What Is Thermal Cycling?

Thermal cycling refers to the repeated expansion and contraction of materials due to temperature fluctuations. In a typical facility, the concrete substrate and the coating or polish on top expand at different rates. Over time, this movement can cause:

  • Cracking

  • Peeling or delamination

  • Joint separation

  • Surface discoloration

Facilities like food processing plants, pharmaceutical production, and cold storage warehouses are especially at risk.

Why Thermal Movement Matters

When temperatures fluctuate significantly—say, between 0°F and 180°F—floors without thermal flexibility begin to fail. Epoxy coatings, while tough, are still rigid. Polished concrete, though durable, can develop microcracks when subjected to rapid changes.

Ignoring this leads to:

  • Safety hazards from uneven surfaces or lifted coatings

  • Bacterial growth in cracks and joints

  • Increased maintenance costs due to constant repair cycles

How Epoxy and Concrete React Differently

Epoxy Floors:

  • Excellent for temperature control zones, but require the right formulation

  • Certain resin systems handle freezing and high heat better than others

  • Seamless surface prevents water or bacteria intrusion if installed correctly

Polished Concrete Floors:

  • Ideal for stable temperature zones

  • Densifiers strengthen surface structure

  • Can be combined with breathable sealers to handle light thermal change

Solutions for Thermal Stress

  1. Flexible Epoxy Systems
    • Use formulations with higher elongation rates for cold storage or thermal washdown areas.

    • Flexible membranes or urethane topcoats absorb micro-movement between slab and coating.

  2. Joint Reinforcement
    • Proper joint fill material expands and contracts with temperature changes, preventing cracking.

  3. Vapor Barriers and Moisture Mitigation

    • Control vapor pressure from below to prevent coating detachment during thermal expansion.

  4. Routine Maintenance

    • Annual inspection and resealing reduce the risk of delamination or joint failure.

Case Example: Cold Storage Distribution Center

A regional cold storage operator in New Jersey faced peeling epoxy floors due to repeated defrost cycles. Surface Solutions replaced the failed coating with a high-flex epoxy system and urethane topcoat. Two years later, the floor remains seamless despite daily temperature swings.

Industries Most Affected by Thermal Cycling

  • Food and beverage processing

  • Pharmaceutical manufacturing

  • Cold storage and refrigerated warehousing

  • Commercial kitchens

  • Chemical plants

Choosing the Right System

Every environment is different. Factors to consider include:

  • Frequency of temperature shifts

  • Cleaning procedures (steam, hot washdowns)

  • Substrate condition and reinforcement

  • Safety and slip resistance requirements

A professional installer can evaluate your environment and recommend a flooring system that balances flexibility, durability, and hygiene.

Surface Solutions’ Approach

  1. Thermal Movement Assessment – Evaluate temperature range and exposure duration

  2. System Design – Choose epoxy, urethane, or concrete polish compatible with your operation

  3. Expert Installation – Seamless, compliant systems engineered to last

  4. Ongoing Maintenance – Optional inspection and resealing programs

Build for Every Temperature

Call 877-CSTM-FLR
Email carolina@cstmflr.comVisit www.cstmflr.com

A floor should never limit your operation. Let’s engineer one that performs in every condition.

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