Resin flooring is becoming more popular in industrial and commercial settings due to its flexibility and the significant range of benefits it can provide. Resin flooring can offer, enhanced, hygiene, performance and aesthetics, however, choosing a professional contractor is essential. Since resin flooring is installed in situ, the quality and success of the floor rely heavily on the resin flooring contractor’s experience.
While it is not possible to prevent every failure, a professional and experienced resin flooring contractor will identify ways to reduce risks and minimise the likelihood of problems or future failures. Site conditions, improper preparation or installation, and incorrect specifications can all negatively impact the final product and lead to failures.
Common resin flooring failures and their root causes:
- Delamination and Adhesion Failure
At RESYN we always reinforce the message that surface preparation is key to achieving a long-lasting resin floor. Identifying and removing any contamination along with the correct use of primers (when required) is essential in ensuring the resin floor adheres securely to the substrate and minimises delamination.
An experienced contractor will ensure that the substrate has the correct moisture content and compressive strength for the specified resin.
Prevention: Mechanical preparation (diamond grinding or shot blasting), moisture testing, correct priming.
- Cracking
Cracking typically arises from substrate movement, thermal expansion or insufficient joint detailing.
Cracking resulting from substrate movement can be hard to avoid but it can sometimes be avoided if this is identified prior to the installation. The contractor may be able to repair or stabilise the substrate and if necessary, include joint detailing with a flexible compound.
Thermal expansion is caused when the floor expands and contracts causing the substrate and the resin to expand at different rates. Choosing the correct resin system and installing anchors can aid in the prevention of cracks arising from thermal expansion.
Some resin flooring solutions are specifically designed to provide greater flexibility in areas where it’s needed.
Prevention: Proper substrate evaluation, correct resin system selection (rigid vs. flexible), and joint detailing.
- Osmotic Blistering
Osmotic blistering is a common defect that appears as blisters or bubbles on the surface of the floor coating. These blisters occur due to a combination of factors including, moisture, vapour pressure and osmotic forces. This type of failure can be a result of high moisture content in the substrate, lack of moisture barriers or primers (when required) or contaminants.
To prevent this failure, moisture levels in the substrate should be tested, appropriate primers applied where needed, and any substrate contamination identified.
Prevention: Moisture barriers, correct primers, substrate moisture testing.
- Discoloration and UV Degradation
Discolouration of resin can occur due to chemical reactions, exposure to sunlight or moisture and temperature fluctuations.
Some resin flooring systems offer better resistance to discolouration and UV degradation.
Identifying the environmental factors and choosing the most suitable resin type can help to reduce the risks of discolouration.
Prevention: Selecting UV-stable systems where required and maintaining cleaning protocols. Evaluating whether potential chemical exposures are compatible with the resin flooring solution.
- Uneven or Soft Finish
Uneven or soft finishes in resin flooring usually occurs during mixing, application or curing. Incorrect mixing ratios or poor mixing technique can result in the resin flooring solution not curing properly or looking patchy.
Changes in temperature and humidity can also affect how some resins cure, possibly causing uneven texture or colour and soft spots.
Prevention: Professional mixing equipment, site control, and trained applicators.
The Role of Specification and Design:
The role of specification and design is critically important because this will determine, how well the floor will perform, how long it will last and whether it meets the functional, safety and aesthetic needs of the client.
As discussed in our previous blog, Understanding Resin: The Differences between resin flooring types, there are different types of resin (Epoxy, Polyurethane and MMA), each with different chemical, mechanical and thermal properties. The selection of the correct product and system will greatly influence the suitability within the chosen environment.
It is essential to assess the environmental conditions, including, substrate type and condition, traffic load, chemical exposure and maintenance regimes to allow the correct specification to be applied.
The wrong specification can lead to premature failure, safety hazards, and major repair costs. The right specification and design ensure durability, compliance, and performance.
The Professional Contractor’s Approach: Checklist for Success:
An experienced resin flooring contractor will assess potential risks and implement strategies to minimise problems and prevent future failures. The checklist below serves as a useful tool for evaluating the service that a professional resin flooring contractor will provide.
- Comprehensive Site Survey: Assess substrate, moisture, and environmental conditions.
- Surface Preparation Plan: Mechanical preparation, cleaning, and moisture mitigation.
- System Design and Compatibility: Matching the resin to the substrate and conditions.
- Skilled Application: Certified installation teams, correct mixing ratios, environmental control during curing.
- Quality Control: On-site supervision, adhesion testing.
- Aftercare Guidance: Maintenance schedules and cleaning instructions to extend service life.
The Value of Professionalism
Although it is not impossible for the product to be the cause of resin flooring failure, it is most commonly the result of an installation error.
While resin flooring solutions may not always be the most cost-effective option upfront, the long-term value they provide can be significant. Investing in skilled and qualified installation professionals is crucial to ensuring that your resin flooring is applied correctly and performs optimally over time. Proper installation not only maximises the lifespan and durability of the flooring but can also help prevent costly repairs, replacements, or maintenance issues down the line. By prioritising expertise during installation, you ultimately protect your investment and achieve greater cost savings over the life of the flooring.
RESYN has extensive knowledge of the different types of resin flooring solutions available. Drawing on extensive experience across a diverse range of industry sectors, RESYN is well-equipped to offer professional, reliable, and tailored guidance, helping clients select the most suitable flooring solution to meet their specific operational, aesthetic, and safety requirements.
Need further assistance?
By choosing professional commercial or industrial resin flooring, you can avoid resin flooring failures, reduce repair costs, and achieve a durable, attractive finish. For expert advice from an experienced resin flooring contractor, complete our contact form or call 01778 343 670.