – Engineered for Extreme Traffic & Maximum Durability
We call this our Heavy Tonnage Epoxy Floor Coating for a reason—it's engineered to withstand extreme traffic, both in vehicle weight and high volume. This is a complete turnkey two-layer epoxy floor system that is a whopping 30 mils thick and has a Shore D hardness rating at the top of the chart, exceeding the hardness of all other epoxy coatings and even construction hard hats.
This extra heavy duty industrial epoxy system cures to a high gloss finish that's tough as nails. It easily handles daily caustic wash downs, high heavy impacts, oversize abrasive tires, high performance tires, harsh operating conditions and heavy repetitive traffic such as in most production and repair facilities. This coating has the lowest cost of ownership because it will last the longest.
What's Included in Your Complete System
- High-Performance Primer – Creates the strongest bond to concrete (tougher than most standalone epoxy systems)
- Heavy Tonnage Super Duty Floor Epoxy – 30 mils thick with bunker-concrete hardness
- 18" Calibrated Application Squeegee – Ensures proper thickness application
- Application Tools – Mixing wand, rollers, spike soles, and buckets included
- DIY-Friendly Design – Can be easily applied by anyone with no prior experience required
The only thing you need to supply is elbow grease and Xylene for cleanup. Be sure to clean anything that is not supposed to be coated before it cures—once cured it can only be removed by mechanical means.
What Makes Heavy Tonnage Different
- 3 mg Abrasion Loss Rating – Many times harder than construction hard hats (competitors rate 25+ mg)
- Chemically Hardened Formula – Cures to bunker-concrete hardness for extreme durability
- Highest Quality Primer – Creates the strongest possible bond to concrete
- Forklift Tested – We've driven forklifts with blades down over this floor with no adverse effects
- 30 Mils Thick – Complete two-layer turnkey system for maximum protection
- Shore D Hardness at Top of Chart – Exceeds all other epoxy coatings
The Bottom Line: Once you get over 25 mg abrasion loss, you're no better off than using semi-gloss wall paint from your local paint store.
Proven Performance in Real-World Applications
We don't know of any other epoxy floor coating that could handle this kind of floor traffic. This huge aluminum factory has giant forklifts running around moving extremely heavy skids with coils of aluminum from production areas to storage areas, all the while not being gentle at all when picking the skids up or placing them down.
You might be wondering why we have a picture of a dog kennel in the Heavy Tonnage picture gallery. Well it's because dogs have sharp nails and they like to dig. This is the only coating that dogs that like to dig can't harm.
See It In Action
Watch this video of a beautiful installation of medium gray in a service shop. Notice how light-reflective the coating is with LED lighting. The bluish hue is from the reflection of all the blue lifts; the actual color is a true medium gray as shown in the color chart.
Need to Go Over Existing Coating?
Bonding Primer Option: If going over an existing coating or steel plate, select the Bonding Primer. We'll switch out the standard primer at no extra charge. The Bonding Primer will bond to any previous paint, epoxy or steel and is odorless.
Odorless Primer Option: If applying to bare concrete in an occupied space, select the Odorless Primer to avoid unpleasant odors disturbing employees.
States requiring Low VOC: CA, CT, DE, IL, IN, MD, MA, ME, NJ, NY, OH, PA, RI, VA, KY and all of Canada. Orders shipping to these states require that the Low VOC option be selected for the size kit you need in the Size dropdown box.
Minimum order size is 550 square feet and ordered in 100 square foot increments.
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Colors Not Listed That Are On Color Chart Are Available As Special Order Of 5000 Sq Ft Or More
Traffic Yellow & Safety Yellow Available IN Small Quantities For Line Stripping.
ENTER THE SQUARE FOOTAGE OF YOUR FLOOR PLUS AT LEAST A 10% SAFETY FACTOR TO ALLOW FOR DIFFERENT POROSTIES, EVERY CONCRETE FLOOR IS DIFFERENT. PLEASE ROUND UP TO THE NEXT FULL HUNDRED SF INCREMENT. EXAMPLE: IF YOUR ACTUAL FLOOR SIZE IS 1050 SF + SAFETY FACTOR =1155, ORDER 1200 SF.
PLEASE NOTE THAT LIGHTER COLORS SUCH AS WHITE AND OFF WHITE AND HIGH PIGMENT COLORS SUCH AS YELLOW, RED & BLACK MAY YIELD LESS COVERAGE.
Below we go through the three steps of doing this type of floor. This requires 1-2 days of installation and another couple of days to let the final epoxy coating fully harden. The epoxy flooring system is designed for 10-15 yrs of heavy duty service.
While installation of the epoxy flooring system requires proper floor prepping. Many times installation can be accomplished while maintaining the facility in full service by doing the floor in sections. For faster installation use our No-Prep Instant Primer. That allows you to prime over minimally prepped concrete and epoxy over it 15 minutes later.
