What is Resin Concrete Floor Repair?
Cracks in concrete floors and screed are extremely common and one of the biggest causes of failed floor coatings and finishes. Once a crack appears it is important to repair it as quickly and professionally as possible to extend the life of your warehouse or industrial surface.
The method of repairing a crack varies on the width, depth, floor finish, subfloor and usage of the area. But as a general rule the repairs are carried out by cleaning the opening where possible and filling with high strength 2 component epoxy resin, polyurethane or cementitious crack filler.
Benefits of Concrete Floor Repair Resin
- Can be installed from a feathered edge all the way up to any desired thickness without any curing issues.
- Grades available for interior and exterior use.
- Epoxy mortar can also be used on concrete in conjunction with aggregate to create a slip resistant surface with high abrasion resistance.
- Epoxy resin mortar can be used for rapid and permanent repairs to make ramps, fix holes and pot holes.
- Solvent free systems that are chemical resistant and free from shrinkage.
- Resin is the perfect repair as it is stronger than concrete itself.
The Main Types of Resin Floor Repair Concrete Repairs
- Epoxy concrete repair mortar – High strength mortars that can fill voids of any size.
- Fast cure screeds – Cementitious or resin based screeds, perfect for deep fill applications.
- Crack repairs – Low viscous resins suitable for penetrating deep in to failed areas.
- Resin coatings and finishes – Wide range of finishes to protect your floors from the harshest of environments
Industrial Flooring Demands Quality Repair and Maintenance
Industrial and commercial subfloors are known for their hard wearing and overall tough characteristics. However, that’s not going to prevent cracks, imperfections or other kinds of damage to appear from time to time. As such, it’s always best to work with an expert resin floor repair specialist who has years of expertise resin crack repair, resin joint repair and concrete repair products.
At DC Flooring, we have decades of experience in resin crack and floor joint repair, with our services tailored to your specific needs. We also offer regular flooring check-ups, inspections and service & maintenance plans. Rest assured, once your floor has been repaired by ourselves it will be fit for one of resin floor systems to be applied which will make the area look brand new. Alternatively if no coatings are going to hide the repairs we will do to your concrete floor, we will do our upmost to make them as neat as possible to blend into your existing surface. This means your floor will stay in the best shape possible all year round.
Resin Floor Repair or Replacement? Decisions, Decisions!
At times, big cracks appearing in your floor may point to underlying damage to your concrete base/subfloor – in such a situation, a repair may be feasible – although for smaller cracks and joint deformities, resin floor repair is an ideal option. In any case, our resin flooring specialists will conduct a survey of your space and recommend the most cost-effective solution, which may involve replacing your old flooring with the latest resin flooring system.
We can install top-quality stainless steel kerbs or coved resin skirting where your flooring system meets with walls/pillars to reduce vulnerability to cracks and impact damage as much as possible.
In most cases, we recommend resin crack repair and resin joint repair as it is a cost-effective solution for resin floors which haven’t yet taken too much of a beating. Our team is mindful of any long-term costs which may result due to repeat repair jobs and will recommend a resin floor replacement if it is more cost-effective for you and your business in the long run.
Our resin floor repair specialists would be happy to provide a free, no-obligation quote on the spot, helping to keep your business operations running smoothly.
Why DC Flooring for Crack and Joint Repair?
- Established resin floor repair company with decades of experience in resin floor systems
- Specialists in industrial and commercial resin floor repair and installation
- Core drilling option to more accurately determine the depth of cracking
- Diamond concrete grinding where required to give your floors a smooth and even appearance – also done in-house
- Free initial surveying available to investigate delamination and hollow areas
- Free technical advice regarding your damaged concrete floor or resin systems, throughout the UK.
- Conducting repair, service and maintenance for all types of resin and concrete floors across all industries. From light scratches and abrasions to more prominent cracks and joint defects, our resin flooring specialists are well-versed in all kinds of permanent repairs to concrete.
