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Seamless Floors

Introduction… All seamless floors are “manufactured” at the jobsite, so any detail or non-standard configuration of a room can be coated with a poured-in-place flooring system, yielding a clean, monolithic surface.

Seamless flooring is ideal for commercial, industrial, or institutional settings. The partial list below indicates the range of seamless floor applications. Any space where cleanliness, low maintenance, and high overall performance and aesthetics are desired is an opportunity for a seamless flooring system.

• Animal Care Facilities • Detention Facilities • Food Preparation Areas • Laboratories • Manufacturing Areas • Medical Facilities • Pharmaceutical Plants • Research Facilities • Airplane Hangar Floors • Schools • Shower, Locker, & Toilet Rooms • Exterior/Interior Vehicle and Pedestrian Areas

Applications of Seamless Flooring

Characteristics of a Seamless Floor

• No joints

• Non-porous

• Chemical and Stain resistant

• Resistant to Bacterial Growth

• High impact resistance

• High compressive strength

• Self-extinguishing

• Easy to maintain

• Integral Cove Base options

• Customizable finishes, textures

Resinous Flooring Design

Decorative & Non-Decorative

Seamless Floors The seamless floor market segment has two broad-brush distinctions: decorative or non-decorative. Non-decorative seamless floors have a solid color look, with no speckled or mosaic appearance. The binder and topcoat resin is usually one or more thin applications of epoxy, urethane, polyaspartic, or methyl methacrylate (MMA) resin.

PrimerGroutMortar

Non-Decorative Seamless Floor: Mortar System

Topcoat

Key Mortar Systems

Key Mortar Systems EPOXIES

Key Mortar STD• Trowel applied mortar system using graded aggregates + a 100% solids epoxy

as a binder

• Thicknesses can be 3/16” to ¼” • Product is grouted and sealed with a pigmented topcoat• Finish can be smooth to aggressive texture

Key Mortar SL• Specially graded aggregates + 100% solids epoxy as a binder• Product is applied using a V-notched squeegee or trowel• Finished thickness is 1/16”• Finish is smooth

Key Mortar SLT

• Specially graded aggregates + 100% solids epoxy as a binder• Product is applied using a V-notched squeegee or trowel• Allow material to level then broadcast 20/40 mesh silica sand to refusal• Finish with appropriate topcoats• Finished thickness is 1/8”

Key Mortar Systems – EPOXIES

Features Benefits100% Solids Epoxies Low odor during installationHigh tensile/compressive strengths High wear, impact and abrasion

resistanceEase of cleaning Low maintenance costsSeamless installations No grout joints to collect dirtChemical resistant finishes Withstands chemical attacksLight reflective finishes Increased productivityFinished coats can vary in texture Increased safety in plant

Key Urecon Mortar SystemsUrethane Cement Binder Key Urecon TG

• Trowel mortar system that is a urethane modified cementitious topping• Thicknesses can be 3/16” to ¼” • Finish can be smooth to aggressive texture

Key Urecon SL• A modified urethane cementitious slurry system• Product is applied using a V-notched squeegee or trowel• Finished thickness is 3/16” – ¼”• Finish is smooth

Key Urecon SLT• A modified urethane cementitious slurry system• Product is applied using a V-notched squeegee or trowel• Allow material to level then broadcast 20/40 mesh silica sand to refusal• Finish with appropriate topcoats• Finished thickness is 3/16” – ¼””

Key Urecon Mortar Systems Features BenefitsThermal shock resistant Can be cleaned with steamMoisture tolerant Can be installed over high MVT slabsHigh Impact resistance Can be installed in abusive environmentsOne step application reduces downtime for plantLow odor Low odor during installationEase of cleaning low maintenance costsSeamless installations no grout joints to collect dirtChemical resistant finishes withstands chemical attacksFinished coats can vary in texture increased safety in plant

Key MMA Mortar Systems Methyl Methacrylate Binder

Key MMA Mortar STD• Trowel applied mortar system using graded aggregates + a 100% reactive methyl

methacrylate binder• Thicknesses can be 3/16” to ¼” • Product is grouted and sealed • Finish can be smooth to aggressive texture

Key MMA Mortar SLT• Specially graded aggregates + 100% reactive methyl methacrylate binder• Product is applied using a V-notched squeegee or trowel• Allow material to level then broadcast 20/40 mesh silica sand to refusal• Finish with appropriate MMA topcoats• Finished thickness is 3/16” – ¼””

