A well-installed epoxy floor can give many years of reliable service. But when something goes wrong — peeling, bubbles, cracks or a sticky surface — the problem almost always comes from a small number of causes. This guide explains the most common epoxy floor problems, why they happen, and how they are fixed and prevented on industrial and commercial projects in Bangladesh.
1. Peeling or Delamination
What you see: the coating lifts or peels off in patches, often starting at edges, joints or forklift routes.
Common causes: poor surface preparation (no grinding or shot blasting), dust, oil or curing compound left on the concrete, a weak or laitance-covered surface, or coating applied over an incompatible old paint.
Solution: remove loose coating, mechanically prepare the surface by diamond grinding or shot blasting, repair weak concrete, then re-prime and recoat. Prevention: never apply epoxy on unprepared concrete — surface preparation is the single most important step.
2. Bubbles, Blisters and Pinholes
What you see: small craters, pinholes or raised blisters on the surface.
Common causes: air escaping from porous concrete (outgassing), especially when the slab is warming up; moisture pushing up from below; over-mixing that traps air; or applying too thick in one coat.
Solution: sand the affected area, fill pinholes, and apply a new coat. Prevention: use a penetrating primer or scratch coat to seal porous concrete, apply when the slab temperature is stable or falling, mix at the recommended speed, and use a spiked roller on self-leveling systems.
3. Moisture Problems from the Concrete
What you see: blistering, white haze, soft patches or loss of bond, often on ground-floor slabs.
Common causes: new concrete that has not dried enough, no damp-proof membrane under the slab, or rising ground moisture — very common in Bangladesh’s humid climate.
Solution: remove failed areas and apply a moisture-tolerant primer or a moisture barrier system before recoating. Prevention: test slab moisture before application, and where moisture is high, choose a moisture-tolerant system or PU concrete (Ducrete MF), which is more tolerant of damp substrates.
4. Cracks in the Floor
What you see: lines or cracks running through the coating.
Common causes: cracks in the concrete underneath that were not repaired, structural movement, or joints that were coated over instead of being treated as joints.
Solution: open and repair cracks with epoxy crack filler before coating, and keep movement joints open and sealed with a flexible joint sealant. Prevention: inspect the slab carefully and repair all cracks and joints during preparation.
5. Yellowing and Colour Change
What you see: the floor turns yellow or changes colour, especially near windows, doors or in outdoor areas.
Common causes: standard epoxy is not UV-stable and yellows under sunlight; some chemicals and hot liquids can also stain it.
Solution and prevention: for areas exposed to sunlight, use a UV-stable PU top coat or a polyaspartic coating over the epoxy.
6. Sticky or Soft Surface That Does Not Cure
What you see: the floor stays tacky or soft days after application.
Common causes: wrong mixing ratio of resin and hardener, incomplete mixing, very low temperature, or high humidity during curing.
Solution: remove the uncured material completely and reapply. Prevention: always mix full kits at the correct ratio, mix thoroughly, and follow the temperature and humidity limits on the technical data sheet.
7. Slippery Floors
What you see: the glossy floor becomes slippery when wet or oily.
Solution and prevention: add anti-slip aggregate in the top coat for wet areas, ramps and loading bays, or choose a textured system such as PU concrete for food processing and washdown areas.
8. Wear, Scratches and Impact Damage
What you see: worn traffic lanes, scratches or chipped areas.
Common causes: a thin coating used in a heavy-traffic area, steel-wheeled trolleys, dropped tools or dragging pallets.
Solution: repair damaged areas and recoat. Prevention: choose the right thickness for the traffic — a roller coat for light traffic, 2–3 mm self-leveling for medium traffic and 4–6 mm epoxy mortar for heavy forklift and impact areas. See our flooring system and price guide.
Quick Summary Table
| Problem | Main Cause | Prevention |
|---|---|---|
| Peeling / delamination | Poor surface preparation | Grinding or shot blasting, clean surface |
| Bubbles / pinholes | Outgassing, over-mixing | Primer or scratch coat, correct mixing |
| Moisture blistering | Damp slab, rising moisture | Moisture test, moisture-tolerant system |
| Cracks | Unrepaired slab cracks, joints | Crack repair, keep movement joints open |
| Yellowing | UV exposure | UV-stable PU or polyaspartic top coat |
| Sticky surface | Wrong mix ratio, low temperature | Correct ratio, follow TDS limits |
| Slippery floor | Smooth gloss in wet areas | Anti-slip aggregate or textured system |
| Wear and damage | Coating too thin for traffic | Correct system thickness |
Frequently Asked Questions
Can a damaged epoxy floor be repaired, or must it be replaced?
Many problems can be repaired locally. If the failure is widespread — for example peeling across most of the floor — the coating is usually removed, the surface re-prepared and a new system applied.
Why did my epoxy floor fail within a few months?
Early failures are most often caused by poor surface preparation, moisture in the concrete or a system that was too thin for the traffic. A proper site inspection before application prevents most of these issues.
Does DPF repair floors installed by other contractors?
Yes. Our team can inspect an existing failed floor, find the cause and recommend the right repair or replacement system.
Get Your Floor Inspected
If your epoxy or PU floor is peeling, blistering or wearing out, Ducon Polymer Flooring (DPF) can inspect the site and recommend a lasting solution.
Phone / WhatsApp: +880 1711-037659 | Email: info@duconasia.com
