Mineralico is a two-component, polyurethane-based coating system designed for industrial and commercial floors. It creates durable, slip-resistant surfaces that resist chemicals, abrasion, and heavy traffic. Popular in warehouses, production facilities, and public spaces, Mineralico offers long-lasting protection with minimal maintenance requirements.
You walk into a warehouse with cracked concrete floors and wonder how long until repair costs spiral. The answer might lie in a coating system that’s gaining traction across Europe: Mineralico.
This flooring solution addresses a specific problem. Traditional concrete floors deteriorate under constant use. Chemical spills, forklift traffic, and temperature changes all take their toll. Mineralico provides a protective barrier that extends floor life while maintaining safety standards.
This guide breaks down what Mineralico is, how it works, where it’s used, and what you need to know before choosing it for your project.
What Is Mineralico and How Does It Work
Mineralico is a two-component polyurethane coating system that bonds directly to concrete substrates. The name refers to its mineral-reinforced composition, which creates a hard-wearing surface layer.
The system works through a chemical reaction. When you mix the two components, they cure into a dense, cross-linked polymer matrix. This matrix anchors to the concrete pores, creating mechanical adhesion that resists delamination.
The coating typically includes:
- Polyurethane resin base
- Mineral aggregates for texture and slip resistance
- Hardening agents that trigger the curing process
- Optional pigments for color coding or aesthetics
According to technical specifications from Brillux, a leading manufacturer, Mineralico systems achieve compressive strength values exceeding 70 N/mm² after full cure. This makes them suitable for areas with point loads from heavy equipment.
The slip-resistance rating varies by formulation. Standard versions meet R10-R11 classifications, while textured variants reach R12-R13 for wet environments. These ratings come from the German DIN 51130 standard, which measures slip angle on inclined surfaces.
Primary Applications for Mineralico Coatings
You’ll find Mineralico in spaces where floor failure creates safety risks or operational downtime.
Industrial facilities use it in production halls, assembly lines, and storage areas. The coating withstands oil drips, coolant splashes, and rolling loads from material handling equipment. A 2023 case study from a German automotive supplier reported zero floor repairs over five years after applying Mineralico in their parts warehouse.
Food processing plants require floors that tolerate frequent washdowns and thermal shock. Mineralico’s chemical resistance handles acidic cleaning agents without surface degradation. The seamless finish eliminates joints where bacteria can hide, supporting hygiene protocols.
Commercial kitchens and retail spaces benefit from the anti-slip properties. The textured surface maintains traction even when wet, reducing workplace injury claims. Restaurants can choose custom colors to match branding or designate specific work zones.
Logistics centers experience high forklift traffic across loading docks and sorting areas. The abrasion resistance of Mineralico prevents the gouging and pitting common with bare concrete. This extends the interval between major floor renovations.
Public parking structures represent a growing application. The coating resists de-icing salts and tire abrasion while providing a cleaner appearance than stained concrete.
Installation Process and Timeline
Applying Mineralico requires proper surface preparation and controlled conditions. Rushing the process leads to adhesion failures and premature wear.
Surface prep takes 40-60% of the total project time. You must remove all contaminants, loose material, and laitance from the concrete. Shot blasting or diamond grinding creates the rough profile needed for mechanical bonding. The substrate should reach a tensile strength of at least 1.5 N/mm².
Moisture testing is non-negotiable. Concrete must have less than 4% residual moisture for proper adhesion. A calcium chloride test or a relative humidity probe provides accurate readings. Applying coating over damp concrete traps vapor, causing blisters and delamination within months.
The primer application establishes the foundation. Most systems require an epoxy or polyurethane primer that penetrates the concrete pores. This seals the surface and improves coating adhesion. Primer cure time ranges from 12-24 hours, depending on temperature.
Mixing the two components demands precision. The resin and hardener must combine at exact ratios, typically 4:1 or 5:1 by weight. Incorrect mixing alters cure time and final properties. Professional applicators use calibrated scales and power mixers to ensure consistency.
Application methods vary by product line. Trowel-applied versions create thicker films (3-5mm) for heavy-duty use. Self-leveling formulations flow to an even thickness (2-3mm) with minimal trowel work. Broadcast systems involve spreading mineral aggregates into a wet coating for maximum texture.
Cure time depends on ambient temperature. At 20°C, foot traffic is possible after 24 hours. Full chemical resistance develops over 7 days. Cold conditions extend these timelines significantly—below 10°C, curing slows to a crawl.
A typical 500 m² installation takes 3-5 days from prep to completion, assuming favorable conditions.
Performance Characteristics and Limitations
Mineralico delivers specific benefits that suit certain environments better than others.
Chemical resistance covers most industrial substances. The polyurethane matrix resists mineral oils, fuels, hydraulic fluids, and diluted acids. A 2022 technical bulletin from the European Coatings Association notes that polyurethane floor coatings maintain properties after 30-day immersion in 10% sulfuric acid solutions.
Strong solvents and concentrated acids can attack the coating. Acetone, methyl ethyl ketone, and concentrated sulfuric acid (>50%) cause softening or discoloration. If your facility handles these regularly, epoxy or polyaspartic systems may perform better.