STEP 1 - Preferred method of preparation is a diamond grind to get the floor clean. For oil and grease stains scrub in some Liquid Tide with Muriatic acid, let acid work for 5-6 minutes then rinse off. Repeat as necessary and then rinse with TSP powder on the final rinse to neutralize. Repair any cracks or spalled concrete with one of our repair kits after cleaning. For heavily oil stained floors that cannot be cleaned select the oil primer option.
If acid etching you must etch twice with a 2 gallon of water to 1 gallon of muriatic acid solution for 300 sf. Etch then rinse and then etcha gain and prior to rinsing the second time lightly brush in TSP powder at the rate of 1 lb/1000sf to neutralize.
See the HOW TO PREP AND EPOXY PAINT YOUR FLOOR for further preparation details.
STEP 2 - Apply the high performance epoxy primer coat or the oil primer if oil cannot be removed from floor completely.
STEP 3 - When primer is dry to the touch(5-6hrs) apply the epoxy at a 125 sf/gal rate. We recommend spreading the floor epoxy with our calibrated notched squeegee first then back rolling over it to smooth it out. Do not mix more than 1 gallon per person rolling. This is a high catalytic reaction epoxy and the more you mix the faster it sets up. Do not mix on high speed, this will infuse air into the epoxy. Make sure to move the mixer all around the bucket to ensure you mix all the epoxy at the bottom and edges of the bucket. After mixing the part A & B together transfer from mixing bucket to smaller pails and give it a quick remix. Then pour the epoxy directly on the floor in a bead from left to right, squeegee and back roll(Do Not Leave Mixed Epoxy In Bucket). Then repeat till done. For nonslip finish purchase 1 unit of heavy duty nonslip per 500 sf of floor, evenly broadcast the nonslip onto the epoxy after squeegeeing but before you back roll, this is where spike soles really come in handy(Included on orders of 2000sf or more). Once the floor epoxy is dry to the touch(8-12hrs) you can walk on it and put light traffic on it. Let floor cure for 2 days to reach full hardness before putting heavy vehicles on it.
Mix primer Part A & Part B at the indicated ratio on product label. Apply with supplied roller as you would regular paint. Allow primer to dry 4-8 hrs until dry to the touch without leaving a fingerprint.
Next mix the Heavy Tonnage epoxy in a 2:1 ratio with supplied mixing wand for 2 1/2 minutes. Do not mix more than you can apply in 30 minutes. We recommend 1 gallon of mixed epoxy per person rolling. If mixing more then one gallon, split the epoxy into separate pails for each person rolling.
Once mixed pour the epoxy directly onto floor (Do Not Leave In Bucket) in a left to right bead and squeegee up and down with the supplied calibrated squeegee. Do not try to roll out directly without squeegeeing first, this is epoxy is way too thick for that. If using nonslip additive mix in one pint per gallon of epoxy. Once squeegeed back-roll with to even out and do final spreading of epoxy. Failure to back-roll will result in a coating that is too thick and you will consume much more material. Repeat the mixing, squeegee and back-roll process until floor is done. Allow epoxy to dry over night. Light traffic next day. Heavy traffic the second day.
It's important that your floor looks like the cleaned floor below, even though this is a garage floor the concept for your industrial application is the same. The floor must be prepped properly.
BEFORE & AFTER OF A PROPERLY PREPPED FLOOR THAT WAS GRINDED CLEAN
THE FLOOR PREP MACHINE RENTED FROM HOME DEPOT DID A GREAT JOB, OIL STAINS WERE CLEANED WITH LIQUID TIDE AND MURIATIC ACID. FOR FLOORS LARGER THAN 3000 SF WE RECOMMEND YOU USE THE LARGEST COMMERCIAL GRINDING MACHINE YOU CAN RENT WITH NEW 25-30 DIAMOND BITS.
BEFORE
AFTER
This is the epoxy flooring system you use when you're worried about traffic wearing out the coating.
This is a worry-free floor coating that's virtually indestructible. There are many uses for this product and we've found it is often the only coating that can survive in certain extreme applications.
Typical Applications
Aviation & Aerospace
- Jumbo jet hangars
- Aircraft assembly plants
- Maintenance facilities
Medical Facilities
- Operating rooms
- Recovery rooms
- Patient rooms
- Emergency rooms (ERs)
Manufacturing & Production
- High-production floors with heavy forklift traffic
- Pallet jack & autonomous vehicle traffic
- Automotive assembly plants
- Machine shops
- Clean rooms
Automotive & Repair
- Auto body shops with dropped power tools
- Large commercial auto repair shops
- Diesel repair shops
- High abrasive debris environments
Commercial Spaces
- Office floors (grinding office chair wheels)
- Large warehouse floors
- High-volume hallways
Food & Beverage
- Brewery floors
- Cafeterias with constant chair scraping
- Food processing facilities
Educational Facilities
- School classrooms (desk/chair leg scraping)
- High-traffic hallways
- Cafeterias with dropped stoneware
Retail & Warehouses
- Warehouse clubs with shopping cart traffic
- High dolly & hand truck traffic
- High-volume foot traffic
When standard epoxy fails under extreme conditions, Heavy Tonnage stands strong. Built for the toughest applications on earth.
