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Chapter 4.2
Coatings for Concrete
Richard W. Drisko
Introduction
Industrial concrete is usually coated to provide
resistance to deterioration or other desired properties.
Coating material requirements for concrete are signifi-
cantly different than those for steel. This chapter
presents general information that will assist the reader
in the selection and use of coatings for specific types
of service on concrete structures.
Concrete Properties That Affect Its
Successful Coating
Concrete has several chemical and physical
properties that affect the selection and use of coatings.
These properties must be addressed for successful
coating performance.
Alkalinity
The natural alkalinity (as much as pH 13 on
newly placed concrete) reacts with coatings containing
drying oils to rapidly degrade them. Thus, only alkali-
resistant coatings must come into direct contact with
concrete.
Porosity
The natural porosity of cured concrete permits
water to penetrate into and migrate through it. Water
migration through concrete causes alkaline and other
aggressive soluble salts to damage coated surfaces.
Such contaminents must be removed before recoating.
Surface Texture
The natural roughness of concrete surfaces
makes it more difficult to cover completely without film
imperfections (holidays). On the other hand, smooth
finished concrete may have insufficient profile (rough-
ness) for good primer adhesion. Table 1 describes
typical surface properties of finished concrete.
Reference 2 presents a selection method for
matching recommended concrete surface profile
(CSP) with coating film thickness; the greater the film
thickness, the greater is the recommended profile.
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Reasons for Coating Concrete
The reasons for coating concrete are many
and varied. Some are distinctly different from uses of
coatings on steel, while others are also applicable to
steel structures.
Appearance Enhancement
In most exterior and many interior services,
the appearance of coated concrete surfaces is very
important. This is especially true when there is public
exposure. Appearance can be enhanced by proper
selection of coating materials to provide desired color,
gloss, and/or texture. Smooth coatings are much less
susceptible to unsightly mildewing than rough, un-
coated concrete and also is much easier to clean.
Reduction of Permeability
All concrete surfaces are permeable to
moisture to some extent. Continuous dampness may
promote coating deterioration, mildew growth, corro-
sion of embedded steel, or other undesirable effects.
Coatings can be used effectively to control moisture
penetration and migration. Water vapor transmission
through concrete can be measured using the calcium
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chloride test, ASTM F 1869.3
Substrate Protection
Concrete is subject to deterioration by a
number of mechanisms.4 Coatings most frequently
protect concrete from deterioration by providing a
protective barrier from aggressive environments.
Dusting Control
Exposed concrete slowly deteriorates to
produce dust. Coatings can effectively control this.
Ease of Cleaning
Rooms in hospitals, food processing facilities,
nuclear power plants, and electronic equipment
manufacturers that contain sensitive components or
otherwise require a high level of cleanliness need
smooth surfaces. These coatings may also have to be

Table 1. Typical Surface Properties of Finished Concrete.
resistant to detergents, disinfectants, and
decontaminants.
Improved Lighting
Smooth, reflective epoxy and polyurethane
floor coatings have been successfully used on con-
crete floors in hangars and other work areas to supple-
ment available lighting. These coatings must be
resistant to contamination by fuels, hydraulic fluid, and
lubricants. They frequently have aluminum oxide grit
embedded in them to provide slip resistance.
Chemical Resistance
Coatings for concrete must be resistant to
chemical attack. This is especially true for linings used
for primary and secondary containment.
Electrical Continuity
Coatings for concrete floors may be formu-
lated with conductive filler materials such as carbon to
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provide electrical continuity to dissipate static electric-
ity. This is of importance in operating rooms, munitions
Hitesh Thakrar.
plants, microchip manufacturing areas, and solvent
storage areas where combustible vapors or dusts may
be present.
Identification, Delineation, or Other Information
Painted markings on concrete floors,
pavements, walls, or other surfaces can provide vital
information for traffic control, identification, or hazards.
Often, different colors are used for specific
identifications.
Thermal Resistance
In some environments, coatings for concrete
must have thermal resistance to:
• Continuous high temperatures
• Cycling temperatures
• Thermal shock from sudden temperature changes

