An electrically-conductive coating composition for an electrically-resistive heating element comprises an electrically-conductive carbon allotrope, a thermally-conductive powder, and a water-borne polymeric binder. The carbon allotrope may be graphene nanoplatelets of 50 microns with a thickness of 5nm. The thermally-conductive powder may be ferrosilicon, titanium dioxide, carbon microspheres, or glass microspheres. The weight ratio of thermally-conductive powder to carbon allotrope is typically 5:1 to 15:1 and their combined weight may constitute 50-90 wt.% of the composition. The polymeric binder may be polyurethane, acrylic polymer, or copolymers of styrene-acrylic or styrene-butadiene. An electrically-conductive coating for underfloor or in-wall heating comprises a first electrically-conductive layer comprising an electrically-conductive carbon allotrope, a thermally-conductive powder, and a polymeric binder and a second dielectric layer comprising a thermally-cured coating located adjacent thereto. The thermally-cured coating may be a two-part coating comprising an epoxy, polyurethane, or polyurea resin. A method of forming an electrically-resistive heating element is also disclosed.
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