One of the most common problems that can occur in epoxy floor coatings is the appearance of air bubbles. These surface bubbles can be unsightly and sometimes can compromise the floor’s integrity over time, so it is important to take steps to prevent their formation.
There are a number of causes for air bubbles in an epoxy floor, the most common of which is outgassing. Outgassing is a natural phenomenon that typically occurs during the epoxy curing process in which air or gas is emitted from the concrete substrate, causing bubbles, blisters, or pinholes to appear.
Causes of outgassing and other problems that lead to bubbling, as well as their prevention methods, include:
Air moving in and out of the concrete due to fluctuations in temperature. This is best prevented by maintaining a consistent temperature in the room before, during, and after application.
Excess air in the product due to over-mixing. Always follow the epoxy manufacturer’s mixing instructions to avoid introducing too much air into the mix.
Moisture vapor or liquid coming up through the slab. Epoxy coatings must be applied to a dry slab, and moisture issues can often be prevented with water-based epoxy primers.
High room humidity, which can prevent epoxy from setting properly.
Residual oil, silicone, or grease on the concrete surface. The residue reacts with the epoxy mix, resulting in pinholes. This can be prevented with proper surface preparation.
Excessive solvent in the epoxy mix. When the solvent evaporates, it can often leave pinholes behind.
Air movement across the floor from natural airflow, blowing fans, or air being sucked into the room due to negative pressure.
Application of the epoxy coating too soon after concrete surface preparation and removal of existing sealer. It is advised to wait at least 24-72 hours to apply product after the surface is prepped to allow gases to be released.
Gas emissions due to chemical reactions during the floor cleaning process.
If bubbles begin appearing while the product is being applied, a spiked porcupine roller can be used to pop the bubbles and allow the coating to fill in the affected areas. If the bubbles appear after product application, a second coat can often solve the problem, but not always. Affected areas may require sanding, patching, and recoating. Bubbles that appear after finish coats have been applied can usually be sanded and patched.
SRI & Company is an expert in the installation of epoxy floor coatings, and our experienced installers are thoroughly trained in proper surface preparation and procedures for preventing the appearance of air bubbles and pinholes. For more information, please contact SRI & Co. at 973-832-7627.
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