Desired Coating Properties
Coatings for concrete must be specially
formulated to provide the combination of specific
physical and chemical properties required for the
intended service. Some of the more important proper-
ties are described here.
Good Adhesion
Coatings applied directly to concrete must
bond well and provide a good base for subsequent
coatings. This requires a clean, profiled surface (as
described in Reference 2) and a coating with good
wetting and leveling properties.
Ease of Application
It is desirable that coatings for concrete
surfaces be relatively easy to apply. The manufactur-
ers’ recommended instructions for application should
always be carefully followed.
Alkali Resistance
Because concrete surfaces are normally very
alkaline, coatings applied to them must have a high
level of alkali resistance. This eliminates the use of
alkyd and other drying oil coatings that are subject to
alkaline hydrolysis (saponification).
Water Resistance
All coatings on concrete should have a low
rate of water vapor transmission (WVT). This will
control the penetration of water and the subsequent
deterioration of coating and corrosion of reinforcing
steel. On the other hand, there are times when a
“breathing coating” with a higher WVT is desired to
permit the slow escape of water vapor. A coating that
seals a concrete surface is more susceptible to
blistering and delamination from moisture attempting
to escape.
Strength and Flexibility
Strong, hard coatings tend to bond well and
have good chemical resistance but be relatively brittle
and subject to physical damage. More flexible coat-
ings, such as elastomers, resist impact well, can
expand and contract with substrate movement, and
can bridge small cracks. However, they are generally
softer, less chemically resistant, higher in permeability,
and less tightly bonded. The proper combination of
strength and flexibility must be appropriate for
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the particular service.
Coefficient of Thermal Expansion
Significant differences in coefficients of linear
thermal expansion (CLTE) between the coating and
the concrete may cause stresses in the coating that
result in loss of adhesion and/or cracking. Similarly,
adjacent coats of different materials in a coating
system should not have significantly different CLTEs.
This may cause cohesive failure within the coating film
or the concrete surface.
Chemical Resistance
Coatings for concrete surfaces in industrial
environments should resist those stored products with
which they may come into contact. Concentrations and
temperatures of these products may also affect
coating selection.
Resistance to Exterior Weathering
Of course, exterior finish coats must be
resistant to weathering. This will protect their appear-
ance as well as their durability. The sun’s ultraviolet
light will deteriorate aromatic coating materials, such
as epoxies, phenolics, and aromatic polyurethanes.
Resistance to Physical Damage
Coatings must also be resistant to impact,
adhesion, and traffic.
Definitions of Thin- and Thick-Film
Hitesh Thakrar.
Coatings
Currently, there are no accepted definitions for
thin- and thick-film coatings for concrete surfaces. For
the purpose of this chapter, a thin-film coating is
defined as a coating that:
• Is no greater than 20 mils (500 micrometers) in dry
film thickness and not reinforced but may be filled with
aggregate or other filler material
• Is applied by conventional means comparable to
those used for coatings 20 mils [500 micrometers] or
less dry film thickness on steel substrates
• Is not generally used in severe industrial service
A thick-film coating, then, would be greater
than 20 mils (500 micrometers) dry film thickness and
used in severe industrial environments. Obviously, this
is an imperfect definition but it will help delinate most
of the thick-film coatings that are used for primary and

