In this post, we’ll discuss the eight main reasons why an epoxy resin floor might start to cause problems in various ways, as well as the issues that can arise from these situations.
1. Poor surface preparation
The bond between the new epoxy and the existing floor is essential. The existing surface must be roughened to ensure the epoxy adheres properly.
To prepare the surface for the epoxy installation, we recommend grinding the floor with a diamond or metal disc to remove any imperfections.
The installation surface must be clean, dry and completely free of dust. Otherwise, your new floor will adhere to contaminants on the floor.
What problems can this cause? Total or partial loss of adhesion (‘peeling’)
The causes of this loss of adhesion may include:
- The resin was applied to a surface that does not ensure proper adhesion.
- Poor surface preparation: excess moisture, the surface was very dirty, etc.
Another problem this can cause: Lumps or clumps on the applied surface
Once again, the problem stems from poor cleaning and preparation of the substrate or the incorrect use of equipment when applying the resin.
2. Excess moisture
Solvent-based epoxy resins do not bond well to damp or wet substrates, which is why we emphasised in the previous section the importance of the surface being completely dry.
However, even if the floor is dry, we cannot prevent there being some residual moisture in the substrate or rising damp.
The severity of the damage to the epoxy floor will depend on several factors:
- Water accumulation in the subfloor.
- Burst water pipes beneath the flooring.
What problems might arise? A surface with greasy stains, loss of gloss and discolouration (‘amine blush’).
This occurs due to condensation, high humidity or because, during curing/drying, the resin came into contact with water.
This results in waxy, greasy or sticky surfaces. Greyish or whitish stains may also appear, or the surface may simply lose its shine.
3. Weak substrate
This could mean several things:
The pavement has reached the end of its service life
A poor mix of ingredients (excess water or low cement content).
What problems can this cause? The formation of blisters or pinholes
The formation of craters or blisters is known as degassing and occurs when epoxy resin is applied to porous surfaces, such as concrete.
Air becomes trapped in the pores of the concrete after curing and, as it tries to escape, exerts pressure on the resin layer, creating these blisters or craters.
4. No primer or an incorrect primer
Once the surface has been prepared, you must apply the appropriate primer and wait for it to dry to ensure proper adhesion between the substrate and the epoxy.
Therefore, as soon as the primer has dried, there is no time to lose in laying the flooring.
Commercial and industrial flooring experience a lot of usage and it’s essential to ensure that the correct primer is chosen to meet the specific needs and requirements of your substrate.
5. Incompatible or inappropriate substrate
Epoxy floors are durable, but they cannot compensate for an unsuitable substrate, such as wood. Wood is never a suitable surface for an epoxy installation.
Plywood floors are too flexible for epoxy, and the expansion and contraction they undergo during changes in temperature and humidity are too great for epoxy to withstand successfully.
This leads to tearing, peeling, cracking, and in the end, to failure.
In short, it is essential to ensure that the surface is compatible with the epoxy resin.
Furthermore, a surface’s adhesion and tensile strength are also important factors to assess before beginning the installation.
What problem can this cause? A sticky or soft surface (‘tacking’)
This occurs after the necessary curing time has elapsed, and we find that the resin has not only failed to harden properly, but is still completely fresh or soft.
This may be due to unsuitable environmental conditions or the condition of the surface to be coated.
Epoxy resin remains completely wet for many hours after being poured
Another problem this can cause: Sagging (vertical applications)
This problem is specific to vertical applications of epoxy resin. It occurs when too much resin is applied, or when temperatures are very high.
6. Reconditioning contaminated floors
These problems are very common in premises with old flooring that is due for renovation. Industrial activities carried out on these surfaces have caused them to absorb contaminants such as grease, oil and other residues, which result in poor adhesion of the flooring or the coating coming away.
We are talking about food and drink factories, car repair workshops, industrial chemical plants, etc.
In cases such as these, special preparation is required to ensure that any contaminants that could cause the epoxy to fail are removed or completely eliminated before the new floor is installed.
However, if the level of ‘contamination’ is already very high, it is difficult to rectify the situation.
All oils, greases and residues must be thoroughly cleaned away before the new epoxy is installed.
7. Incorrect mixing of the resin
If the floor remains very sticky after a long time or has not cured properly, this may be because the mixing time was insufficient or the components were not mixed in the correct proportions
What problem can this cause? The formation of air bubbles
This occurs when air becomes trapped within the mixture due to very rapid stirring, causing bubbles to form on the surface after curing. The problem is exacerbated when applied at very low temperatures, as the product is more viscous and makes it difficult for the air to escape.
8. Using the floor earlier than planned
Sometimes, our eagerness to get back to business doesn’t work in our favour. If we expect to return to normal within hours, nothing could be further from the truth. You may have to wait up to a week for the epoxy to cure completely and ensure proper adhesion to the surface.
If you want to avoid future problems with the epoxy, it is advisable to allow it to dry for the recommended time.
PLEASE NOTE: We’re not saying you can’t even walk on it. Rather, we mean you should avoid intensive cleaning, contact with water, or the use of heavy machinery or vehicles.
CONCLUSION
Epoxy is a type of flooring commonly found in industrial units, warehouses, logistics centres and industrial facilities in general, but it causes a great many problems. Unfortunately, it doesn’t last as long as one might hope and requires re-application over time.
There is, however, an alternative, which we outline in the following article: Alternatives to epoxy.
In any case, if you’re sure you want to repair your epoxy floor, read this other article: How to repair an epoxy floor?
Case study: From epoxy to polished concrete
We restored a problematic epoxy floor that was in poor condition and transformed it into an attractive polished concrete finish that offers greater safety and durability.