Introduction
Commercial and industrial floors are built to last — but even the toughest epoxy or polyurethane system has a lifespan. Over time, daily wear, heavy traffic, temperature changes, and harsh cleaning chemicals can break down your floor’s protective coating.
Ignoring the early signs of damage can lead to safety risks, compliance breaches, and costly repairs. In this article, we’ll walk you through the key indicators that your floor coating needs to be replaced — and what to do about it.
Why Floor Coating Maintenance Matters
Floor coatings serve multiple purposes:
- Protecting your concrete subfloor
- Preventing slip-and-fall injuries
- Withstanding chemicals, spills, and abrasion
- Making cleaning faster and more effective
- Enhancing the appearance of your space
But when a coating begins to break down, all of these benefits are compromised. Worse still, damage can sometimes be invisible until it’s too late.
1. Cracks, Peeling, or Flaking
One of the most obvious signs your floor coating is failing is visible cracking or peeling. This often happens due to:
- Age (especially over 7–10 years old)
- Improper surface prep during installation
- Moisture beneath the slab
- Constant thermal expansion (hot/cold cycles)
Once the coating begins to lift or peel, water and dirt can penetrate underneath — accelerating further damage and causing trip hazards.
🛠️ What to do: If flaking is isolated, patching might be possible. But widespread peeling often means a full recoat is necessary.
2. Staining or Discolouration
Epoxy and polyurethane are resistant to most spills — but over time, chemical exposure, UV light, and poor cleaning practices can cause:
- Yellowing or browning in high-use areas
- Rust stains from equipment or shelving
- Uneven colour or fading in sun-exposed zones
In settings like kitchens, medical clinics, or retail showrooms, these stains can create a poor impression or lead to hygiene concerns.
🧽 What to do: Deep cleaning may restore surface colour temporarily, but if stains persist, resurfacing will be more effective — especially in client-facing spaces.
3. Surface Becomes Slippery or Uneven
Safety is non-negotiable in most commercial settings. If your floor used to have a textured or slip-resistant finish, but now feels smooth, worn, or patchy — it’s time for action.
Common causes include:
- Constant foot traffic wearing down texture
- Aggressive scrubbing or cleaning products
- Heat damage or oil accumulation
⚠️ This is especially dangerous in kitchens, hospitals, and manufacturing facilities.
👟 What to do: Apply a new slip-resistant topcoat or consider a full resurfacing with the appropriate R-rating (e.g. R11 or R12).
4. Loss of Gloss or Dull Finish
While aesthetic isn’t everything, a dull floor can signal underlying wear. If your previously glossy floor now appears chalky or uneven in shine, it’s likely that the surface sealant has been worn down.
This exposes the floor to:
- Faster staining
- Increased absorbency
- Harder cleaning and disinfection
✨ What to do: A fresh topcoat can bring back the shine and restore protective properties. But check for deeper damage before recoating.
5. Visible Damage from Machinery or Heavy Loads
In warehouses and industrial sites, forklifts, trolleys, and pallet jacks put enormous pressure on the floor. Look for:
- Deep gouges or impact craters
- Tire marks that don’t clean off
- Areas where the coating has worn down to bare concrete
🧯 In high-risk environments, this can quickly become a compliance issue, especially under workplace safety inspections.
🔧 What to do: Consider a high-build polyurethane system with greater impact resistance or use a protective zone matting system where forklifts frequently turn.
6. Moisture Issues or Bubbling
Blistering, bubbling, or “sweating” spots on your floor could be signs of subfloor moisture problems. These are especially common in older buildings or where a proper moisture barrier wasn’t applied.
If left untreated, moisture can:
- Disrupt adhesion of the coating
- Cause microbial growth or mould
- Lead to premature coating failure
💧 What to do: Moisture testing is essential. If moisture levels are high, a moisture-tolerant primer may be needed before recoating.
7. It’s Been 8–10 Years Since Installation
Even the best floor coating systems have a finite lifespan. Most commercial-grade coatings are designed to last:
- 5–7 years in kitchens or high-traffic areas
- 8–10 years in showrooms, offices, and retail
- 3–5 years in heavy industrial or forklift zones
If your floor is approaching or past its service life, it’s time for a full inspection — even if visible damage isn’t apparent yet.
Conclusion: Don’t Wait for the Damage to Get Worse
A worn or damaged floor doesn’t just look bad — it compromises safety, hygiene, and operational efficiency. Catching issues early can save you money, prevent downtime, and keep your business compliant.
✅ Wolffes Can Help
We offer:
- Floor inspections and safety assessments
- Targeted patching or full resurfacing
- Slip rating upgrades and compliance-friendly solutions