Key MMA Mortar Systems Features BenefitsFast cure down to -25°F Can be installed in a wide range of

environmentsHigh Impact resistance Can be installed in abusive

environmentsEase of cleaning Low maintenance costsSeamless installations No grout joints to collect dirtChemical resistant finishes Withstands chemical attacksFinished coats can vary in texture Increased safety in plant

Decorative Seamless FloorsDecorative floors use a colored “filler,” usually either a vinyl flake or color-coated quartz. The aggregates are finished with a clear resin (epoxy, etc.), then a final top coat(s) is applied. The topcoat can be epoxy, urethane, polyaspartic, or MMA. Water-based options can also be used. Typical system thickness: 1/8″ – 1/4″.

Key Vinyl Flake Systems

Key Vinyl Flake Flooring Systems Epoxy Key Chip 100 Flooring

• Is a 100% solids epoxy decorative vinyl flake flooring system• The system can be installed with a full or partial broadcast of vinyl flakes• The system is completed by applying a clear topcoat

Urethane CementKey Urecon Chip Flooring

• Is a moisture vapor tolerant polymer flooring system consisting of a urethane cement mortar base and a decorative vinyl flake broadcast finish

• The system can be installed with a full or partial broadcast of vinyl flakes• The system is completed by applying a clear topcoat• The system thickness varies from 3/16”-1/4”

Methyl MethacrylateKey MMA Chip 900 Flooring

• Is a 100% reactive methyl methacrylate decorative vinyl flake flooring system• The system can be installed with a full or partial broadcast of vinyl flakes• The system is completed by applying a clear MMA topcoat• The system thickness varies from 1/16”-1/4”

Key Decorative Quartz Systems

Key Decorative Quartz Flooring Systems

EpoxyKey Quartz B-125• Is a decorative resin flooring system consisting of a clear, 100% solids epoxy resin binder and colored quartz aggregates• The system is installed by encapsulating the color quartz aggregate in a clear resin binder and “double broadcast” of aggregate• The system is completed by applying one or more clear top coats• The system can be installed with a texture or smooth finish•‘ The finished system thickness is 1/8” (125 mils)

Key Quartz B-195• Is a decorative resin flooring system consisting of a clear, 100% solids epoxy resin binder and colored quartz aggregates• The system is installed by encapsulating the color quartz aggregate into a self-leveling binder and a “double broadcast” of aggregate• The system is completed by applying one or more cleat top coats• The system can be installed with a texture or smooth finish• the finished system thickness is 3/16”

Key Decorative Quartz Flooring Systems

EpoxyKey Quartz T-250

• Is a decorative trowelled resin flooring system consisting of a trowel blend of color quartz and a clear, 100% solids epoxy resin binder

• The system is completed by applying one or more clear top coats• The system can be installed with a texture or smooth finish• The finished system thickness is 3/16”-1/4”

Key Commercial• Is a decorative resin flooring system consisting of a trowelled epoxy mortar

base and broadcasted with a color quartz finish• The system is completed by applying one or more clear top coats • The system can be installed with a texture or smooth finish• The finished system thickness is 3/16”-1/4”

Urethane Cement BinderKey Urecon SLT Quartz

• Is a moisture vapor tolerant polymer flooring system consisting of Urecon SLT, a urethane cementitious slurry with a colored quartz aggregate broadcast finish

• The system is completed by applying one or more clear top coats• The system can be installed with a texture or smooth finish• ‘ The finished system thickness is 3/16”-1/4”

Methyl Methacrylate BinderKey MMA Quartz SLT

• Is a decorative rapid setting flooring system consisting of a 100% reactive MMA resin, self-leveling filler and a colored quartz aggregate broadcast finish

• The system is completed by applying one or more clear MMA top coats• The system can be installed with a texture • ‘ The finished system thickness is 1/8”-3/16”

With quartz and vinyl flakes as the color medium, the decorative combinations of seamless flooring are endless. Many custom patterns and formulas can be achieved with these systems.Applications include:

•Lab floors•Locker rooms•Clean room environments•Corridors•Kitchens•Retail spaces•Vet clinics•Manufacturing facilities•Numerous other applications

Applications:Decorative Seamless Flooring

Cushioned Seamless FloorsSome versions of seamless flooring systems have soft base coats and fillers that produce cushioned floors that create an ergonomic environment for the user of the space.

