Troubleshooting Common Issues in Epoxy & Polyaspartic Floor Installation

If you’re an Albertan considering a durable, high-performance floor coating, chances are you’ve come across polyaspartic floor installation as a top contender. At Elegant Coatings, we’ve seen firsthand how this technology transforms spaces with its rapid curing and exceptional durability.

But, like any sophisticated system, it’s not without its quirks and challenges. Let’s dive into the nitty-gritty of troubleshooting common issues in epoxy and polyaspartic floor installations, with a particular eye on the Calgary market.

Why Polyaspartic Floor Installation?

Recent studies show that polyaspartic floor installation and coatings can achieve full cure times as fast as 80 minutes under moderate temperature and humidity conditions, while maintaining superior abrasion resistance and low VOC emissions, making them an optimal choice for fast-paced commercial projects in climates like Calgary’s.

The city’s climate throws a curveball at many construction materials — from freezing winters to sudden humidity spikes. Polyaspartic coatings are gaining traction here because they cure within 24 hours, tolerate sub-freezing temperatures, and are less sensitive to humidity compared to traditional epoxy coatings. This makes them ideal for Alberta’s variable environment, where downtime is costly and conditions unpredictable.

The Critical First Step

You can’t build a fortress on a shaky foundation — and the same goes for floor coatings. The single most common culprit behind installation failures is poor surface prep.

Concrete Grinding: Diamond grinding is non-negotiable. It removes contaminants like oil and grease — which are notorious for wrecking adhesion — and creates a scratch profile that polyaspartic coatings can grip onto. In Calgary’s industrial and commercial settings, where concrete often bears the scars of heavy machinery and spills, this step is crucial.
Cleaning: After grinding, vacuuming is mandatory to eliminate dust and debris. Don’t even think about rinsing the floor unless you’re prepared to wait for complete drying — moisture trapped in the substrate can sabotage your entire coating.
Moisture Testing: Calgary’s concrete slabs can harbor moisture from melting snow or groundwater. Use a hygrometer to test for moisture content. If levels are too high, wait or apply moisture mitigation systems. Fresh concrete must cure for at least 28 days before coating.

Mixing and Application

Polyaspartic coatings are a two-part system that demands exact mixing ratios. Here’s where many installers slip:

Incorrect Ratios: Too much or too little of either part can cause the coating to either partially evaporate or fail to cure entirely. This leads to a thin, brittle surface or a gummy, uncured mess that never hardens. The cure time in Calgary’s climate is about 24 hours, with walk-on possible after 6 hours — but only if mixed correctly.
Mixing Technique: Use a slow-speed drill with a 2-inch paddle to ensure pigment and components blend evenly. Mix for about one minute, moving the paddle around the bucket edges to avoid unmixed pockets.
Pot Life and Speed: Polyaspartic coatings cure fast — sometimes in minutes. This means you must work quickly and efficiently. A slow or inexperienced crew risks uneven coverage and roller marks.

Common Polyaspartic Floor Installation Issues and How to Fix Them

1. Bubbles and Pinholes

Bubbles are often caused by gases escaping from the concrete or trapped air during application.

Cause: Poor substrate sealing, temperature fluctuations (like Calgary’s midday sun warming the slab), or humidity in the substrate.
Fix: Use a primer coat to seal the substrate thoroughly before applying the polyaspartic. Avoid applying self-leveling coats in the morning when slabs are cold and warming rapidly. Use spiked rollers to pop bubbles during application.

2. Inconsistent Coverage and Visible Concrete

A patchy finish with visible concrete underneath is a red flag.

Cause: Inconsistent application thickness, pooling in some areas, or inadequate grinding at edges.
Fix: Re-grind the floor to ensure a uniform profile. Apply a 10 mil base coat with pigment, allow it to dry, then scrape and vacuum excess before applying a 16 mil top coat. Sand edges carefully to avoid rough patches.

3. Flaking and Poor Adhesion

Flaking flakes or chips in the coating often mean the bond between the coating and concrete failed.

Cause: Contaminants like oil that penetrated the concrete or insufficient surface profile.
Fix: Thorough grinding and cleaning are your best bets. If oil has seeped deep, professional remediation might be necessary. Always use a self-priming polyaspartic coat to improve adhesion.

4. Trowel Marks and Uneven Surface

Visible trowel marks or rough texture indicate poor flow or insufficient product.

Cause: Using too little material or applying in cold temperatures that prevent proper flow.
Fix: Follow manufacturer’s recommended coverage rates precisely. Store materials in a warm environment before use. If solvent-based, adding a solvent can improve flow.

Environmental Factors of Polyaspartic Floor Installation

Temperature: Polyaspartic coatings can be installed in sub-zero temps, but curing slows down. Plan installations during stable weather windows to avoid surprises.
Humidity: Unlike epoxy, polyaspartic coatings actually cure faster with higher humidity, but rain during application is a no-go. Ensure the air and substrate are dry before starting.
Concrete Age: New concrete must cure for at least 28 days. Calgary’s freeze-thaw cycles can extend this period, so testing is essential.

Why Trust Elegant Coatings?

At Elegant Coatings, we don’t just slap on a floor; we engineer a system tailored to Calgary’s climate and your specific needs. Our team is trained extensively in polyaspartic and epoxy systems, ensuring every project meets the highest standards. We also offer specialized Calgary Epoxy & Polyaspartic Floor Coating Training for contractors who want to master the craft and avoid costly mistakes

Polyaspartic Floor Installation with Elegant Coatings

Polyaspartic floor installation is a high-reward, high-precision game. The rapid cure times and superior durability make it a no-brainer for Calgary’s demanding environments — but only if you get the prep, mixing, and application right. Skip the shortcuts, trust the pros, and your floors will thank you for decades.

For Albertans ready to upgrade their floors with confidence, Elegant Coatings stands ready to deliver expert installation and training. Get in touch, and let’s make your floor the envy of Calgary.

FAQs

Can polyaspartic coatings be applied over existing epoxy floors?
Yes, polyaspartic coatings can be applied over existing epoxy floors, provided the epoxy is fully cured and the surface is properly prepared by cleaning and light abrasion. This allows for enhanced durability and faster cure times on top of an older coating.
How long does a typical polyaspartic floor installation take in Calgary?
Thanks to polyaspartic’s rapid curing properties, most installations in Calgary can be completed within a day, with foot traffic allowed in as little as 6 hours and full vehicular use by the next day. This fast turnaround is a major advantage in commercial and industrial settings.
Does Elegant Coatings offer customized polyaspartic floor installation’s solutions for different industries?
Absolutely. Elegant Coatings specializes in tailored polyaspartic floor installations designed to meet the unique demands of sectors such as manufacturing, warehousing, retail, and residential garages across Calgary and Alberta. Our expert team ensures optimal performance and longevity.
What maintenance is required for polyaspartic floors?
Polyaspartic floors are low maintenance; regular sweeping and occasional mopping with a pH-neutral cleaner keep them looking pristine. Their chemical and UV resistance means they don’t require frequent recoating, making them cost-effective over time.
Are polyaspartic coatings environmentally friendly?
Polyaspartic coatings generally have low volatile organic compound (VOC) emissions compared to traditional epoxy, making them a cleaner option for indoor air quality. While not 100% green, they are a preferable choice for environmentally conscious projects.