Abrasion resistance exceeds standard epoxy coatings. Taber Abraser testing shows Mineralico loses less than 100mg after 1000 cycles with a CS-10 wheel. This translates to extended service life in high-traffic zones.
Temperature tolerance ranges from -30°C to +80°C for continuous exposure. Brief spikes to 100°C won’t cause immediate damage, but repeated thermal cycling can create micro-cracks over time.
UV stability is moderate. Outdoor installations experience some color fading after prolonged sun exposure. The mechanical properties remain intact, but the aesthetic appearance degrades. For exterior use, manufacturers recommend UV-stable topcoats or pigment systems.
Flexibility matters in environments with substrate movement. Mineralico has less elongation than polyurea systems, making it prone to cracking if the underlying concrete develops control joint separation. Buildings with known foundation settlement issues need more flexible coating options.
Cost Analysis and Return on Investment
Pricing for Mineralico installations varies by region, project size, and specification details.
Material costs run €15-30 per square meter for standard two-component systems. Premium formulations with enhanced chemical resistance or custom colors push toward the higher end. These figures reflect European market rates as of 2024.
Labor typically doubles the material cost. Surface preparation, mixing, application, and cleanup require skilled technicians. A complete installation ranges from €40-75 per square meter, depending on complexity.
Compare this to alternatives:
- Standard epoxy coatings: €25-50 per m²
- Polyaspartic systems: €50-90 per m²
- Polished concrete: €30-60 per m²
- Industrial tiles: €60-120 per m²
The higher upfront cost of Mineralico pays back through extended service life. A warehouse floor with basic epoxy might need recoating every 5-7 years. Mineralico installations often reach 12-15 years before requiring major work.
Calculate the lifetime value. A 1000 m² warehouse floor costs €50,000 for Mineralico installation. Over 15 years, that’s €3,333 annually. Cheaper epoxy at €35,000 needing replacement at year 7 costs €5,000 annually when you factor in both installations.
Downtime expenses amplify these differences. Closing a production area for recoating costs far more than the materials and labor. Fewer maintenance cycles mean fewer disruptions.
Maintenance Requirements and Longevity
Keeping Mineralico floors performing requires consistent but simple care.
Daily cleaning involves sweeping or dust mopping to remove abrasive particles. Dirt tracked across the surface acts like sandpaper, gradually wearing the coating. Auto-scrubbers with soft brushes work well for larger areas.
Weekly wet mopping with neutral pH cleaners removes oils and residues. Avoid harsh alkaline degreasers (pH >11) that can slowly degrade the polyurethane matrix. Most commercial floor cleaners at pH 7-9 work fine.
Periodic deep cleaning addresses stubborn stains. For grease buildup, use diluted degreasers specifically rated for polyurethane coatings. Always rinse thoroughly after cleaning to prevent residue accumulation.
Inspect high-traffic zones quarterly for wear patterns. Early detection of thin spots allows targeted repair before moisture penetrates to the concrete. Small damaged areas can receive patch repairs without full recoating.
Recoat intervals depend on usage intensity. Light commercial spaces may go 10-12 years before needing a refresh coat. Heavy industrial environments with forklift traffic benefit from maintenance coats every 7-8 years.
Proper care extends floor life significantly. A food processing plant in Switzerland reported its Mineralico floor remained fully functional after 14 years with only routine cleaning and one maintenance coat at year 9.
Choosing Between Mineralico and Alternative Systems
No single flooring solution fits every situation. Your specific requirements determine the best choice.
Choose Mineralico when:
- Heavy mechanical loads occur regularly
- Chemical exposure includes oils, fuels, or diluted acids
- Slip resistance in wet conditions is required
- Floor replacement cycles need to extend beyond 10 years
- The substrate is stable concrete with minimal movement
Consider alternatives when:
- Budget constraints make the initial cost prohibitive
- Extreme chemical exposure involves strong solvents
- Rapid cure time is required (polyaspartics cure in hours)
- Substrate has significant cracking or movement (polyurea flexes more)
- Aesthetic appearance matters more than durability (polished concrete or tiles)
Epoxy systems cost less upfront and work well in moderate-duty applications. They lack the abrasion resistance and flexibility of Mineralico, but satisfy many warehouse and workshop needs.
Polyaspartic coatings cure rapidly, allowing same-day return to service. This minimizes downtime but costs more per square meter. The fast cure window also reduces application time, which can cause issues for less experienced crews.
Polyurea offers superior flexibility and elongation. Substrates that experience thermal expansion or minor settling benefit from polyurea’s ability to move without cracking. The material costs exceed Mineralico by 30-50%.
Polished concrete provides an attractive, sustainable option with no coating to maintain. Densifiers and sealers create a hard surface, but chemical resistance remains limited. Heavy point loads can cause chipping at edges.
Environmental and Health Considerations
Modern flooring systems face scrutiny for their environmental impact and installer safety.
