8/10 Factories choose Epoxy or PU as their flooring.

7/10 of these Factories regularly complain about damage and repair of Epoxy and PU coatings.
Forklift operations, careless ground team, oil, lubricants, moisture etc are usually blamed for repeated damage of floor coatings. But there is one and only one reason for it - Floor coatings are not strong enough for a factory environment!

In the article below, we will discuss -

• Why floor coatings get damaged again and again

• How Odus is a better alternative to Epoxy and PU

• Why Odus doesnt get damaged in a factory environment

Why Epoxy and PU coatings get damaged again and again?

How does Epoxy and PU work?

Epoxy and PU coating form a layer over concrete base, thus blocking dust coming out of the flooring. (as shown in the image below)

Initially, these coatings look good and are also successful in creating a dust free environment.

However, problems start to emerge after few months of use.

• One of the main drawbacks of Epoxy and PU coating is their relatively low hardness rating, which is below 2 on the Mohs scale, making them prone to scratches and damage, especially in high traffic areas.

• The bond between the coating and concrete weakens over time due to factors like an inadequate surface preparation, the presence of lubricants, or moisture, resulting in peeling off coating.

How Factories generally repair Epoxy/ PU damage?

We spoke to more than 50 factory managers and discovered a common problem. They said that the average life of Epoxy/ PU coating ranges between 9-15 months. This is a big problem because of frequent audits. Also it hampers continuity of operations and sometimes is even a threat to product quality.

Therefore, to solve this quickly - 83% of factories add another layer of coating on top of existing coats. The diagram below shows what exactly happens in this case.

Here, nothing has changed - neither the material nature of Epoxy, nor the damaging conditions. So again, after a few months - a new layer has to be laid on top.

This continues like a cycle and factories keep on stacking layer after layer of Epoxy/ PU on the floor - as shown below:

Why Stacking Epoxy layer isn’t a sustainable solution for Factory floors?

While adding new layers of epoxy might seem like a quick fix, it often creates more issues than it solves:

1.    Weak bond between Epoxy layers:  The strength of bond between Epoxy (smooth) coating to a concrete (Porous) base is much stronger than the bond between Epoxy coating (smooth) to an Epoxy base (smooth).

2.    Instability of Layers: Each new layer increases the overall thickness, but these thick stacks can be unstable, resulting in faster peeling.

3.    Uneven floor level: Adding more layers of epoxy to an uneven base creates an uneven surface on top. This unevenness isn’t visible to the eye, but forklifts and other vehicles feel every bump. Thus adding stress to the floor, making the coating wear out even faster. This unevenness also affects the vehicles, causing extra wear on their tires and systems.

 Factories end up getting caught in a cycle of adding more epoxy, which quickly wears out and needs another fix, resulting in higher maintenance costs and a shorten the life of the floor.

How Odus is a better alternative to Epoxy and PU?

If “coating” is peeling off – lets not do coating at all!

Odus flooring offers an innovative solution for industrial flooring by addressing the problem at its root. Instead of adding a surface coating like Epoxy, Odus works beneath the ground level to make the floor naturally stronger and more durable.

Thus making the floors dust-proof and scratch-proof by adding 0 (yes Zero) thickness on the floor!

When there is no coating – there is nothing to peel off!

How Odus lasts longer?

While Epoxy and PU form a coating above the floor.

Odus works Below the floor.

Absorption and Regeneration: Odus chemical is absorbed into the topmost layer of concrete, where concrete regeneration happens and increases the hardness of top most layer.

Increased Durability: With a Mohs hardness rating of 4.5 to 6 (For brief overview of the Mohs scale refer to blog https://www.rezovate.com/blogs-for-industries/how-odus-flooring-helps-create-forklift-proof-floor-35 ), Odus is significantly more resistant to damage from heavy and regular operations.

Since Odus does not form a layer on the surface of the concrete, there is no risk of peeling due to weak bonds. This characteristic ensures that the floor retains its integrity over time, reducing the need for frequent maintenance.

Proven Performance in Real-World Applications

The effectiveness of Odus Flooring is not just theoretical; it has been successfully implemented in various industrial settings. A notable example is the P&G Mandideep factory, where Odus was installed in 2018. As of today (2024 November), the floor remains in excellent condition without the need for any rework, showcasing the long-term benefits of choosing Odus over traditional epoxy coatings.

Here are few pictures of the floor.