When it comes to industrial flooring, choosing the right solution is crucial to ensuring safety, durability, and cost-efficiency. Epoxy and Odus flooring are two popular options, each with unique strengths and limitations. In this article, we will break down these two flooring types, explaining what they are, how they work, and how they perform across essential factors like durability, maintenance, and environmental impact. By understanding these elements, industrial facility managers can make an informed decision on which flooring solution best meets their needs and budget.

Lets start with understanding both Epoxy and Odus first.

What is Epoxy Flooring?

Epoxy floors are created by curing epoxy resins with a hardener, forming a densely cross-linked polymer matrix. The molecular structure is built on repeating epoxide groups which react with amine hardeners. This cross-linking yields a rigid, thermoset network that forms a layer on top of base floor surface.

Typically, factories use a 3-5 mm Epoxy layer on top of base concrete floor.

What is Odus Flooring?

Odus Flooring involves transforming the top most layer of concrete floor to a dustless, smooth, and highly durable surface. Odus chemicals get absorbed inside the top most layer of concrete floor to start concrete regeneration there. Thus reducing porosity of the top most layer and increasing the hardness. Because of this increased hardness, the floors become unaffected by any abrasive forces. Thus transforming normal concrete to more durable, smooth and dust free surface.

While Epoxy works by forming a layer on top of concrete floors, Odus works under the floor surface. Thus it is a 0 thickness solution.

Now comparing Odus vs Epoxy across various parameters

1. Which flooring is best for a dust-free environment?

Epoxy

Epoxy prevents dust by forming a non-porous coating on top of concrete and blocks dust coming from the base floor. However, scratches (Epoxy is prone to scratches) can create rough area that trap dust and dirt overtime.

Odus

Dust emission happens when small particles get eroded from concrete surface. Odus increases the hardness of top most layer of concrete thus making it scratch proof and therefore stops dust emission.

Result: Which Flooring is best for Dustless Environment?

Assuming that the Epoxy coating is intact and damage free – both Epoxy and Odus will equally be successful in creating a floor that doesn’t emit dust.

2. Which Flooring is best for durability?

Epoxy

Generally, the environment of a factory is not suitable for long life of Epoxy coatings. Thus, the average life of Epoxy in factories varies between 9 to 15 months. It starts needing repair or reapplication after that. The following factors contribute to less lifespan of Epoxy in factories and warehouses.

1.    Forklifts and Metal wheeled trolleys scratch and damage the coating

2.    Presence of lubricants weakens the bond of Epoxy with base floor - leading to wearing off

3.    Presence of moisture/ humidity weakens the bond of Epoxy with base floor - leading to wearing off

4.    Tropical Weather conditions in India also lead to pinholes, bubbles and wear of Epoxy fast

Odus

Odus lasts at least 5X longer than Epoxy coatings. All the factors that damage Epoxy - don’t have an impact on Odus.

Result: Which Flooring is best for Durability?

When it comes to durability, Odus is clearly the winner. In a factory environment, when there are multiple damaging forces, Odus should always be preferred against Epoxy.

3. Which Flooring is best suited for Factory Audits?

Epoxy

Since Epoxy wears off in every 9-15 months. It may need to be done each time there is an audit. Therefore, from a long term perspective, it is not recommended to have Epoxy floors if you are an industry that keeps having audits regularly.

However, Epoxy has the advantage of faster application, making it a feasible option for urgent audits.

Odus

Odus provides a long-term audit-readiness flooring, due to its durability, maintaining a clean and compliant surface without the need for frequent application. However, it takes time to execute Odus flooring. Therefore, it is not suitable for urgent audits.

Result: Which flooring is best suited for factory audits?

There are 2 parts to this recommendation

Long Term: If your industry faces audits regularly, it is highly recommended to go for Odus Flooring.

Urgent Solution: If you have an audit coming in next 2 days and need to be ready for it – go for Epoxy flooring.

4.Which is the most cost effective Flooring Solution?

To understand which flooring is most cost effective for factories, lets classify the costs related to flooring under 3 headings:

1.    One time Cost
i.e. the cost incurred to get a particular flooring treatment done once.

2.    Recurring Cost
i.e. the cost incurred over a longer period of time – say 10 years to get repair, maintenance and reinstallation done.

3.    Opportunity Cost
i.e. the cost incurred due to production loss over a longer period of time – say 10 years – while stopping production each time there has to be some re-work on the flooring

One Time Cost of Flooring

One time cost is same for both Odus and Epoxy flooring. The exact price for both depends on the present condition of the floor and the kind of usage that is to be done on the floor.

Recurring Cost of Flooring

Lets calculate the recurring cost of Epoxy flooring

Assuming, the average life of 15 months for Epoxy Flooring. And a one-time installation rate of Rs 85 per SFt. Calculating the recurring cost incurred on Epoxy flooring repair over 10 years.

In 10 years, Epoxy will have to be done in 8 times. (10 x 12/15 = 8)
Therefore the recurring cost incurred = 8 x 85 = Rs 680 per Sft

Considering the fact that most factories end up getting Epoxy flooring each time there is an audit, the above numbers are defensive.

Lets Calculate the recurring cost of Odus Flooring

Due to high durability of Odus, the recurring cost is close to 0 – yes Zero!

At max, once in 3 years, the top most coat might need refurbishing, which will cost 1/3th of Epoxy. (Depending on floor conditions)

Opportunity Cost

Every time there is rework on Epoxy flooring, there would be a shutdown of 2-3 days. More than the cost of flooring, the loss of production is a big problem for factories and warehouses.