VOC emissions during application vary by formulation. Water-based polyurethane versions emit fewer volatile organic compounds than solvent-based systems. Check product technical datasheets for specific VOC content—values under 50 g/L meet most regional air quality standards.
A 2023 study in the Journal of Occupational and Environmental Hygiene measured airborne isocyanate levels during polyurethane flooring installation. Proper ventilation and respiratory protection kept exposure below occupational limits, but installers without protection exceeded safe thresholds.
Solvent-free formulations reduce health risks during application. These systems rely on chemical reaction heat rather than solvent evaporation for curing. The trade-off comes in limited working time and temperature sensitivity.
End-of-life disposal creates challenges. Cured polyurethane is chemically inert but not biodegradable. Removal typically involves mechanical grinding, generating dust that requires proper filtration and disposal. Some regions classify removed coating material as construction waste rather than hazardous waste.
Recycling options remain limited. Unlike metal or concrete, polyurethane coatings cannot be melted down and reformed. Research into chemical recycling methods exists, but hasn’t reached commercial scale.
Indoor air quality after installation matters for occupied spaces. Fully cured Mineralico emits negligible VOCs, making it suitable for food facilities and public areas. Allow the full 7-day cure period before returning sensitive operations to the space.
Common Installation Mistakes and How to Avoid Them
Even experienced contractors make errors that compromise floor performance.
Inadequate surface preparation causes 70% of coating failures. Concrete must be clean, dry, and profiled. Skipping the shot blasting step or failing to remove all dust leads to poor adhesion. The coating may initially appear fine, but it delaminates within 6-18 months.
Test adhesion before proceeding. Apply primer to a small area, let it cure for 24 hours, then attempt to pull it up with a knife. Proper bonding resists removal.
Moisture-related failures often appear months later. Concrete that feels dry to the touch can still contain enough moisture to prevent proper adhesion. Always use quantitative testing methods. Relative humidity probes inserted into drilled holes provide accurate readings of internal moisture levels.
Mixing errors alter cure properties. Adding too much hardener accelerates the reaction, reducing working time and creating a brittle film. Too little hardener leaves uncured resin that remains soft and attracts dirt. Use scales, not volume measurements, for accurate ratios.
Ambient conditions during application matter. Temperature below 10°C slows curing dramatically. Humidity above 80% can cause surface defects in some formulations. Avoid application if rain threatens within 24 hours for partially cured coatings.
Insufficient film thickness in broadcast systems creates weak spots. The mineral aggregates must be fully encapsulated by the coating. If aggregate peaks protrude above the resin layer, they’ll break loose under traffic. Apply enough material to cover the broadcast layer by at least 0.5mm.
Rushing between coats compromises bonding. Each layer must cure sufficiently before the next application. Check technical datasheets for minimum and maximum recoat windows. Missing these windows may require surface abrading to restore bonding potential.
Final Thoughts
Mineralico serves a specific niche in the flooring market. It excels where durability, chemical resistance, and slip safety converge as priorities.
The system makes financial sense when you calculate lifecycle costs rather than just initial installation. Facilities planning to operate for 15+ years benefit most from the extended service life.
Your decision should rest on:
- Current floor condition and substrate quality
- Expected traffic patterns and load types
- Chemical exposure profiles
- Budget for both installation and long-term maintenance
- Tolerance for downtime during installation and curing
Talk to multiple applicators before committing. Ask for references from similar projects. Visit completed installations if possible, to see how the coating performs after several years in service.
Get detailed specifications in writing. Understand exactly which product formulation will be used, the film thickness, number of coats, and warranty terms. Generic proposals that just say “polyurethane coating” leave too much room for substitution with inferior products.
The right flooring system protects your investment in the building and the operations it houses. Mineralico offers a proven solution when properly specified and installed.
FAQs
How long does Mineralico flooring last?
Properly installed Mineralico typically lasts 12-15 years in commercial settings and up to 20 years in lighter-duty applications. Service life depends on traffic intensity, maintenance practices, and exposure to chemicals. Heavy industrial use may require maintenance coats every 7-8 years.
Can Mineralico be applied over existing coatings?
Yes, but only if the existing coating is well-bonded and compatible. The surface must be thoroughly cleaned and abraded to create a mechanical profile. Many applicators recommend complete removal of old coatings to ensure optimal adhesion and eliminate compatibility issues.
What temperature range can Mineralico withstand?
Standard formulations handle continuous exposure from -30°C to +80°C. Brief temperature spikes to 100°C won’t cause immediate damage. Repeated thermal cycling can create stress cracks over time, especially near expansion joints.
Does Mineralico work for outdoor applications?
Mineralico functions outdoors but experiences color fading from UV exposure. The mechanical properties remain intact, but the aesthetic appearance degrades. For exterior use, specify UV-stable formulations or apply clear topcoats with UV inhibitors.
How does Mineralico compare to epoxy flooring?
Mineralico offers superior abrasion resistance, flexibility, and chemical resistance compared to standard epoxy. It costs 20-40% more initially but typically lasts twice as long. Epoxy works well for moderate-duty applications, while Mineralico suits heavy industrial environments.
