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Commercial Epoxy Flooring Problems
Epoxy flooring has become a favourite choice for commercial spaces across Australia. From warehouses and retail stores to hospitals and schools, it’s known for being tough, glossy, and long-lasting. But like anything in the building game, epoxy floors aren’t completely foolproof. If the prep or application isn’t done right, you can run into some pretty frustrating problems.
In this article, we’ll walk through the most common commercial epoxy flooring problems, why they happen, and what can be done to prevent or fix them. Whether you’re a business owner trying to understand what went wrong with your floor, or a contractor looking to avoid headaches on the job, this guide should help.
Why Epoxy Flooring is Popular in Commercial Spaces
Before we jump into the problems, let’s take a quick look at why epoxy flooring is so widely used in commercial settings.
- Durability: Epoxy floors can handle forklifts, heavy trolleys, and constant foot traffic.
- Aesthetics: A clean, glossy finish makes the space look professional and modern.
- Easy to clean: Perfect for food preparation areas, workshops, and medical facilities where hygiene matters.
- Safety options: Anti-slip additives and coloured zones improve safety in busy workplaces.
But even with all these perks, epoxy is only as good as the surface prep and application. That’s where problems often creep in.
The Most Common Epoxy Flooring Problems
1. Peeling and Delamination
One of the biggest headaches is when epoxy starts peeling off the concrete. You’ll often see sheets of coating lifting up or edges flaking away.
Why it happens:
- Poor surface preparation (e.g., not grinding or etching the concrete properly).
- Moisture trapped under the slab.
- Oil or contaminants on the surface before application.
How to prevent it:
Always ensure the slab is clean, dry, and profiled correctly before application. Moisture tests are crucial in commercial spaces where the slab might not have a vapour barrier.
Fix:
Unfortunately, once epoxy peels, you usually need to grind it back and reapply the coating. Spot repairs don’t last long.
2. Bubbles and Blisters
Ever noticed little bubbles across the surface of epoxy floors? They can range from tiny pinholes to big blister-like bubbles.
Why it happens:
- Outgassing of the concrete slab (air escaping from pores during curing).
- Applying epoxy in hot weather, which speeds up curing too much.
- Using a roller incorrectly or too aggressively.
How to prevent it:
Apply epoxy in the right temperature range, usually between 15–25°C. Use a spiked roller to release trapped air. Always check the manufacturer’s instructions for curing times.
Fix:
Sand down the bubbles, re-coat the floor, and make sure conditions are stable before the next application.
3. Discolouration and Yellowing
Nothing kills the look of a floor faster than when a once-crisp grey or white epoxy turns yellowish or patchy.
Why it happens:
- UV exposure (sunlight streaming through windows).
- Using cheaper epoxy products not designed for UV stability.
- Chemical spills that stain the coating.
How to prevent it:
For commercial spaces with lots of natural light, go with a UV-resistant topcoat like polyurethane. Regular cleaning also helps avoid chemical stains.
Fix:
Re-coating with a UV-stable clear coat can bring back the finish, though badly yellowed floors may need sanding and refinishing.
4. Cracking
Cracks can appear either in the epoxy layer itself or in the concrete underneath.
Why it happens:
- Movement in the slab due to settling or temperature changes.
- Applying epoxy too thickly, causing it to become brittle.
- Using a rigid epoxy without considering the substrate's movement.
How to prevent it:
Control joints in the slab should be honoured during coating. Flexible epoxy systems or polyaspartic coatings can also help.
Fix:
Small cracks may be filled and re-coated, but larger structural cracks often need proper repair before reapplying epoxy.
5. Moisture Problems
Moisture is one of the biggest enemies of epoxy.
Why it happens:
- Rising damp from below the slab.
- Applying epoxy to a wet or recently washed floor.
- No vapour barrier installed during construction.
How to prevent it:
Perform a calcium chloride test or relative humidity test before application. If moisture is an issue, a moisture-tolerant primer may be needed.
