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Epoxy bubbles

Innovate1

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Jul 28, 2014
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Illinois near St. Louis, Missouri
I had one spot that bubbled up. About 1/2" high and about 1.5" diameter. The contractor "fixed" it twice and it kept bubbling up when it got warm. I punctured it and it was dry with just air inside. Then I started looking around and found a number of much smaller spots. Yesterday I noticed another large spot in another location. They flatten out when it gets cooler and puff up when warm (at least that's my observation).

I finally said don't come back because this is just bad every time and they said they wanted to bring their material supplier by. I think they are trying to line that up and I insisted I be there for that although they said I didn't need to be. Planning to get someone else to look at this too as I think the main issue is poor prep and lack of bonding. His standard operating procedure seems to be to cut corners and say "it will be fine".
 

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Innovate1

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Jul 28, 2014
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Location
Illinois near St. Louis, Missouri
I'm hoping some with experience will comment on what might be happening, if my thinking on the likely cause is reasonable, and what needs to be done to fix it. I looked this morning and the big bubble is gone - the area is flat with no obvious issues. I know that air expands when warm but that's a lot of air that must be coming from the epoxy outgassing as it cures, moisture under the slab, or somewhere. The bubbles are at least a foot from any edges or expansion joints. I am guessing the real fix is to strip it all off and start over. It's getting late this year for good weather for it so will probably be next summer to rework it if it needs complete replacement. Surface flakes are still loose in spots and really rough. He said he was going to scrape it and give it another coat but I don't see any evidence of that.

My guess is the bubbles may settle down and stop after while but the surface may crack off with tires and other things putting pressure on the surface. So I may get a few years out of it before it starts to come apart. Just a wild guess.
 

Shea

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Sep 19, 2012
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California
Was this a licensed floor coating contractor? How was the floor prepped? Was there ever any efflorescence or other indications of moisture in the concrete? If so, was a moisture test performed?
 
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Innovate1

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Licensed? No. I don't believe there is such a license here. Who would they be licensed with?

Floor prep: Floor is about 4 months old. It's on the top of a hill and at the highest point so no moisture or efflorescence issues. Floor had a curing sealer applied when it was fresh. Wouldn't have done that for epoxy but we changed course. They used a floor buffer type rig to take up the coating. I know there were some smears in the corners of gummed up coating. Then muratic acid wash and pressure wash. Then shop vac to pull up excess water in joints and such. Two day wait to put down first coat. No moisture test. I delayed him putting down the first coat or he would have put it down the next day after power washing.
 

CombatNinja

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Aug 24, 2013
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Sounds like the guy was just winging it and hoping it would hold long enough for you to lose his phone number. What kind of ***** would try to coat a floor with epoxy one day after power washing it?
 

Shea

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Location
California
Licensed? No. I don't believe there is such a license here. Who would they be licensed with?

Floor prep: Floor is about 4 months old. It's on the top of a hill and at the highest point so no moisture or efflorescence issues. Floor had a curing sealer applied when it was fresh. Wouldn't have done that for epoxy but we changed course. They used a floor buffer type rig to take up the coating. I know there were some smears in the corners of gummed up coating. Then muratic acid wash and pressure wash. Then shop vac to pull up excess water in joints and such. Two day wait to put down first coat. No moisture test. I delayed him putting down the first coat or he would have put it down the next day after power washing.

They would be licensed with the state as a contractor to do business. Most states require a contractors license when a service or job is performed that would alter or make improvements to a home. There is usually a minimum dollar figure attached which varies state by state. For Illinois, I believe it's $1000.

Licensed floor coating companies and installers / contractors tend to take their work much more seriously. Training is involved, good relationships are established with coating suppliers, and etc. In addition, many are bonded. In essence, you are separating the true professionals who know their business vs the ones who "think they know" and are out trying to turn a quick buck under the radar. It doesn't mean that every guy out there without a license is not good. However, our experience has shown that the majority of problems we hear about is from such installers. Many of these installers tend to be house painters and handymen that don't know as much as they think about coatings.

The reason I asked is because all professionals know that proper floor prep is the most important part of the job and the one part that prevents most call backs. In addition, when a surface is properly profiled, the last thing you want to do is introduce water to it, let alone muriatic acid. This was the main tip-off. If it was properly grinded to begin with, then etching would not have been necessary. An installer who is removing a cure and seal film would be aware of this and grind appropriately.

Pressure washers drive moisture deep into the concrete and it takes some time to properly dry out. I think your guess about moisture coming up through the concrete due to inadequate drying time is the likely issue.

Also, was the acid etch neutralized before rinsed or was it just rinsed with a pressure washer? If not properly neutralized, active acid solution can continue working on the concrete from within and cause the concrete to slowly deteriorate under the coating and loose adhesion some time later.

I'm not trying to say you made a bad decision about who you hired. I'm just trying to give the best explanation I can so you can figure out the best course of action. :beer:
 

Armorpoxy

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Aug 18, 2013
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Location
NJ
Hi,
In our opinion any 'professional' garage installer that doesn't diamond grind, and uses a pressure washer should be avoided. A professional should invest in the proper equipment which not only assures the proper job, but also saves them time (money).
 
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