Frequently Asked Questions

What is the key difference between Nitoflor FC130 and Nitoflor Epoxy SL and how should a facility manager or contractor choose between them?

Nitoflor FC130 and Nitoflor Epoxy SL are both epoxy floor coating systems from Fosroc for industrial and commercial concrete floors, but they serve fundamentally different performance tiers and application requirements. Nitoflor FC130 is a thin-film coating (150 to 250 microns DFT) applied in two roller coats over a primer — it seals the concrete surface and provides moderate protection against light foot traffic, dust, oil, and dilute chemicals, but at its thin DFT it does not fill or level the surface texture of the concrete. The floor after FC130 application retains the texture of the prepared concrete substrate — if the concrete was rough or had trowel marks, the FC130 coating is equally rough and textured. This is acceptable for many warehouse and industrial applications but is not suitable for cleanrooms or pharmaceutical floors where a smooth, crevice-free surface is required for hygienic cleaning. Nitoflor Epoxy SL is a self-levelling system applied at 2 to 4 mm DFT that flows to a smooth, level, seamless surface — it fills surface voids and irregularities, producing a flat, glossy, smooth monolithic floor that is easily cleaned to hygienic standards and suitable for pharmaceutical, food, and cleanroom applications. The other key differences are: load-bearing capacity (FC130 is suitable for foot traffic and light wheel loads; Epoxy SL at full thickness supports heavy forklift and pallet jack traffic); chemical resistance (FC130 provides moderate resistance; Epoxy SL at full thickness provides higher resistance suitable for moderate chemical exposure in chemical plants); and cost (FC130 at thin DFT uses significantly less material and is applied more quickly, making it 40 to 60 per cent less expensive per square metre than a full Epoxy SL system). FC130 is the right choice for large areas with light-duty requirements where cost is the primary consideration; Epoxy SL is specified where the floor system must meet heavy-duty, hygienic, or structural requirements.

How is Nitoflor FC130 applied on a freshly built warehouse floor and what is the minimum concrete age before application?

Nitoflor FC130 (and all epoxy floor coating systems) must not be applied to freshly placed concrete that has not fully cured — the minimum concrete age before epoxy coating application is 28 days from concrete pour date. This minimum age is required for two reasons: concrete compressive strength development (epoxy coatings applied before 28-day strength is achieved may have the concrete surface pulling under the surface tension stresses of the curing epoxy resin, causing surface delamination); and moisture content (freshly placed concrete has very high internal moisture content from the gauging water in the mix, and this moisture must diffuse out of the concrete before application — the residual moisture in concrete cured less than 28 days is typically above the maximum allowable moisture content for epoxy application). To verify readiness for FC130 application, two checks should be made: a plastic sheet test (tape a 0.5 m by 0.5 m plastic sheet to the concrete for 16 to 24 hours, then check for moisture condensation under the sheet — if condensation is present, the concrete is too wet for FC130 application); and a hygrometer moisture test at 20 mm depth (the concrete relative humidity at 20 mm depth should be below 75 per cent before FC130 application). If the concrete has cured for 28 days but still fails the moisture test (common in India during monsoon season when the relative humidity is high and moisture diffusion from the slab is slow), the floor coating application must be delayed until the moisture content falls within the acceptable range. Drying the floor with dehumidifiers or low-velocity fans can accelerate moisture reduction. The FC130 application procedure after passing moisture tests: abrasive blast or grind the concrete surface; apply Nitoprime 30 primer (or Nitoprime 25) by roller, allow to cure to touch-dry; apply the first coat of FC130 mixed at the specified base:hardener ratio; allow 16 to 24 hours, then apply the second coat.

Can Nitoflor FC130 be applied over an existing old epoxy floor coating that is worn and chalking and what preparation is needed?

Yes — Nitoflor FC130 can be used as a maintenance recoating product over existing worn, thin epoxy floor coatings on concrete floors in warehouses, factories, and commercial facilities, extending the life of the floor system without the cost and disruption of complete removal of the old coating and full reapplication. This recoating application is common after 5 to 10 years of service when the original epoxy floor coating has worn through in high-traffic areas (exposing concrete), is chalking (UV degradation causing surface powder), or has lost its sheen and is becoming difficult to clean. The preparation required before applying FC130 over an existing old epoxy floor is significantly different from preparation of bare concrete: first, assess the adhesion of the existing old coating to the concrete by a grid cross-hatch test or a pull-off test in multiple representative locations across the floor — if the existing coating is well-bonded to the concrete (no delamination, no hollow areas when tapped), it can serve as a bonding substrate for the new FC130; if large areas are delaminating or lifting, those areas must be removed by grinding before recoating; second, clean the floor surface thoroughly by mechanical cleaning (floor scrubber) and vacuum to remove all oil, grease, contamination, and weak surface; third, abrasive-sand or light-grind the existing coating to remove all surface gloss and chalking (if the old surface is glossy and smooth, the new FC130 will not adhere — it needs a keyed, matt, slightly rough surface for mechanical adhesion); fourth, apply FC130 at the standard two-coat system directly over the prepared old coating without a separate primer (the abraded old epoxy surface acts as the primer interface for the new FC130 coat). A trial area of 5 to 10 square metres should be applied and pull-tested before committing to the full floor recoating to confirm adequate adhesion.