Cementitious urethane and epoxy are the two flooring systems most commonly specified for industrial and food processing environments. Both are resinous, seamless, and chemical resistant. But they are fundamentally different materials designed for different conditions, and choosing the wrong one is an expensive mistake. Here is a straightforward comparison to help you make the right decision.
The Fundamental Difference
Epoxy flooring is a thermoset polymer that cures through a chemical reaction between resin and hardener. It produces a hard, glossy surface with excellent chemical resistance and good compressive strength. It performs well in controlled environments with stable temperatures and moderate exposure.
Cementitious urethane (also called urethane concrete or urethane mortar) combines a urethane binder with Portland cement and graded aggregates. This hybrid chemistry gives it properties that neither pure epoxy nor plain concrete can achieve: the chemical resistance of a resin system with the thermal and mechanical properties of a cementitious material.
Head-to-Head Comparison
Thermal Shock Resistance
Cementitious urethane: Excellent. Rated for continuous service from -40°F to 220°F with intermittent exposure to 275°F. The cement component gives it a coefficient of thermal expansion similar to concrete, so it moves with the slab instead of pulling away from it.
Epoxy: Poor. Most epoxy systems are rated to 140°F maximum. Rapid temperature changes cause differential expansion between the epoxy and the concrete substrate, leading to cracking and delamination. Epoxy floors in washdown environments routinely fail within a few years.
Winner: Cementitious urethane, and it is not close.
Chemical Resistance
Cementitious urethane: Excellent resistance to organic acids (citric, lactic, acetic), animal fats and oils, caustic cleaners, and most sanitizers used in food processing. Handles the full range of CIP chemicals.
Epoxy: Good to excellent chemical resistance, particularly against solvents, fuels, and some acids. However, certain organic acids common in food processing can attack standard epoxy formulations over time. Novolac epoxy offers improved acid resistance but still lacks thermal shock capability.
Winner: Tie in most chemical environments. Cementitious urethane has the edge in food processing due to superior resistance to organic acids and fats.
Moisture Tolerance
Cementitious urethane: Highly tolerant of substrate moisture. Can be installed on concrete with moisture vapor emission rates (MVER) up to 25 lbs/1000 sq ft/24 hrs in many cases. The cementitious component is inherently compatible with moisture in the substrate.
Epoxy: Sensitive to substrate moisture. Most epoxy systems require an MVER below 3-5 lbs/1000 sq ft/24 hrs. High moisture conditions cause blistering, bubbling, and adhesion failure. Moisture mitigation systems add cost and installation time.
Winner: Cementitious urethane. This is a significant practical advantage, as many food processing facilities have older slabs with elevated moisture levels.
Thickness and Impact Resistance
Cementitious urethane: Typically installed at 1/4" to 3/8". This substantial cross-section provides excellent impact resistance and can bridge minor substrate imperfections. Products like SaniCrete STX and SaniCrete HF withstand heavy forklift traffic, pallet jack abuse, and dropped loads without cracking or chipping.
Epoxy: Typically installed at 1/16" to 1/8". Thinner systems are more susceptible to impact damage and cannot bridge substrate cracks or rough spots as effectively. Self-leveling epoxy systems like SaniCoat provide a smooth, durable surface but are best suited for environments without heavy impact or thermal cycling.
Winner: Cementitious urethane for heavy-duty environments. Epoxy is adequate for light-duty applications.
Bond Strength
Cementitious urethane: Bonds chemically and mechanically to properly prepared concrete. The cement in the system creates a cementitious bond in addition to the adhesive bond of the resin. Bond strengths commonly exceed 400 psi, and the bond improves as the cement hydrates over time.
Epoxy: Bonds adhesively to concrete. Bond strength depends heavily on surface preparation. A well-prepared surface yields excellent adhesion, but any contamination, moisture, or laitance weakens the bond significantly.
Winner: Cementitious urethane. The dual bonding mechanism and moisture tolerance make it more forgiving and more reliable long-term.
Cure Time
Cementitious urethane: Fast. Most systems allow foot traffic within hours and full heavy traffic (forklifts, pallet jacks) in approximately 8 hours under ambient conditions. This is critical for facilities that cannot afford extended shutdowns.
Epoxy: Moderate. Typical cure times are 12-24 hours for foot traffic and 48-72 hours for full service, depending on the formulation and conditions. Some fast-cure epoxies are available but sacrifice other properties.
Winner: Cementitious urethane. Faster return to service means less production downtime.
Cost
Cementitious urethane: Higher installed cost per square foot, typically $8-15/sq ft depending on the system and project conditions.
Epoxy: Lower installed cost per square foot, typically $4-10/sq ft depending on the system.
Winner: Epoxy on initial cost. But total cost of ownership over 10-15 years often favors cementitious urethane in demanding environments because it lasts longer and requires fewer repairs.
When to Use Cementitious Urethane
Cementitious urethane is the right choice for:
- Any area with hot washdowns or steam cleaning
- Cold storage and freezer environments
- Meat, poultry, dairy, seafood, and beverage processing areas
- Environments with constant wet conditions
- Areas subject to heavy impact and abrasion
- USDA and FDA-inspected processing areas
- Facilities requiring minimal downtime for installation
For these applications, SaniCrete STX provides the trowel-applied texture and thermal shock resistance needed for the most demanding environments. SaniCrete SL offers a self-leveling option for areas that need a smoother profile while still delivering full cementitious urethane performance. SaniCrete HF is engineered for environments requiring enhanced chemical resistance.
When Epoxy Makes Sense
Epoxy is a legitimate choice for:
- Dry processing and packaging areas
- Warehouses and distribution centers without thermal cycling
- Corridors and office areas adjacent to processing
- Light manufacturing with stable temperatures
- Environments where aesthetics are a priority (high-gloss finish)
SaniCoat is SaniCrete's high-performance epoxy coating system, designed for these lighter-duty environments where thermal shock resistance is not required but chemical resistance and durability still matter.
There is no single flooring system that is best for every situation. The key is matching the system to the conditions. Putting epoxy in a meat processing washdown area is a recipe for failure. Putting cementitious urethane in a dry office hallway is a waste of money. Know your environment, and specify accordingly.
The Bottom Line
If your facility involves wet processing, thermal cycling, aggressive chemicals, or heavy mechanical abuse, cementitious urethane is the answer. If you are working in a dry, temperature-stable environment with moderate traffic, epoxy will serve you well at a lower cost. Many facilities need both: cementitious urethane in processing areas and epoxy in dry storage, packaging, and corridors. The important thing is to get the right system in the right place.