 Whereas since no rework is needed in Odus, the production loss is also zero.

Result: Which is the Most cost effective flooring solution for factories?

Considering the overall sum of one-time, recurring and opportunity cost, Odus cost atleast 70-80% lesser than Epoxy flooring options. Therefore when looking for cost effective flooring solutions, Odus is highly recommended.

4.    Which Flooring has lowest Maintenance Requirements?

Epoxy

To keep the appearance and functionality of Epoxy intact, it requires regular and careful maintenance. As described in the Recurring Cost section. It is needed to re-apply coats of Epoxy at regular intervals.

While cleaning also, only mopping with a mild cleaner is recommended for Epoxy. Any strong cleaning agents might end up reacting with Epoxy and degrade the same. Also washing with water is a strict no. Because exposure to water in high volume will in up peeling Epoxy off.

Overall, it’s a high-maintenance option, especially in environments with heavy use or expose to harsh conditions.

Odus

Odus flooring offers a low-maintenance and durable alternative. It can withstand extreme conditions, heavy traffic, and chemical exposure without frequent repair.

Odus is designed for ease of cleaning; it can be washed and mopped with soap and water without risking the surface.

Result: Which Flooring has lowest Maintenance Requirements?

When it comes to low maintenance, Odus is a clear winner. If one needs a worry free and maintenance free flooring – that doesn’t need frequent rework – Odus is a clear choice.

5. Which Flooring looks best in factories and warehouses?

Epoxy

Epoxy offers a polished, seamless finish with customizable color options and gloss level (glossy, satin, matte). It provides a smooth, uniform appearance, making it ideal for environments where aesthetics are a priority.

Odus

The final finish depends on quality of concrete and its condition at the time of application. Also it shows a little cloudy appearance - as it is not a coating on top. Thus the final color depends on the concrete composition. In some areas it also shows exposed aggregates - which are subjective to choice aesthetically. On Edges, corners and repair areas also, the shade of color varies a little.

Result: Which Flooring looks best in factories and warehouses?

When aesthetics are a priority over durability, then Epoxy is recommended. However, if the base floor is good quality and a natural look is preferred, then Odus can also be considered.

6. Which flooring can give and anti-static or Static surface?

Odus does not provide protection against static electricity. For environments with sensitive electronics, it is recommended to use Anti-Static or Static Epoxy flooring, which are designed to safely dissipate static charges and prevent ESD damage.

7. Which flooring helps to get coving on edges and corners?

Coving is the curved transition between the floor and wall that prevents dirt and microbes from accumulating, essential for hygiene-sensitive environments like hospitals, labs, and cleanrooms.

Epoxy

Epoxy is highly suitable for coving as it can be molded to create a precise, smooth, and seamless transition from the floor to the wall. The flexibility of epoxy allows for the creation of the required curve, ensuring there are no gaps or sharp edges where contaminants could hide.  

Odus

Coving cannot be achieved with Odus, as it is a zero-thickness solution and does not allow for the creation of the necessary molded transition between the floor and wall.

Result: Which flooring helps to get coving on edges and corners?

For effective coving, Epoxy is recommended due to its ability to create a seamless, hygienic transition.

8. Which Flooring helps to get an anti-microbial surface?

Floors with high porosity, such as unsealed concrete can trap dirt, liquids, and organic matter in their tiny gaps or pores, creating ideal conditions for bacterial, fungal, and microbial growth. In industries like F&B, Hygiene products and Pharma, this is a big issue. Thus, the flooring needs to be anti-microbial.

Epoxy

When intact, Epoxy provides a non-porous layer above base concrete floors. Even edges and corners can be made microbe free with coving. Thus providing a perfect surface that stops microbial growth.

However, if there are patches on epoxy layer – it exposes the underneath porous concrete. Moreover, forms shallow potholes on the floor (because of level difference thus created). These patches can then become breeding ground for microbes.

Odus

Odus reduces the surface porosity by upto 80% on concrete floors. Thus preventing microbial growth on the top surface.

Also, Odus is more long lasting, so the probability of top layer getting damaged is far less than Epoxy.

However, edges and corners cannot be protected from microbial growth using just Odus.

Result: Which flooring helps to get an antimicrobial surface?

When intact, Epoxy works best to protect top surface, edges and corners from microbial growth. But since it is prone to damage – the damaged surface will not be protected.

Whereas Odus provides a long term protection of the top most surface, but fails to protect edges and corners.

9. Which Flooring is best for the Environment?

As sustainability continues to be a key consideration, the environmental impact of flooring materials plays an essential role in decision-making. Below is a comparison of the environmental footprint of epoxy and Odus flooring:

Epoxy

Requires frequent reapplication, resulting in increased material use, waste, and environmental harm due to disposal and chemical pollution.

Also, it emits VOCs - that are harmful to the environment.

Odus

Offers a longer lifespan, reducing waste and resource consumption.

If compared with Epoxy for a 5 year period, for every 1000 Sqm of flooring, Odus saves atleast 12500 Liters of Water and 6.5 Tons of Carbon emissions.

 Here are the calculations:

Result: Which flooring is best for the Environment?

Because of low resource usage and longer life, Odus is more environment friendly than Epoxy. The image below also shows the impact created by Odus in just first 3 years of its launch.

Summary: Which Flooring Solution is best for Industries?

Summarizing the findings in the following table: