What Causes Failure of Epoxy Coatings?

The failure of epoxy coatings has basically two causes.

Hydrostatic Pressure
Insufficient Surface Prep

Hydrostatic pressure comes from the movement of moisture from the subgrade up to the surface of concrete by way of capillary action. This causes the floor to "sweat" even when the air is dry. Minor moisture problems are common on garage floors because building codes don't normally require a vapor barrier (plastic sheeting) between the floor and subgrade. This moisture can break the bond between the concrete and the epoxy resulting in chipping and flaking. If your floor stays dry most of the time then you shouldn't have any problems with an epoxy coating. But if there is constant sweating then it's a waste of time and money.

The most prominent reason for the failure of epoxy coatings is the lack of sufficient surface preparation. This is the key to a long lasting finish. The floor must be completely clean and free of any other coatings, stains, grease, dirt, etc. Any foreign substances will prevent proper bonding. The pores of the concrete must also be opened up for good adhesion, whether it's done mechanically or with acid. Without proper surface prep, it's just a matter of time before the epoxy starts peeling away.

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What Causes Failure of Epoxy Coatings?