secondary containment and monolithic flooring.
Thin-Film Coatings
General Compositions
Thin-film coatings for concrete are available in
a variety of generic types with different physical and
chemical dry film properties. They are much cheaper
than thick-film products and have more limited physical
and chemical properties, but are often successfully
used for specific purposes, usually under mild service
conditions. Thin-film coatings are frequently applied in
two or more coats to provide (1) good adhesion of
primer to the concrete, (2) fewer holidays, and (3) a
special property such as slip resistance or electrical
continuity.
Organic Binders
Organic binders are largely responsible for
most of coating’s chemical and physical properties.
The binders must be chosen to meet desired environ-
mental and service requirements, such as resistance
to specific chemicals.
Pigments and Fillers
Pigmentation can be used to provide varia-
tions in color, gloss, and texture. They can also reduce
film permeability and increase resistance to ultraviolet
light. Fillers (e.g., silica or carbon) can be used to
reduce costs or provide special properties (e.g.,
conductivity). They may constitute more than 50% of
the coating weight.
Individual Generic Types
Water-Emulsion (Latex) Coatings. Water-emulsion
coatings are used on concrete surfaces to provide an
attractive finish or pavement markings. Acrylic coatings
provide good flexibility and exterior weathering. Acrylic
resins may also be used in block fillers to reduce
permeability.
Relatively rigid textured coatings are most
often acrylic emulsion formulations. Available in fine,
medium, and coarse textures, they seal concrete
surfaces from wind-driven rain and bridge fine cracks.
The coarser their textures, the more susceptible they
are to soiling and mildewing. Thin-film acrylic elas-
tomers also perform well in bridging cracks and
waterproofing concrete surfaces. Primers may be used
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to ensure adequate adhesion of elastomeric materials.
Two-Component (Thermosetting) Epoxies. Two-
component, chemically-curing epoxies (not epoxy
esters) find general use in waterproofing concrete
surfaces and providing good chemical resistance.
They are sometimes used to make concrete easier to
decontaminate in both the chemical and nuclear
industries. Amine-cured epoxies usually provide better
chemical resistance than polyamide-cured epoxies.
Polyamide-cured epoxies, however, provide better
water resistance. They may contain 60 to 100% solids
and are frequently topcoated with a coat of aliphatic
polyurethane for exterior service.
Coal-Tar Epoxies. Coal-tar epoxy coatings perform
well as linings for concrete waste water tanks and
other interior industrial services. These linings are not
useful in municipal waste water applications where
sulfur-oxidizing bacteria are present or where the pH
may drop below 3 or 4. During exterior exposures,
they are susceptible to deterioration from ultraviolet
light, chalking freely, becoming brittle, and losing
adhesion.
Chlorinated Rubber and Vinyl Lacquers. Chlorinated
rubber and vinyl lacquers were used successfully on
concrete surfaces for many years. Their use has been
virtually eliminated because of their high VOC content.
The one exception to this limitation is the use of
chlorinated rubber coatings for exterior swimming
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pools. Many local air pollution control districts permit
this use, because no other generic type performs as
well in this service.
Two-Component Acrylics. Two-component, 100%
solids acrylics are cured by the further polymerization
(cross-linking) of acrylic resins initiated by a peroxide
catalyst. Proper formulation can produce such desir-
able properties as resistance to moisture, chemicals,
and ultraviolet light.
Polyurethane (Two-Component and Moisture Curing).
Moisture-curing and two-component (chemically-
reacting) and polyurethanes (not uralkyds) can be
formulated for use on concrete to produce films with a
variety of desirable properties. They can range from
hard-film to elastomeric products and provide protec-
tion equivalent to that of epoxies. However, they are

