Epoxy Floor Coatings: A Practical Guide to Avanti’s Three-Coat Flooring System
Updated: Oct 22
A well-designed epoxy floor is more than a glossy finish. It is a layered flooring system intended to protect concrete, improve cleanability and create a hard-wearing surface suited to the demands of a facility. The result depends on the complete system (substrate preparation, primer, screed or body coat, topcoat and careful application), not just on the resin chosen.
For factories, workshops, warehouses, laboratories, showrooms and commercial interiors, epoxy flooring can provide a seamless-looking finish that is easier to clean than untreated concrete. The system must still be selected for the actual site conditions, including traffic, impact, chemical exposure, moisture and slip-resistance needs.
What is an epoxy floor coating?
Epoxy flooring is formed when an epoxy resin reacts with a compatible hardener to create a crosslinked thermoset material. Depending on its design, the coating may be a thin film, a self-levelling layer or a resin-rich screed containing graded aggregates. These systems differ in thickness, surface profile, mechanical performance and intended service conditions.
Epoxy systems are valued for adhesion to properly prepared concrete, abrasion resistance, a smooth finish and resistance to many common chemicals. Actual performance depends on the formulation, film build, cure, substrate and the specific chemical or operating conditions. No single epoxy system is suitable for every floor.
Avanti’s three-coat epoxy flooring system
Avanti’s system combines three distinct layers: Level Sub-Z3ro epoxy primer, Level Z3ro epoxy screed and Level One epoxy topcoat. Each layer has a separate role. The quantities and thicknesses below are Avanti's specified targets; always confirm the current product technical data sheet and project specification before application.
1. Level Sub-Z3ro: 2K epoxy primer
The first coat is Level Sub-Z3ro, a zinc-free two-component epoxy primer. It penetrates and bonds to sound, properly prepared concrete and gives the screed a firm base to bond to.
Kit size: 7.5 kg total, comprising 5 kg resin (Part A) and 2.5 kg hardener (Part B). Mixing ratio: 2:1 by weight (resin:hardener). Specified application thickness: 150–175 microns.
Before priming, remove laitance, dust, oil, grease, curing compounds and weak material. Mechanical preparation is commonly used to create a sound, open surface profile. Repair defects and verify that moisture conditions are within the system’s permitted limits. Primer should be applied evenly without puddles; follow the product’s recoat window and curing instructions.
2. Level Z3ro: 3K epoxy screed
The second coat is Level Z3ro, a three-component epoxy screed. The resin and hardener form the binder while the aggregate contributes bulk and helps build the screed layer. This coat is used to create a more substantial floor build than a conventional thin-film coating.
Kit size: 27 kg total, comprising 5 kg resin (Part A), 2.5 kg hardener (Part B) and 19.5 kg aggregate. Mixing ratio: 5:2.5:19.5 by weight. Specified application thickness: 2 mm.
Mix the resin and hardener thoroughly first, then incorporate the specified aggregate as directed by the product procedure. Apply at a consistent thickness and compact or level the material using the appropriate tools. Do not add extra solvent or unapproved filler to extend the mix. The available working time and recoat window depend on temperature, batch size and product instructions.
3. Level One: 3K self-levelling epoxy topcoat
The final coat is Level One, a three-component self-levelling epoxy floor topcoat intended to provide the finished appearance and service surface. Its selection and application should reflect the required gloss, colour, cleanability, traffic and chemical exposure.
Kit size: 16.5 kg total, comprising 4 kg resin (Part A), 2 kg hardener (Part B) and 10.5 kg aggregate. Mixing ratio: 4:2:10.5 by weight. Specified application thickness: 1 mm.
Mix only complete, accurately proportioned kits unless the technical data sheet permits partial batching by weight. Apply within the stated pot life, maintain a wet edge and avoid overworking the material. Protect the floor from dust, water, traffic and chemical exposure until the specified cure has been achieved.
At a glance: system components
Primer: Level Sub-Z3ro, 7.5 kg kit (5 kg resin + 2.5 kg hardener), 2:1 ratio, 150–175 microns specified thickness.
Epoxy screed: Level Z3ro, 27 kg kit (5 kg resin + 2.5 kg hardener + 19.5 kg aggregate), 5:2.5:19.5 ratio, 2 mm specified thickness.
Topcoat: Level One, 16.5 kg kit (4 kg resin + 2 kg hardener + 10.5 kg aggregate), 4:2:10.5 ratio, 1 mm specified thickness.
Ratios are by weight. These thicknesses are application targets, not a guarantee of cured total build or material coverage. Actual consumption varies with concrete profile, porosity, surface flatness, application method and wastage. Confirm the total system build and coverage through the approved technical data and a site trial.
Surface preparation: where durable flooring begins
Many flooring failures begin before the first coat is applied. A glossy resin cannot compensate for weak concrete, contamination or moisture problems. A competent flooring contractor should:
Assess the concrete for strength, cracking, joints, contamination and previous coatings.
Mechanically prepare the surface to remove laitance and expose sound concrete; vacuum away dust.
Repair cracks, spalls and uneven areas using compatible materials and an agreed repair method.
Check substrate moisture and rising-damp risk against the system’s requirements.
Confirm ambient and substrate temperatures, ventilation, lighting and the dew-point margin where relevant.
Plan mixing, movement paths, batch sizes and recoat windows so each layer is placed within its application limits.
What can epoxy flooring look like?
The final appearance depends on the coating, colour, aggregate, lighting and workmanship. A high-gloss grey floor can suit production and office areas, while decorative effects can create a different visual character. The photos below show examples of floor appearances and project conditions; they should not be read as a guarantee that every substrate or site will produce the same result.
Where can an epoxy flooring system be used?
Common applications include manufacturing units, assembly areas, workshops, warehouses, service rooms, commercial back-of-house areas and offices. The precise system should be matched to the load and service environment. Heavy forklift traffic, impact, thermal shock, prolonged chemical contact, exterior exposure or wet areas may require a specifically engineered system or additional measures.
Common mistakes to avoid
Applying over dusty, weak or contaminated concrete.
Ignoring moisture vapour or rising damp.
Guessing the resin-to-hardener ratio or changing aggregate quantities.
Mixing more material than can be placed within its pot life.
Applying the next coat outside the permitted recoat window without the required preparation.
Allowing premature foot or vehicle traffic before the specified cure.
Assuming a glossy surface is automatically slip-resistant. Where wet or oily conditions are expected, specify and validate the required slip resistance.
How to plan your epoxy floor project
Start with the operating conditions, not just the colour. Record the concrete condition, expected traffic, chemical exposure, cleaning regime, required finish, downtime available and any slip-resistance requirements. A site inspection and trial area can help validate preparation, appearance, application method and practical consumption before the full installation.
Discuss your flooring requirement with Avanti
Avanti Paints & Chemicals supplies epoxy flooring products for industrial and commercial applications. Share your floor area, substrate condition, intended use, traffic type and required finish so the appropriate system and application plan can be discussed.
Avanti Paints & Chemicals manufactures the Level epoxy flooring range in Indore, Madhya Pradesh. If you are planning industrial epoxy flooring in Indore or elsewhere, share your area, substrate condition and use with our team.
Related reading: Epoxy coatings: chemistry and limitations
Technical note: Always follow the latest product technical data sheet, safety data sheet and approved project specification for mixing, application, PPE, ventilation, curing and return-to-service times. Use trained applicators and appropriate protective equipment.
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