• Name: Fire Apparatus Floors
• Finish: Gloss or satin
• Surface preparation and detailed application instructions available on request
• Manufacturer: Elite Crete Systems, +1-219-465-7671

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Why This Fire Station Replaced Its Failing Epoxy Paint Floor with an Engineered Multi-Layer Resinous Protective Floor Coating—and Never Looked Back

Background

A fire station located in a mid-sized city in the Midwest was experiencing rapid deterioration of its apparatus bay floors. The bay, designed to house multiple fire trucks, emergency vehicles, and heavy equipment, saw daily wear from the constant movement of heavy vehicles, exposure to chemicals, oils, water, and temperature fluctuations. These factors contributed to the cracking, spalling, and surface degradation of the concrete floor over time. This damage led to increased maintenance costs, operational disruptions, and safety concerns for the firefighters.

Problem

The concrete floor in the apparatus bay was subjected to constant stress due to:

• Heavy Vehicle Traffic: Fire trucks and emergency vehicles, weighing several tons, created significant pressure on the concrete, leading to surface wear and cracks.
• Chemical Exposure: Oil, gasoline, brake fluid, and other chemicals from the vehicles caused chemical degradation of the concrete surface.
• Moisture and Temperature: Snow, rainwater, and ice melted from vehicles, combined with extreme temperature changes, caused the concrete to expand and contract, leading to spalling and water seepage into the floor, accelerating deterioration.
• Safety Concerns: The damaged floor posed a safety risk due to cracks and uneven surfaces, which could cause trips, slips, or falls, particularly when wet.

To address these issues, the fire department sought a long-term flooring solution that would protect the concrete, withstand the bay’s harsh conditions, and improve safety.

Solution: Epoxy Floor Coating

After consulting with contractors and engineers, the decision was made to install an epoxy floor coating system specifically designed for heavy-duty environments like apparatus bays.

Key Features of Epoxy Flooring:

• Durability: Epoxy is known for its ability to withstand heavy loads and resist abrasions, making it ideal for areas with frequent vehicle traffic.
• Chemical Resistance: Epoxy coatings resist chemical damage, preventing oils, gasoline, and other vehicle fluids from penetrating the concrete and causing deterioration.
• Moisture Protection: Epoxy acts as a waterproof barrier, preventing water from seeping into the concrete, reducing the risk of cracks due to freeze-thaw cycles.
• Slip Resistance: The epoxy was installed with an anti-slip additive, improving safety by reducing the likelihood of slips, especially when the floor was wet.
• Ease of Maintenance: The smooth, non-porous surface of the epoxy floor made cleaning spills, chemicals, and dirt easier, reducing maintenance time and costs.
• Aesthetic Improvement: The epoxy coating was applied in a color that matched the fire station’s branding and included line markings to designate vehicle parking and pedestrian walkways, enhancing both functionality and appearance.

Installation Process

• Surface Preparation: The existing concrete floor was thoroughly cleaned and mechanically ground to ensure proper adhesion of the epoxy. Any cracks or surface imperfections were repaired.
• Primer Application: A high-performance epoxy primer was applied to seal the concrete and create a strong bond between the substrate and the epoxy topcoat.
• Epoxy Coating: Multiple layers of industrial-grade epoxy were applied, with the final layer incorporating a non-slip aggregate for enhanced safety.
• Curing Time: The floor was left to cure for 72 hours before vehicles and equipment were allowed back into the bay.

Results

The epoxy flooring system has been in place for over two years, and the fire station has reported several positive outcomes:

• Enhanced Durability: The floor has shown no signs of cracking, spalling, or wear despite the constant heavy load of fire trucks and emergency vehicles. The epoxy has maintained its integrity, withstanding the harsh chemical and physical conditions of the apparatus bay.
• Reduced Maintenance Costs: Previously, the station had to repair the concrete floor every few years due to surface damage. Since the installation of the epoxy floor, there has been no need for repairs, resulting in significant cost savings.
• Improved Safety: The slip-resistant surface has reduced the risk of slips and falls, particularly in wet conditions, improving safety for firefighters and staff.
• Aesthetic and Organizational Benefits: The clear line markings and clean, professional appearance of the epoxy floor have improved the organization of the bay, making it easier to park vehicles and store equipment efficiently.

Conclusion

Epoxy flooring has proven to be an ideal solution for protecting concrete floors in apparatus bays. Its durability, chemical resistance, and moisture protection have extended the life of the bay’s concrete, while also enhancing safety and reducing maintenance costs. The fire station continues to benefit from this long-lasting, low-maintenance flooring solution, providing a more functional and safer environment for its critical operations.