The Top Reasons for Epoxy Coating Failures
Epoxy failures can be traced back to three main areas: the preparation, the application, and the product itself.
1. The Foundation: Improper Surface Preparation
This is the most frequent reason for failure. Epoxy will not adhere to a smooth or contaminated surface. While some DIY kits suggest cleaning or acid etching, this is often insufficient.
No "Wet-Out": The epoxy must "wet out" the surface, soaking into all open pores created by the preparation process. If the concrete is not porous enough, or if the material sets too fast, it won't properly penetrate, leading to poor adhesion.
Hidden Contaminants: Old concrete can have deep contaminants like oil, silicone, or acrylics that are not removed by a simple cleaning. These can prevent a proper bond, even if the surface looks clean.
The Right Method: The most reliable method for preparing a concrete slab is mechanical grinding. This creates a uniform, porous surface that is free of contaminants and ready to accept the epoxy coating.
2. The Application: Mixing and Environmental Factors
The application process is just as critical as the preparation. Overlooking these details can lead to serious problems.
Incorrect Mixing: Epoxy consists of two parts that must be mixed at precise ratios for a specific amount of time. Improper mixing will result in the product not curing correctly, leading to a soft, weak, or uneven finish.
Excessive Humidity: High humidity can have a severe negative impact on the epoxy's bond strength. It can lead to delamination, cloudiness, and a soft, improper cure. Always check the weather conditions before starting a project.
3. The Product: Quality and Quantity
Even with perfect preparation and application, using the wrong product can lead to failure.
Low-Quality Materials: Many cheaper epoxy kits are actually just epoxy-fortified latex paints that contain too many fillers. These products lack the industrial-grade bond strength needed to withstand constant wear and tear.
Not Enough Product: Inexperienced installers may try to stretch the material to cover a larger area. This results in a coating that is too thin, won't harden properly, and will fail prematurely. It is always better to have too much material than not enough.
Final Thoughts
Applying an epoxy floor coating can be tricky, but by understanding and avoiding these common mistakes, you can achieve a professional, long-lasting result. At Empire Coating Solutions, we provide a full range of high-quality products and the expert knowledge needed to ensure a flawless finish. By doing the job right the first time, you save yourself the time, money, and hassle of a failed project.
