Two-component epoxy technology has a proven record of excellent chemical resistance, mechanical strength, and adhesion to various substrates. It has been widely used in many different applications, especially in concrete coatings. Epoxy concrete coatings improve aesthetics, durability, and provide protection to concrete substrates. Traditionally, many epoxy systems require the use of plasticizers to ensure full chemical conversion of the polymer matrix. One of the challenges with epoxy floor coatings is the potential emission of plasticizer to the building inhabitants and environment throughout the service life of the floor. Legislation and end-user demand have driven new product development to focus not only on maintaining high performance but also controlling potential plasticizer emissions. Another challenge for concrete floor coatings is moisture vapor permeance through the concrete floor. Moisture can cause deterioration of flooring adhesives and delamination of coatings by osmotic action, thus reducing or completely eliminating the benefits of epoxy coatings on concrete. It is one of the frequent causes for floor failure. The cost to replace a failed floor can be significant. Recent innovative technology developments have offered a solution to remediate the issue of moisture vapor transmittance through the concrete floor. This paper will present epoxy systems based on innovative total reactive curing agent technology that is extremely low in emission and has excellent moisture vapor barrier property. This fundamental study highlights the full property development of these systems and this paper will discuss model formulations using the new curing agents and key performance attributes. A combination of low emission, tailorable working time, and fast property development offers coating formulators the choices to design new floor systems incorporating ultra-thin coatings with moisture vapor barrier property.
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