The imperfections of industrial resin floors

Smooth, shiny, uniform, and without irregularities: this is the ideal surface of an industrial resin floor. Unfortunately, the result does not always meet expectations. In this article, we will explore the most common imperfections that develop during and after laying a resin floor, their causes, and how to solve them. In the last section, we will provide general information on the ordinary and extraordinary maintenance of resin floors to maintain their aesthetics and functionality at the highest level.

Common Imperfections of Industrial Resin Floors

In general, the causes of a resin floor with an unpleasant appearance are usually found in inadequate preparation of the substrate and incorrect use of the products. Some products require a rest period before application; others necessitate precise mixing of resin and hardener. Not adhering to these instructions means risking improper hardening of the product, leading to various defects.

Inhomogeneity

When resin and hardener are mixed, a chemical reaction releases heat. If too much time passes between mixing and application, the product will increase in viscosity and harden, making the application difficult and uneven.

Partridge Eyes

A substrate contaminated with oil, wax, or silicone residues can cause "partridge eyes"—craters surrounded by a raised rim. These appear because the resin shrinks from the surface until it reaches the primer. To avoid this, ensure the substrate is free from contaminants. If they have already appeared, remove the coating, clean the area thoroughly, and reapply the resin.

Peeling

Peeling occurs when the resin detaches from the cement or when the layers of the floor separate. This happens if the substrate is not properly cleaned or if the primer is not applied. Remove the coating, clean the area, apply the primer if necessary, and reapply the resin.

Moisture Formation

If the cement is not perfectly dry or if there is a significant temperature difference between the resin and the substrate, moisture can form, causing separation and possible shattering of the resin. Test the substrate's humidity and ensure a 24-hour gap between base treatment and resin application.

Air Bubbles

Air bubbles can form due to various factors, such as excessive porosity of the concrete substrate, application in direct sunlight, or improper mixing techniques. To solve this, sand the affected areas, vacuum the residues, fill holes with epoxy material, and reapply the coating. Use low-speed mixers to avoid trapping air in the mixture.

Uneven Colour

Retouching a newly laid epoxy resin after about fifteen minutes can cause discoloration. All touch-ups should be done within ten minutes of application. Incorrect mixing, oil or grease on the substrate, or UV light exposure can also cause color inconsistencies. Ensure uniformity in resin batches to avoid color differences.

Different Thicknesses

Spreading remaining resin too thinly to cover an area can result in different thicknesses, leading to weaker and shinier areas. Always ensure you have the right amount of product for the job.

Milky or Blurred Coating

A milky, oily, or blurred surface can be caused by a wet substrate or too thick an application. Remove the coating, check the humidity level, and reapply the resin in the correct thickness as indicated by the product instructions.

Orange Peel

The "orange peel" effect, where the floor surface appears dimpled, is caused by temperature issues. Too cold or too hot substrates and materials can prevent the resin from spreading properly or cause it to harden too quickly. Remove the affected resin and reapply, ensuring the correct temperatures as specified.

Uneven Flakes

Flakes used for decorative purposes can sometimes concentrate in certain areas rather than being evenly distributed. This can be due to improper technique or haste. To fix this, sand the floor, vacuum the debris, and reapply the resin and flakes evenly.

Post-Laying Problems

Even after careful application, resin floors can sometimes exhibit issues such as sticky areas or yellowing over time. Here's how to address these problems:

Soft or Sticky Resin

If the resin is still soft or sticky 24 hours after application, it may be due to incorrect mixing proportions, low ambient temperatures, or a cold substrate. Ensure materials are stored correctly and mixed thoroughly before application. Remove the soft resin and reapply correctly.

Yellowing

Epoxy resin floors, especially those with white, light, or transparent finishes, can yellow with prolonged sun exposure or if expired products are used. Sand the surface and apply a new layer of resin. Use a UV-resistant topcoat to slow down yellowing and protect the floor from damage.

Maintenance of Resin Floors

One of the main advantages of resin floors is their ease of maintenance. Regular cleaning can be performed using vacuum cleaners, soft microfiber cloths, or common rags. Avoid using aggressive detergents; instead, opt for neutral pH cleaners. Ventilate rooms after washing to prevent water stagnation.

For scratches, use self-polishing waxes. In case of damage from heavy objects, repair with two-component epoxy putty. Depending on the environment, plan for periodic extraordinary maintenance using special waxes to keep the surface shiny, hygienic, and free from dust accumulation.

For optimal and long-lasting results, it is always best to contact professionals. Sivit, with over 40 years of experience, is at your disposal! Contact us at +39 011 2730033 or email commerciale@sivit.it.