Cold rooms — such as those used in food storage, pharmaceuticals, or industrial refrigeration — present unique flooring challenges. Unlike seasonal cold-weather conditions, these spaces operate at consistently low (or sub-zero) temperatures, meaning the installation environment is far less forgiving. Standard resin systems may not cure properly, and environmental control can be difficult. 1. Extremely Low Substrate Temperatures
The Challenge:
Cold-room concrete slabs can be well below the minimum curing temperature for most coating systems (often below 10°C, sometimes even below 0°C). At such temperatures:

• The chemical reaction slows dramatically.
• Adhesion strength is reduced.
• Moisture in the slab may freeze, causing bond failure.

How to Overcome It:

• Use low-temperature curing systems (special epoxies or polyaspartics rated down to -20°C).
• Pre-warm the floor using portable infrared or forced-air heaters before and during application.
• Maintain a controlled heated zone over the working area with temporary enclosures and heat retention blankets.

2. Condensation and Frost Formation
The Challenge:
Cold surfaces attract moisture from ambient air, leading to frost or condensation on the substrate. This moisture prevents proper adhesion and can cause blistering or peeling.
How to Overcome It:

• Shut down cooling equipment temporarily to allow surface temperatures to rise above the dew point.
• Use dehumidifiers and air movers to remove moisture before coating.
• Monitor dew point closely and only apply when the substrate is at least 3°C above it.

3. Moisture Vapor Transmission (MVT)
The Challenge:
If the slab is at or near freezing, moisture within the concrete can freeze. Later, when the room is warmed for maintenance, thawing moisture can push against the coating, causing delamination.
How to Overcome It:

• Perform a moisture test before installation.
• If MVT is high, apply a vapor barrier primer compatible with low-temp coatings.
• Schedule coating work during a temporary shutdown to warm and dry the slab before application.

4. Shorter Working Time with Some Products
The Challenge:
In very cold rooms, some fast-curing low-temp systems (like polyaspartics) may have an extremely short pot life, making them harder to work with.
How to Overcome It:

• Mix smaller batches to prevent premature setting.
• Use application teams to speed up coverage.
• Choose formulations with controlled cure rates suitable for your specific temperature range.

5. Limited Ventilation and Odor Control
The Challenge:
Cold rooms are often sealed environments with minimal airflow. This can trap coating fumes and slow solvent evaporation.
How to Overcome It:

• Use low-VOC, low-odor systems.
• Deploy portable ventilation systems with ducting to exhaust fumes outside the building.
• Ensure workers use appropriate respirators rated for chemical vapors.

6. Strict Hygiene Requirements
The Challenge:
Cold-room flooring must meet food safety or pharmaceutical hygiene standards, meaning installation errors can’t be tolerated. Any contamination or poor finish can lead to costly shutdowns.
How to Overcome It:

• Use approved hygienic coatings (smooth, non-porous, and chemical resistant).
• Follow strict cleaning and preparation protocols before application.
• Apply seamless coving where walls meet floors to eliminate dirt traps.

Key Takeaways
Installing floor coatings in cold rooms demands a combination of specialized materials, controlled environment management, and precise application techniques. The best results come from:

1. Shutting down refrigeration systems temporarily to allow warming and drying.
2. Choosing the correct low-temperature coating system for the specific operating temperature.
3. Managing condensation and moisture through heating and dehumidification.
4. Ensuring rapid, coordinated application to work within reduced pot life and curing constraints.