Epoxy mortar stands as the strongest option in the epoxy flooring family, engineered specifically to withstand:

• Extreme mechanical stress
• Heavy impact forces
• Harsh chemical exposure
• Continuous heavy traffic

Ideal for demanding environments including factories, workshops, loading bays, warehouses, and food processing facilities.

Core Functions of Epoxy Mortar Systems

• Substrate Repair - Effectively fills holes, cracks, and levels uneven concrete surfaces, creating a smooth, uniform base for further applications.
• Reinforcement Layer - Provides a tough base layer that significantly extends the entire floor system's lifespan, preventing premature failure.
• Load Resistance - Engineered to handle heavy forklifts, industrial machinery, and continuous vibration without showing signs of damage or wear.
• Improved Adhesion - Creates an exceptionally strong bonding surface for subsequent layers such as epoxy coating or self-leveling applications.

Exceptional Benefits for Industrial Environments

• Ultra High Compressive Strength - Withstands extreme pressure and weight without cracking or deforming.
• Superior Chemical Resistance - Protects against acids, alkalis, solvents and other aggressive substances.
• Substantial Thickness - Builds floor thickness from 3mm to 8mm or more, providing exceptional durability.
• Cost-Effective Long-Term Solution - Higher initial investment offset by significantly reduced maintenance and replacement costs.

The Installation Process: First Stages

• Surface Preparation - Thoroughly clean the substrate using a grinder or scarifier to create a rough profile. Remove all contaminants including oil, moisture, and laitance to ensure proper adhesion.

Note: Surface preparation is critical4 up to 80% of epoxy flooring failures stem from inadequate prep work

• Primer Application - Apply a specialized epoxy primer to improve adhesion. This creates a chemical bond between the concrete substrate and the mortar layer, preventing future delamination.

Allow the primer to become tacky but not fully dry before proceeding to the next stage.

• Mortar Mixing - Combine 3 parts quartz sand with 1 part epoxy resin/hardener. Mix thoroughly until a uniform, dough-like consistency is achieved. Work in small batches to prevent premature curing.

The Installation Process: Final Stages

• Trowel Application - Hand-trowel or power-trowel the mixture to the desired thickness. Compact it tightly to eliminate air pockets which could compromise strength.
• Curing Time - Allow the mortar to set for 8-24 hours, depending on the specific system and environmental conditions. Maintain temperature control during curing.
• Topcoat Application - Apply an epoxy coating or self-leveling layer over the hardened mortar for enhanced aesthetics and additional chemical resistance.

When to Specify Epoxy Mortar Systems

• Repairing Damaged Substrates - Ideal for restoring old, worn or severely damaged concrete floors that require structural repair before finishing.
• Creating Floor Slopes - Perfect for building proper drainage slopes in wet processing areas, wash bays, and food manufacturing facilities.
• Heavy Machinery Areas - Essential underneath heavy equipment, assembly lines, and high-traffic zones where maximum durability is required.
• Base for Premium Finishes - Creates a robust foundation when applying decorative self-leveling epoxy over structurally compromised substrates.

Key Takeaways & Next Steps
Summary:

• Epoxy mortar provides unmatched strength for extreme industrial environments.
• Offers both structural repair and reinforcement capabilities.
• Requires precise installation but delivers exceptional long-term value.

How to Proceed:

• Consult with a certified epoxy flooring specialist to evaluate your specific requirements .
• Request material samples and on-site testing for your environment.
• Consider lifetime cost calculations rather than just initial installation expenses.