Author: Raymond Alexander Kukkee, Helium.com

In business, an attractive, well-maintained warehouse floor free of clutter gives visitors the impression of a clean, well-managed establishment. Even if other conditions are perfect, however, a warehouse floor that appears in poor condition because of peeling paint or coating failure can leave a bad impression.

Why is your warehouse floor coating failing? There are a number of specific problems that cause coating failure for warehouse floor coatings, and many of them are rooted in the wrong choice of coating, or poor control of conditions when applying the original application.

The Incorrect Coating: Was the original coating the correct type for the application?

Common, inexpensive concrete coatings are not necessarily resistant enough to perform well with chemical spills, or in areas of high abrasion such as high-traffic hallways or fork-lift activity. Coatings that are inappropriate often wear quickly and display poor adhesion with rapid chipping, peeling, and surface failure.

Alternative two-component coatings specifically designed for tough areas may last many years longer under similar heavy traffic and other difficult conditions. Epoxies, urethane and powder coatings are more durable and preferable for extreme conditions but require substantial care in application.

Depending upon estimated conditions, simple, high-quality penetrating concrete sealers that prevent staining may ultimately prove be the best choice in some circumstances.

To avoid using the wrong coating, carefully study and evaluate the potential usage and conditions the floor coating will be expected to meet. Some considerations may be:

• Will the floor always be wet?
• Was the concrete slab poured with polyethylene beneath it?
  – Moisture rising by capillary action from beneath can cause coatings to lift and fail.
• Must the floor be skid-resistant and anti-slip?
• Is the coating you are considering chemical proof, or only ” resistant” to the chemicals you are handling?
• Will the warehouse floor repeatedly be subjected to chemical spills?
• Will the areas treated be subject to extreme traffic conditions?
• Will mechanical equipment such as loaders, fork lifts and other equipment be operated on the floor?
• Will the floor area be used in the food industry? Choose only coatings approved for that purpose.

Poor Substrate Preparation

Adhesion failure and other coating problems are not always the fault of the product. Correct substrate preparation is crucial to success and prevention of peeling , pinholes, and other surface defects. Excessive delays after surface prep and improper preparation of the substrate surface, regardless of type, almost guarantees poor results and product failure.

Was the concrete floor prepared properly prior to installing the coating? For some coating products, the concrete substrate must be cleaned and etched with phosphoric acid, other agents, or even sand-blasted and sealing. Was the floor completely dry at the time of application? If the floor was improperly prepared, coatings may easily peel off almost immediately upon use.

To avoid improper substrate preparation, do :

• Prepare the substrate as required by the manufacturer’s product instructions.
• Ensure the floor is not contaminated with silicone, oils or other materials that can cause pinholes and other coating defects.
• Ensure the surface is dry and free of dust.
• Follow product instructions for mixing components very accurately and carefully. Even the best product will not perform if mixed improperly.
• Ensure that all ambient conditions required for optimal application are met including absence of dust and other particulate matter.

Humidity, Temperature and Dew Point

Poor ambient conditions at the time of coating application can cause poor results including improper curing, pinholes, and inadequate adhesive performance. Ambient temperature, humidity, and dew point are critical at the time of application. If the floor or the product itself is too cold, component systems will not mix properly, flow when applied, or cure adequately. If the humidity is too high, the temperature/ dew point spread becomes critical and must be changed and controlled for a superior outcome and a reliable warehouse floor coating.

Your floor coating specialists can help you identify potential problems and offer remedial care, but using some of these tips will help you avoid having to deal with coating failure on your warehouse floor, and ensure your floor will look not only look great, but perform well for years.