Quartz sand serves as core aggregate and functional filler for epoxy flooring systems, including epoxy mortar screeds, broadcast‑type heavy‑duty floors, self‑levelling epoxy, anti‑slip top layers and thin‑film epoxy coatings. Particle‑size selection is governed by floor build‑up thickness, load‑bearing requirement, surface texture and anti‑slip performance. As introduced on quartz‑mill.com, high‑quality epoxy‑grade quartz sand requires precise sieving and air classification to control oversize grains and fine dust, with low iron contamination to avoid discoloration. JACAN milling‑classification equipment can produce full‑range graded quartz sand for various epoxy‑floor formulations.
Typical mesh‑micron conversion for epoxy‑floor quartz sand
| Application Segment | Mesh Range | Particle Size (μm) | Primary Function |
|---|---|---|---|
| Heavy‑duty epoxy mortar base layer | 20‑40 mesh | 425‑850 μm | High compressive strength, main skeleton aggregate for thick screed (3‑6 mm) |
| General‑purpose medium aggregate | 40‑80 mesh | 180‑425 μm | Most widely‑used grade; for mid‑layer mortar and broadcast flooring |
| Fine aggregate for fine‑textured / anti‑slip surface | 80‑120 mesh | 125‑180 μm | Fine anti‑slip texture, self‑levelling epoxy system |
| Filler powder for thin‑film top‑coat | 120‑200 mesh | 74‑125 μm | Reduce resin shrinkage, smooth thin‑film surface |
Critical rule: Maximum particle size of quartz sand must be smaller than dry film thickness to prevent grain protrusion and pin‑hole defects.
Size selection for different epoxy‑flooring construction types
1. Epoxy mortar screed (heavy‑load industrial floor, 3‑6 mm thickness)
- Primary fraction: 40‑80 mesh (180‑425 μm). For extremely high‑wear warehouse / workshop floors, blend with 20‑40 mesh coarse quartz sand as skeleton aggregate.
- Purpose: Build thickness, improve compression and abrasion resistance, reduce epoxy resin consumption.
- Process note: Continuous graded mixture (coarse + medium + fine fractions) optimizes packing density and lowers void ratio.
2. Broadcast epoxy flooring
- Broadcast base sand: 40‑70 mesh. Excess sand is scattered onto wet epoxy binder, excess sand is swept off after curing. Delivers high‑wear textured industrial surface.
- Fine anti‑slip broadcast: 80‑120 mesh, used for wet‑zone anti‑slip top‑layer, producing subtle slip‑resistant texture without overly rough feel.
3. Self‑levelling epoxy flooring
- Main aggregate: 80‑120 mesh. Finer particle size preserves good flow‑ability for self‑levelling formulations.
- Partial addition of 120‑200 mesh quartz powder optimizes rheology and reduces curing shrinkage. Coarse particles above 200 μm must be strictly limited to avoid surface grain defects.
4. Thin‑film epoxy top‑coat (<200 μm dry film)
- Typical filler: 120‑200 mesh quartz powder.
- Avoid coarse sand; large particles will pierce thin film and create gritty surface.
Key quality requirements besides particle size
- Particle‑size distribution: Strictly limit oversize particles; excessive ultra‑fine dust will sharply increase resin absorption and system viscosity. Precision screening and air classification are essential.
- Purity: High SiO₂ content, low iron impurity, preventing yellow‑spot discoloration on light‑coloured epoxy floors. Magnetic separation removes ferromagnetic contaminants.
- Particle morphology: Angular‑sub‑angular grains deliver better mechanical interlocking with epoxy resin; over‑rounded sand may slightly reduce interface bonding strength.
Summary
- 20‑40 mesh (425‑850 μm): Thick heavy‑duty mortar base layer.
- 40‑80 mesh (180‑425 μm): Most common general‑purpose grade for epoxy mortar and broadcast flooring.
- 80‑120 mesh (125‑180 μm): Self‑levelling epoxy and fine anti‑slip top‑surface.
- 120‑200 mesh (74‑125 μm): Thin‑film top‑coat filler for smooth surface.
In practical projects, formulators often adopt blended graded fractions rather than single mesh grade to achieve better packing density, mechanical performance and cost balance. Reliable classification technology guarantees stable particle‑size distribution for consistent epoxy‑floor performance.