Other benefits of this type of seamless floor include chemical resistance and improved acoustic qualities.

For labs, hospitals, pharmaceutical, and vet clinics, the advent of soft, quiet floors is an ever-growing market. For such applications, a seamless floor solution provides a hygienic solution with no unsightly seams or joints to harbor dirt and bacteria.

Elastomeric Systems •Available in the market are elastomeric waterproof seamless flooring systems

•These systems are designed for critical areas requiring waterproofing

• Ideal for those occupied spaces under equipment rooms

• When installed they provide the insurance needed when pumps or pipes fail

• They also provide sound-deadening and cushioning underfoot

Key Elastomeric Flooring Systems

NON-DECORATIVE ELASTOMERIC FLOORING SYSTEMS Key Lastic ME

• Is a fluid applied, resilient flooring system formulated for concrete floors in mechanical equipment rooms

• The system consists of a crack-bridging membrane, a flexible epoxy and broadcast aggregate

• Allows for horizontal movement up to 1/8” without fracturing• Finished with appropriate topcoats• Finished thickness is 1/8”

Key Lastic SWS• Is a fluid applied, resilient flooring system formulated for concrete floors, overhead

walkways, promenade decks, and other exterior surfaces requiring a watertight wear surface

• The system consists of a crack-bridging membrane, a flexible epoxy and broadcast aggregate

• Allows for horizontal movement up to 1/8” without fracturing• Finished with appropriate topcoats• Finished thickness for Pedestrian traffic 50-60 mils• Finished thickness for Vehicular traffic 100-110 mils

DECORATIVE ELASTOMERIC FLOORING SYSTEMSKey Lastic Chip 100 Flooring system

• Is a flooring system consisting of flexible epoxy or urethane resins, a resilient epoxy body coat and finished with a broadcast of decorative vinyl flakes

• The system is completed by applying appropriate top coats• Finished thickness is 1/8”-3/16”

Key Lastic DE flooring system• Is a fluid applied, decorative resilient flooring system for classrooms, shower

rooms, cafeterias, mechanical equipment rooms, activity centers and more• The system consists of a crack-bridging membrane, a flexible epoxy and broadcast

aggregate• Allows for horizontal movement up to 1/8” without fracturing• Finished with appropriate topcoats• Finished thickness is 1/8”

Key MMA Elastomeric Chip Flooring• Is a 100% reactive methyl methacrylate elastomeric resin and decorative vinyl

flake flooring system• The system can be installed with a full or partial broadcast of vinyl flakes• The system is completed by applying a clear MMA topcoat• The system thickness varies from 1/16”-1/4”

Key MMA Elastomeric Quartz Flooring• Is a decorative rapid setting flooring system consisting of a 100% reactive MMA

elastomeric resin, self-leveling filler and a colored quartz aggregate broadcast finish

• The system is completed by applying a clear MMA topcoat• The system finish is textured• The finished system thickness is 1/8”-3/16”

Key MMA Elastomeric Decking• Is composed of a 100% reactive MMA elastomeric resin system, and specially

graded broadcast aggregates.• Finish with appropriate MMA topcoats• Finished thickness is 3/16” – ¼”• Is composed of a 100% reactive MMA elastomeric resin system, and specially

graded broadcast aggregates.

Key MMA Freezer Flooring• Is a flooring system this consists of 100% reactive MMA elastomeric resins,

specially graded silica broadcast aggregate and pigmented MMA top coats• Finished thickness is 3/16”-1/4”

Decorative Elastomeric systems continued

ESD / Conductive SystemsWhen the needs of the space require an electro static dissipative system to eliminate static discharge, a resinous floor with an ESD finish can be specified. An ESD system is electrically conductive in the range of 1,000,000 to 1,000,000,000 ohms. The other version of this system is categorized as a “Conductive” floor system, which provides lower electrical resistance (i.e., greater conductivity) in the range of 25,000 to 1,000,000 ohms. Both ESD and Conductive finishes can be utilized with decorative and non-decorative seamless floors, as well as epoxy terrazzo floors.