generally more expensive.
Siloxanes. Siloxane coatings provide good color
retention, hardness, and moisture resistance. Because
they are relatively new, they do not have the perfor-
mance records of other coatings.
Thick-Film Coatings
Thick-film coatings for concrete are used most
often as linings for primary and secondary containment
and on industrial floors.1, 5 In these and other industrial
services, they must have good resistance to chemical
attack and physical damage. On floors, they must also
be resistant to heavy traffic and loading.
Binders
Most thick-film coatings are based on thermo-
setting polymers that impart chemical and physical
properties that can be modified by the use of fillers,
reinforcement, hybrid polymers, and plasticizers.
Pigments, Fillers, and Reinforcements
Pigments. Pigments can provide a variety of colors.
They may also increase the coating’s resistance to
moisture penetration and ultraviolet light.
Fillers. Fillers are most often used to enhance the
strength and other physical properties of coatings.
Silica fillers are the most commonly used because of
their low cost, inertness to chemicals, and other
beneficial properties imparted. They are available in
several compositions and particle sizes and shapes
and may constitute up to 80% of the coating composi-
tion. More costly carbon fillers are normally used only
to impart special properties, such as conductivity, not
achievable with silica fillers. Other fillers may be used
to impart special properties to a coating. Thus, an
aluminum oxide filler may be added to improve impact
resistance. Other reinforcing materials include carbon
fiber and veils to provide conductivity, special chemical
resistance, or a thicker barrier to the environment.
Reinforcements. Fiberglass is the most common
reinforcing material for additional strength. It is mostly
used in hand lay-up of woven fabric but may also be
applied as chopped strands or loose mats. Fiberglass
may constitute as much as 50% by weight of the
coating system. On the other hand, resin-rich formula-
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tions are used for greater chemical resistance.
Shrinkage Problems
All thick-film coatings shrink to some extent
during solvent evaporation and/or cross linking. This
may vary with different formulations from less than 1%
to more than 10%. Shrinking normally continues during
aging by continuous cross-linking or other chemical
reactions, producing stresses that may result in loss of
adhesion and/or cracking. These stresses can be
controlled to some extent by proper selection of
polymer, fillers and reinforcement, and use of thinner
coats to achieve the desired higher film thickness.
Individual Generic Types
Individual generic thick-film coatings are
discussed in References 1 and 5, and this information
is summarized here. Most thick-film coatings for
concrete are proprietary formulations that may vary
widely within a generic type to provide desirable
properties and performances in a variety of aggressive
environments.
Epoxies. The two-component (thermosetting) thick-film
epoxies used for concrete in aggressive environments
exhibit high strength, durability, adhesion, and resis-
tance to a wide variety of chemicals but are not
generally used in highly acidic service. Most epoxies,
however, exhibit low flexibility and resistance to
ultraviolet light. Glass or other inert fiber products can
impart additional strength.
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The two components of epoxy systems are
epoxy resins and amine co-reactants (commonly
called hardeners or catalysts). Most epoxy resins are
derived from bisphenol A or bisphenol F, and phenol
Novolac-based (EPN) resin.6 For the new solvent-free
epoxy coatings, a reactive diluent may be used to
lower the viscosity to one more easily sprayed. Co-
reactants include aliphatic amines, cycloaliphatic
amines, amidoamines, and polyamides. Because of
their high functionalities, EPN resins react with ali-
phatic or cycloaliphatic amines to form polymers with
high cross-link densities and consequently high
chemical resistance. Aromatic amine curing agents
were once used extensively to form highly chemically
resistant films. However, they are used less today
because of their toxicities.
Unsaturated Polyesters. Unsaturated polyesters

