Epoxy Floor System Thickness: How Broadcast Layers Build 1/16 Inch Increments

Introduction

Epoxy floor thickness is not just a number. It is engineered.

Understanding how broadcast systems build thickness in controlled increments allows floors to be designed to match real-world abuse rather than simply targeting an arbitrary mil value.

Coatings vs Reinforced Systems

A single coat applied at 10 to 20 mils is fundamentally a coating. It provides abrasion resistance and chemical protection but does not significantly increase structural impact resistance.

We typically recommend a minimum coating system of:

• A primer
• Two coats of 100% solids epoxy
• Each applied at approximately 8 to 10 mils
• Inclusion of anti-skid aggregate when appropriate

At this thickness, a coating performs best when abrasion is the primary wear mechanism.

The advantage of a thicker reinforced broadcast system is increased resistance to impact.

The 1/16 Inch Per Broadcast Principle

A properly installed full aggregate broadcast layer produces approximately 1/16 inch (about 60 to 70 mils) of finished build once sealed.

This includes:

• Resin application
• Full aggregate broadcast
• Removal of excess aggregate
• Lock coat and/or topcoat

Thickness increases predictably:

• 1 broadcast approximately equals 1/16 inch
• 2 broadcasts approximately equals 1/8 inch
• 3 broadcasts approximately equals 3/16 inch
• Add one additional broadcast for each additional 1/16 inch desired

This method allows system thickness to be engineered in controlled increments.

Quartz Broadcast vs Chip Systems

Double broadcast quartz systems are typically used where sharp, concentrated impact is expected.

A single broadcast of decorative chip, properly sealed, often performs very well in applications where chip flooring is the appropriate system.

Chip systems differ because:

• They provide slightly more flexibility than quartz systems
• Wear is concentrated in the topcoat rather than exposed aggregate
• Most long-term wear in these environments is abrasion

In commercial kitchens, offices, bathrooms, and similar spaces, a single broadcast chip system with two topcoats often performs exceptionally well.

Why Double Topcoats Matter in Chip Systems

Installing two topcoats over chip flooring increases abrasion resistance by effectively doubling the wear surface thickness.

It is uncommon to see properly installed double-topcoated chip floors worn through in typical commercial interior environments.

When Double Broadcast Quartz Is Recommended

Double broadcast quartz systems are recommended where sharp metal impacts are likely, such as:

• Automotive mechanic shops
• Machine shops
• Fabrication facilities
• Areas where steel parts are routinely dropped

These environments involve concentrated, sharp-edged impact that benefits from the additional 1/16 inch reinforcement layer.

Broadcast vs Troweled Systems

Troweled systems can build thickness more quickly and may reduce installation time on heavy-build projects.

However, broadcast systems offer greater finish uniformity and are often more forgiving in application.

System Selection Matters

Not every floor requires 1/8 inch. Some require more. In many cases, a 20 mil 100% solids coating may be sufficient.

The correct thickness depends on:

• Impact type
• Abrasion level
• Chemical exposure
• Traffic type
• Service expectations

When thickness is engineered as part of a complete system, performance becomes predictable.

For complete flooring system options, see our Seamless Flooring Systems Overview.

Predictable performance is the goal.

Proper mixing and installation is critical to the optimal success of all products.  See Installation Tips, Techdata, & MSDS for more details on our products.  Be sure to contact us with any questions and/or concerns that you have.

For more information please contact:

Epoxy.com
A Division of Epoxy Systems, Inc
A Vermont Corporation
USA

We have products that have passed the test of time as well as the best new Systems available today.

Since 1980 - Over 45 years of the highest quality products

Hours: 9AM-4PM Eastern Time (6AM-1PM Pacific Time)

Closed for lunch from 12Noon to 1PM

321-206-1833  Customer Service - Ordering and Order Status
Katey Lambert-Fontaine - Vice President & Chief Operations Officer
katey@epoxy.com

352-533-2167  Technical Support
Norm Lambert - President & Technical Support Director
info@epoxy.com

Debby Lambert, Co-Founder and Strategic Planning

Website: www.epoxy.com

24 hour Hazmat Emergency Telephone Response Service - 1-800-633-8253

[Home] [Catalog of Products] [MSDS in Acrobat Format] [Online Ordering Authorization Form]