ESD / Conductive System Applications

Common applications for ESD/Conductive seamless flooring systems include:

•Electronics Industry• Manufacturing/Assembly

– Data Processing– Repair

• Pharmaceutical • Manufacturing• Military/Avionics• Chemical Processing• Explosion Hazard Areas• Plastics (Nuisance Static)

• Explosives • Manufacturing

Thin-Mil/High-Build Coating Systems Thin-mil/high-build coating systems typically consist of a primer, a bodycoat, and a topcoat(s). They are designed for light to medium duty traffic. The total thickness of a thin-mil/high-build coating system ranges from 10 mils to 50+ mils, and may be comprised of one or more of the following resins: Epoxy, urethane, polyaspartic, or MMA.

Cove Base & Termination Strips Various thicknesses of cove base and termination strips can be utilized. Sometimes, a sealant bead is used at the top of these base details. Details are illustrated in the next slide.

Cove Base & Termination Strips

Details of Cove, Strips, Joints, Termination Details

These photos illustrate how the floor system may be carried up onto the wall, creating a seamless surface. Terminations can be done with or without a strip, depending on the adjacent floor finish. It is advisable to saw-cut and “key in” the floor system into an unfinished space to negate any change in elevation from one floor finish to the other.

Optional Crack Isolation Membrane System

This laboratory sample shows a concrete crack running through the slab, into the light gray filler epoxy, and stopping at the yellow flexible epoxy membrane. The fiberglass scrim, placed on top of the membrane, provides additional reinforcement against the movement. If horizontal movement is less than 1/8″, the cracks can be bridged using 32-40 mils of membrane.

Generally, this fluid-applied flexible membrane is used for both slab-on-grade and elevated slabs where crack isolation and/or waterproofing is needed. Note that a crack isolation membrane is not also a moisture mitigation system.

Moisture Mitigation System When installing a seamless polymer floor it is required that the concrete be tested for moisture. If the test results are high, a mitigation system must first be applied to avoid any potential for moisture-related failure in the future.

Moisture mitigation systems are applied directly on top of the properly prepared concrete slab.

Some seamless floor systems have incorporated a moisture mitigation layer within the floor system design, which is a more economical way to deal with a potential moisture issue.

TYPICAL JOB PHOTOS

KEY LUSTER METALLIC - BRONZE

LIGHTING SHOWROOM

KEY MMA SLT

AIRPORTS

KEY

KEY HIGH BUILD COATING – CRU FINISH

AUTOMOTIVE REPAIR SHOP

KEY INDUSTRIAL WEAR SURFACE

MACHINE SHOPS

PROCESS FLOORS

KEY URECON TG

WAREHOUSING

KEY HIGH BUILD COATING SYSTEM

TESTING LABORATORIES


FOOD PROCESSING

KEY GLAS/KEY URECON TG

CORRECTIONAL FACILITIES

KEY URECON SLT

LOCKER ROOMS/COVE BASE

KEY QUARTZ B-125 CRU FINISH

HALLWAYS

KEY QUARTZ B-125

EXTERIOR DECKS

KEY LASTIC SWS PEDESTRIAN

RESTROOMS

KEY CHIP 100 CRU FINISH

HIGH SCHOOL LOCKER ROOMS

KEY MORTAR SLT – CRU FINISH


GYM FLOORS

HIGH SCHOOL NATATORIUM

KEY LASTIC SWS PEDESTRIAN

DECALS

FOOD PROCESSING

KEY URECON SLT

HANGAR FACILITIES


MUNICIPAL ANIMAL HOLDING FACILITY

KEY MORTAR STD – CRU FINISH

ANIMAL CARE


TEACHING HOSPITAL MORGUE

KEY MORTAR STD – CRU FINISH

ANIMAL RESEARCH

KEY MMA CHIP 900

HYDRATHERAPY

KEY QUARTZ B-125

MEDICAL IMAGING

KEY QUARTZ T-250

KEY QUARTZ B-125 – CRU FINISH

REHABILITATIVE SURGICAL SUITE

PHARMACEUTICAL


Define The Need of the Space Seamless floors have many different uses. To determine a suitable solution, one needs to define the need of the space.

• Is it a decorative requirement? Or, is it truly a functional space first; aesthetics are secondary?

(e.g., a food processing plant or industrial facility)

• Is the space a public space, or is it only to be seen and walked on by the users of the facility?

• Is the area a “wet space,” requiring a slip-resistant seamless floor?

• Will people be standing on the floor for extended periods of time, requiring consideration of an ergonomic cushioned system?

All of these are important considerations in the selection of the type, thickness, and appearance of the seamless flooring system.

Site Survey Form

Please contact Key Resin if you require any technical assistance…

Thank you for your time!

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