Heavy-Duty Mortar Epoxy Flooring

Mortar Epoxy Flooring, also known as epoxy mortar screed or troweled epoxy mortar, is a thick, aggregate-reinforced epoxy system applied at 4-10mm or more for superior compressive strength and durability. This heavy-duty coating integrates silica sand or quartz with 100% solids epoxy to form a dense, impact-resistant layer. At Mayon Flooring, our mortar epoxy solutions excel in repairing cracked or pitted concrete while providing a seamless, chemical-resistant surface for high-abuse areas.

Process Overview

Our certified installers ensure precise, professional mortar epoxy application:

Substrate PreparationDiamond grind or shot-blast concrete to remove contaminants and create a strong profile.
Priming & RepairApply epoxy primer; fill deep cracks or pits with mortar patch.
MixingBlend epoxy resin, hardener, and silica/quartz aggregates for a trowel-grade consistency.
Trowel ApplicationHand-trowel the mortar mix evenly, building to desired thickness.
Seeding (Optional)Broadcast additional aggregates for enhanced texture and slip resistance.
TopcoatingSeal with clear or pigmented epoxy for added protection and gloss.
CuringAllow full cure (3-7 days) for maximum hardness.

This labor-intensive process delivers a custom, ultra-durable finish.

Benefits

Mayon Flooring's mortar epoxy flooring stands out with:

Extreme Impact & Abrasion Resistance → Withstands heavy machinery, dropped tools, and forklift traffic.
Superior Compressive Strength → Ideal for repairing damaged slabs and supporting intense loads.
Thermal Shock Resistance → Handles hot/cold cycles in food processing or manufacturing.
Chemical & Stain Protection → Impervious to oils, acids, solvents, and spills.
Seamless & Hygienic → Easy to clean with no joints to trap dirt.
Long-Term Durability → Reduces repairs and downtime for excellent ROI.

Our systems provide the toughest protection, extending floor life in abusive environments.

Where to Use

Mortar Epoxy Flooring is essential for high-abuse settings, including:

Heavy manufacturing plants and factories
Food & beverage processing facilities (USDA/FDA compliant options)
Chemical plants and laboratories
Warehouses with intense forklift traffic
Automotive workshops and service bays
Commercial kitchens and breweries
Loading docks and ramps

Guidance

For best performance, ensure substrate compressive strength >25 MPa and moisture <4%. Typical thickness 6-9mm for resurfacing; thicker for cove bases or slopes. Incorporate anti-slip aggregates for wet areas. We recommend early site survey to evaluate damage, select aggregate size/color, and plan topcoats based on chemical exposure and traffic type.

FAQs

How thick is mortar epoxy applied?

Typically 4-10mm or more, depending on repair needs and load requirements.

Is it suitable for sloped or coved areas?

Yes – trowel application allows custom shaping for drains, ramps, or cove bases.

How long before heavy use?

Light traffic in 24-48 hours; full heavy loads in 5-7 days.

Can it be applied over existing coatings?

Possible with proper preparation and compatibility testing.