exhibit high strength and generally good chemical
resistance. Glass or other inert fiber can impart
additional strength. They are prone to stress cracking
from high shrinkage and low elongation. Polyester
resins are produced by the condensation reaction of
saturated and unsaturated acids with polyols. These
resins are diluted with a vinyl co-reactant, typically
styrene, to cross-link to form a larger molecular weight
polymer. Methyl ethyl ketone peroxide, cumene
hydroperoxide, and benzoyl peroxide are typically
used as initiators and cobalt and tertiary amines as
promoters.
Vinyl Esters. The properties of vinyl esters are gener-
ally similar to those of polyesters. Thermal cycling may
further increase the stresses from high shrinkage and
low elongation.
Polyurethanes and Polyureas. Polyurethane and
polyurea coatings are available in a variety of formula-
tions with differing dry film properties. A major use is
as an elastomeric coating (>100% elongation) that can
bridge hairline cracks and move with changes in
substrate dimensions. These elastomeric products,
however, have reduced chemical resistance. Aromatic
formulations have poor resistance to ultraviolet light.
Polyurethanes and polyureas are two-component
(thermosetting) polymers in which isocyanates are one
of the reactants. With polyurethanes, the other reac-
tants are polyols; with polyureas, the other reactants
are amines. Often, mixtures of polyols and amines are
reacted with isocyanates to produce polyurethane/
polyurea hybrid products. Reference 7 describes the
many different types of these coatings available for
use today.
Polysulfides. Polysulfide elastomeric coatings have
high elongation and ultraviolet resistance. As with
polyurethane and polyurea polymeric coatings, the
polysulfides have reduced chemical resistance.
Selecting Coatings
Coatings for concrete are selected for chemical
and physical properties that meet the requirements for
a particular service. These include:
• Interior or exterior use (Exterior coatings need
ultraviolet protection)
• Thermal effects (temperature range, recycling,
thermal shock)
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• Contact with chemicals, solvents, and fuels (concen-
tration and temperature)
• Anticipated physical abuse
• Importance of appearance
• Needed repairs and surface preparation before
coating
• Expected dimensional changes
Each year, the June issue of the Journal of
Protective Coatings and Linings contains the names
and addresses of manufacturers of coating and lining
materials for concrete as well as other substrates.8
These manufacturers should be contacted about
specific products for use on concrete.
Thin-Film Coatings
Information on thin film coatings can often be
found in the June issue of the Journal of Protective
Coatings and Linings as well listed by specific use,
such as marking paints, garage deck coatings, and
catchments.9, 10
Floor Coatings
Information on selecting floor coatings can be
found in Reference 11.
Chemically Resistant Coatings
Reference 12 provides selection guidance for
coatings and linings exposed to different chemical
environments.
Hitesh Thakrar.
Coatings for Primary Containment
Information on linings for primary containment
is described in Reference 4.
Coatings for Secondary Containment
Information can be obtained from References
1 and 4.
Summary
Many different compositions of thick- and thin-
film coatings for concrete are available for a variety of
different uses. Selection of a particular system should
be based upon the desired chemical and physical
properties for the particular use. General information
on selecting appropriate materials is presented here.
Contact with manufacturers’ technical representatives
for more detailed information about specific products.
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References structures. He is a professional corrosion engineer in
1. SSPC-TU 2/NACE 6G197. Design, Installation, and the state of California, an SSPC certified protective
Maintenance of Coating Systems for Concrete Used in coatings specialist (PCS), and a NACE International
Secondary Containment; SSPC: Pittsburgh, 1995. certificated corrosion specialist. Dr. Drisko received his
2. ICRI Technical Bulletin 03732. Selection and BS, MS, and PhD degrrees from Stanford.
Specifying Concrete Surface Preparation for Sealers,
Coatings, and Polymer Overlays; ICRI: Farmington
Hills, MI, 1997.
3. ASTM F 1869. Standard Test Method for Measuring
Moisture Vapor Emission Rate of Concrete Subfloor
Using Anhydrous Calcium Chloride; ASTM: West
Conshohocken, PA.
4. The Fundamentals of Cleaning and Coating Con-
crete; Randy Nixon and Richard W. Drisko, eds.;
SSPC: Pittsburgh, PA, 2001.
5. NACE RP0892-92. Coatings and Linings Over
Concrete for Chemical Immersion and Containment
Service; NACE: Houston, 1992.
6. Thomas, E. Dail; Webb, Arthur A. The U.S. Navy
Advances in Coating Ship Tanks. Journal of Protective
Coatings and Linings, February 2001, pp 29-41.
7. Hare, Clive H. Protective Coatings, Fundamentals of
Chemistry and Composition, Technology Publishing
Company: Pittsburgh, 1994.
8. Journal of Protective Coatings and Linings: Annual
Buyer’s Guide Issue, Technology Publishing Company:
Pittsburgh.
9. Mailvagnam, N. Waterproofing Garage Decks.
Materials Performance; October, 1996.
10. Drisko, Richard W.; Yanez, Jeffrey R. Coatings for
Concrete Surfaces. In Proceedings of SSPC ‘89.

Hitesh Thakrar.
11. Boova, A. A Guide to Selecting Industrial Flooring.
Journal of Protective Coatings and Linings, February
1990.
12. Aldinger, Thomas I.; Fultz, Benjamin S. Selecting
Coatings and Linings for Concrete in Chemical Envi-
ronments. Journal of Protective Coatings and Linings,
August 1995.

About the Author

Dr. Richard W. Drisko

Dr. Richard W. Drisko has been the senior technical
advisor to SSPC: The Society for Protective Coatings
since January 1995. Prior to this, he was employed for
over 40 years at the Naval Civil Engineering Labora-
tory, Port Hueneme, California, where he conducted
research, evaluation, and testing, and served as the
Navy’s center of expertise on coatings for shore

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