Fix:
Peeling or bubbling caused by moisture usually requires removing the coating and installing a proper moisture mitigation system.
6. Uneven Finish and Roller Marks
In commercial settings, you’ll sometimes see streaks or patchy gloss levels across the floor.
Why it happens:
- Uneven mixing of resin and hardener.
- Not maintaining a “wet edge” during rolling.
- Poor lighting during application, making it hard to spot mistakes.
How to prevent it:
Work systematically, mix batches properly, and have enough applicators for large spaces.
Fix:
A fresh topcoat can usually even out the finish.
7. Slippery Surface
Epoxy looks shiny, but it can be slippery when wet, definitely not ideal for a workplace.
Why it happens:
- Using a high-gloss finish without anti-slip additives.
- Oil or water spills not being addressed quickly.
How to prevent it:
Add silica, polymer beads, or aluminium oxide to the topcoat for grip. Different areas can have different slip ratings depending on safety needs.
Fix:
A re-coat with anti-slip additives usually does the trick.
8. Soft or Sticky Surface
Sometimes epoxy never fully hardens, leaving a tacky surface that attracts dust and dirt.
Why it happens:
- Incorrect mixing ratios between resin and hardener.
- Cold temperatures slowing the curing process.
- Old or expired epoxy products.
How to prevent it:
Always follow the manufacturer’s mixing instructions carefully and check product shelf life.
Fix:
Unfortunately, tacky epoxy often needs to be stripped back and reapplied.
9. Staining and Chemical Damage
In commercial kitchens, workshops, or factories, epoxy can get stained by oils, chemicals, or rust from machinery.
Why it happens:
- Not using the right topcoat for chemical resistance.
- Leaving spills unattended.
How to prevent it:
Choose epoxy systems designed for the specific environment. For example, food-grade coatings for kitchens or chemical-resistant epoxy for workshops.
Fix:
Light stains can be cleaned, but deep chemical damage usually needs sanding and re-coating.
10. Poor Adhesion Around Edges and Joints
Edges and expansion joints are notorious trouble spots.
Why it happens:
- Insufficient grinding near walls.
- Not sealing joints properly before application.
How to prevent it:
Pay extra attention to edges during prep. Seal joints correctly before applying epoxy.
Fix:
Edge repairs often involve re-grinding and applying patch products before re-coating.
How to Avoid Epoxy Flooring Problems in the First Place
Most epoxy issues come down to three main factors:
- Surface preparation
- Environmental conditions
- Application technique
Hiring professional painting services or experienced epoxy contractors is the best way to avoid these costly mistakes. In Sydney, for example, many businesses rely on painters in Sydney who specialise in floor coatings and understand the local climate’s impact on curing.
Case Study
One of our clients in Parramatta had a warehouse floor that started peeling within six months of installation. On inspection, we found the slab hadn't been moisture-tested before the original job, and water was seeping through from underneath.
We stripped the old coating, applied a moisture-tolerant primer, and reinstalled the epoxy system with an anti-slip finish. The client's forklifts have been running on it for two years now without any issues.
It's a good reminder that cutting corners at the start often costs more in the long run.
FAQs About Commercial Epoxy Flooring Problems
Final Thoughts
Epoxy flooring is brilliant for commercial spaces when it's done right. It's strong, looks great, and is relatively low-maintenance. But as we've seen, there are plenty of pitfalls if the prep, products, or application aren’t handled properly.
If you're dealing with peeling, bubbles, or yellowing floors, don't panic, it can usually be fixed with the right approach. And if you're planning a new installation, make sure you choose experienced contractors who understand the common challenges.
A well-installed epoxy floor should last for many years, saving your business money and keeping your workplace looking sharp.
2 Comments
Looking for a quote to repair epoxy floor on my back patio. Has a few cracks in it
Thank you for reaching out to us Kevin. We’ll be in touch with you in a few minutes regarding fixing your epoxy floor.