Epoxy flooring is one of the most popular choices for industrial and commercial facilities—but it isn’t perfect. When installed correctly, epoxy floors perform well under heavy traffic, frequent cleaning, and demanding work environments. When installed incorrectly or used in the wrong environment, however, epoxy can develop issues that shorten its lifespan and increase maintenance costs.
With years of experience installing epoxy systems across the Midwest, CustomCrete has seen the patterns behind epoxy failures—and more importantly, how to prevent them. Below, we break down seven of the most common problems with epoxy floors and what decision-makers can do to avoid them.
1. Improper Surface Preparation
Surface preparation is the foundation of any successful epoxy floor. If the concrete isn’t profiled correctly, the epoxy won’t bond, leading to peeling, bubbling, or delamination within a short time.
Improper prep can include:
- Skipping mechanical grinding or shot-blasting
- Failing to remove old coatings or contamination
- Applying epoxy over dust, oil, or moisture
- Not repairing cracks or damaged joints
How to Avoid This Problem
Epoxy must be applied to a clean, dry, and properly profiled surface. Mechanical surface preparation (CSP 2–4 depending on system) is essential. Always ensure your installer uses industrial grinders, HEPA-controlled vacuums, and moisture testing equipment.
2. Outgassing and Fisheyes
Outgassing happens when air escapes from the concrete slab during coating, creating bubbles or craters known as fisheyes. This often occurs when epoxy is applied while temperatures are rising or when the slab contains trapped air or contaminants.
How to Avoid This Problem
- Apply epoxy as temperatures fall (late day or overnight)
- Use primers designed to minimize outgassing
- Avoid applying epoxy over porous, untreated, or contaminated concrete
- Ensure the slab is fully cured and dry
Proper timing and priming are key to preventing surface defects.
3. Discoloration from UV Exposure
Epoxy is not UV-stable. Under sunlight or strong artificial UV exposure, epoxy floors can turn yellow, fade, or discolor—even if the coating remains structurally sound. This is common near windows, dock doors, or outdoor-connected spaces.
How to Avoid This Problem
- Use UV-resistant topcoats such as polyaspartics or urethane sealers
- Minimize direct sunlight exposure when possible
- Choose lighter-colored blends that show discoloration less prominently
A UV-stable topcoat is the best long-term protection for epoxy in sunlit areas.
4. Moisture Vapor Problems
Moisture vapor transmission (MVT) is one of the leading causes of epoxy failure. When moisture pushes upward from the concrete slab, it forces the coating to lift, flake, blister, or completely delaminate.
This is especially common in older buildings, areas with high groundwater levels, or facilities that experience temperature swings.
How to Avoid This Problem
- Conduct moisture vapor testing (ASTM F2170 or F1869)
- Install moisture mitigation systems if readings exceed product limits
- Avoid coating green concrete without proper cure time
Moisture testing is non-negotiable—no epoxy should be installed until moisture levels are confirmed safe.
5. Susceptibility to Scratches and Abrasions
Epoxy is durable, but it is not invincible. Forklift routes, pallet dragging, and heavy cart traffic can scratch or wear down the surface over time. Without proper topcoats or maintenance, epoxy floors can develop visible wear paths.
How to Avoid This Problem
- Apply a urethane or polyaspartic topcoat for added abrasion resistance
- Use protective mats or guides in high-traffic zones
- Maintain a regular cleaning routine to prevent dirt from acting as an abrasive
Choosing a system with the correct topcoat can significantly extend lifespan in high-traffic environments.
6. Sensitivity to Temperature Fluctuations
Epoxy is highly sensitive to temperature during installation. If the slab or ambient air is too cold, too hot, or fluctuating rapidly, the coating may cure improperly, bubble, or fail to bond.
Temperature issues are common during seasonal transitions, especially in Midwest facilities without climate control.
How to Avoid This Problem
- Install epoxy within the manufacturer’s recommended temperature range
- Use industrial heaters or climate controls if necessary
- Avoid installation during extreme weather conditions
A controlled environment ensures proper curing and prevents coating defects.
7. Limited Lifespan Compared to Other Flooring Solutions
While epoxy is strong, it typically lasts 5–10 years depending on traffic, environment, and maintenance. Other solutions—like urethane cement or polished concrete—can last significantly longer.
Epoxy’s lifespan is reduced by:
- Heavy equipment traffic
- Chemical exposure
- UV light
- Improper maintenance
- High moisture conditions
How to Avoid This Problem
- Choose epoxy only when it’s the right match for your facility
- Consider urethane cement for wet, hot, or chemically aggressive environments
- Use polished concrete for low-maintenance, long-term durability
- Reapply protective topcoats every few years
Understanding your facility’s needs ensures you select a system that delivers optimal longevity.
Final Thoughts
Epoxy floors can provide excellent performance—but only when installed correctly and in the right environment. Many of the common issues arise from skipped steps, uncontrolled conditions, or system mismatches. By understanding these potential problems, decision-makers can choose the right flooring system and the right installer for long-term success.
If you want to explore accurate pricing for your flooring project, try CustomCrete’s Pricing Estimator to receive an instant cost range tailored to your facility.
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