Epoxy-based flooring is widely used in industrial, commercial, and even residential projects due to its durability, chemical resistance, and clean finish. Two common systems in this category are:

• Epoxy Coating (Thin-Film Roll Applied)
• Epoxy Self-Leveling (High-Build Flow Applied)

Though they share similar base materials, the installation methods and requirements for each are quite different. Below is a detailed comparison from floor preparation to final finish. 🔧 1. Surface Preparation (Common for Both)
Proper floor preparation is crucial for both systems to ensure adhesion and long-term durability.
Steps:

1. Inspection of Substrate
   • Check for cracks, moisture, oil, laitance, or loose particles.
   • Moisture content should be <4% by CM test or per manufacturer's specs.
2. Mechanical Grinding or Shot Blasting
   • Diamond grinding or shot blasting to open pores and remove contaminants.
   • Target surface profile: CSP 2–3 for coatings, CSP 3–5 for SL.
3. Repair and Patching
   • Fill cracks, holes, and damaged areas using epoxy putty or mortar.
4. Cleaning
   • Vacuum dust and debris. Ensure surface is dry and oil-free.

🎨 2. Epoxy Coating Installation (Thin-Film System)
System Overview:

• Typically 0.3mm to 1.0mm thick
• Applied with rollers or brushes
• Designed for light-duty areas such as warehouses, showrooms, etc.

Installation Steps:

Step	Description
Primer	Apply a compatible epoxy primer (roller applied), typically 0.1–0.2mm. Cures for 6–12 hours.
Base Coat / Main Coat	Apply 100% solids epoxy using roller or squeegee and back-rolled to even out. Thickness: 0.2–0.8mm. Can be one or two coats.
Optional Topcoat	Optional polyurethane or UV-resistant clear coat may be applied for extra durability or aesthetics.

Tools:

• Rollers (solvent-resistant)
• Brushes for edges
• Mixing paddles
• Spiked shoes (for walking during wet application)

Cure Time:

• Light foot traffic: 24 hours
• Full mechanical: 3–7 days

🧪 3. Epoxy Self-Leveling Installation (High-Build Flowable System)
System Overview:

• Thickness: 1.0mm to 5.0mm (typical is 2–3mm)
• Applied using notched trowels and spike rollers
• Designed for medium to heavy-duty areas like cleanrooms, pharma, food factories

Installation Steps:

Step	Description
Primer	Epoxy primer with good penetration to seal surface (roller applied). May require sand broadcast for intercoat adhesion.
Scratch Coat (optional)	A thin levelling layer to fill minor surface imperfections before SL coat. Applied with a trowel.
Self-Leveling Layer	Mixed 100% solids epoxy (often with fine fillers) poured and spread using notched trowel to desired thickness. Spike roller used to remove air bubbles.
Optional Topcoat	Optional clear or pigmented PU or epoxy for additional resistance.

Tools:

• Notched trowels
• Mixing drill with helical paddle
• Spike roller
• Gauge rake (for thicker applications)
• Spiked shoes

Cure Time:

• Light traffic: 24–36 hours
• Full cure: 5–7 days

📊 4. Comparative Summary

Feature	Epoxy Coating	Epoxy Self-Leveling
Thickness	0.3 – 1.0 mm	1.0 – 5.0 mm
Application Method	Rollers/brush	Trowel + Spike Roller
Finish	Thin film, visible texture of substrate	Smooth, seamless, high-gloss or satin
Durability	Light-duty	Medium to heavy-duty
Installation Time	Shorter	Longer (more steps and curing)
Surface Imperfections	May show through	Covered/leveled by self-leveling layer
Cost	Lower	Higher (more materials & labor)
Slip Resistance	Can add fine sand	Can add anti-slip aggregates
Best Use	Warehouses, corridors, car parks (light)	Labs, pharma, F&B, showrooms

🛠️ Special Considerations

• Moisture Tolerance: Use moisture-tolerant primer if substrate is not fully dry.
• Temperature: Application temperature usually >10°C and <35°C.
• Ventilation: Ensure good airflow, especially with solvent-based systems.
• Safety: PPE is essential — gloves, goggles, masks (some systems may contain VOCs).

📌 Conclusion
Choosing between Epoxy Coating and Epoxy Self-Leveling depends on:

• Service Load (light vs. heavy traffic)
• Aesthetic Requirements (smooth vs. textured)
• Budget Constraints
• Installation Time and Complexity

While epoxy coating is quicker and more economical for general applications, epoxy self-leveling provides superior durability, aesthetics, and long-term performance in demanding environments.