- Working with a highly durable repair system – we use epoxy repair mortar, grouts only for all resin floor installations and repair. Grouting materials are excellent for repairing resin floors which have developed cracks or where joints need to be repaired.
- Fast cure repairs with high chemical resistance. With as little as 1 hour cure time, ready for traffic even in temperatures as low as -30°C.
- Health and safety for our staff and yourself is of the highest importance
When working with resin flooring specialists, always ensure that they repair cracks and/or joints using high quality industrial materials, materials bought in most high street stores will do the job for a limited time, but will never provide a long term solution. Our grouts work very well to fill voids and cracks, and they are used for anchoring in structural applications.
Our epoxy injection grout, for example, is a low viscosity grout used to fill gaps and cracks in resin as well as concrete floors. It effectively seals both sides of the crack to prevent any resin drainage or further damage to the site in future. We have a versatile range of resin grouts which are used to fill fine cracks and larger ones alike without any hammering. Structural repairs through injection resin to your floor is an ideal method for prolonging the life of resin floors which have undergone crack and joint repair.
Contact our Resin Crack and Joint Repair Specialists Today
If left unchecked, cracks in your resin floor can spread easily and lead to more widespread, permanent damage, where a replacement may be the only viable solution. Our team can deploy rapidly and conduct a thorough inspection to get your resin floor looking and feeling like new again.
All subfloor preparation is done in-house using our specialised equipment – shotblasting, scabbling, and concrete grinding.
You’re only a phone call away from investing in leading-class flooring systems, all approved by FeRFA.
How do you fix a crack in a resin floor?
There are three main methods of crack repair.
- Chase and Fill – This method involves opening the crack up by chasing it with a floor saw and diamond blade to make the opening bigger and removing any friable or damaged concrete. Specialist strong epoxy crack repair resin is poured into the crevasse until the crack fills to the top of the concrete surface and finished level with a trowel. It is important to monitor these repairs as after a while they may “sink” and require topping up. This is due to the resin sometimes needing more time to find its way through to the bottom of the crack.
- Crack Injection – When crack repairs are of the upmost importance structurally, we would recommend crack injection. The crack and its surrounding area are thoroughly cleaned and prepared to ensure proper adhesion of the injection material. This may involve removing any loose debris, dust, or contaminants from the substrate. Small plastic or metal nipples, also known as injection ports, are inserted into the crack at regular intervals.
These nipples serve as access points for injecting the repair material into the crack. The nipples are securely sealed to the surface using an appropriate sealant or epoxy adhesive. This helps to prevent the injected material from leaking out during the injection process. A specialized repair material, such as epoxy or polyurethane resin, is injected into the crack through the nipples using a pressure injection system or a manual injection gun.
The material is forced into the crack, filling it from the inside out and bonding with the surrounding substrate. This method ensures that the whole crack is being filled as much as it can, this is because you can visually see the resin coming out of each of the injection ports. This method can be used for repairs to damaged floors and walls.
- Stitch Pinning – If there is major structural movement in a concrete subfloor usual methods can fix the original crack, but new issues may well appear where the floor is still trying to move. In this case stitch pinning is an option. This is basically putting numerous saw cuts across the existing concrete crack, drilling a hole at each end of it and the affixing a metal “staple” with resin to try to fight against the movement of the slab.
What is the difference between epoxy and resin flooring?
Epoxy is a type of resin. There are a number of different resin flooring systems – epoxy, polyurethane, mma, acrylic, polyaspartic etc. They all have different properties and characteristics. Please contact our office for free technical advice if you need some guidance in choosing your flooring solution.
Why is my epoxy floor cracking?
Although epoxy has an extremely high compressive strength making it great for industrial applications and wearing characteristics, it is also brittle. This means that if the subfloor that it is attached to is sound, secure and free of movement it will very rarely crack. If it is cracking, by far the most probable cause is movement of the subfloor, self levelling compound or industrial floor screed that it is attached to. Expansion joints in concrete are a very common cause, sometimes these are not dealt with correctly by contractors and sometimes are completely ignored. If the cracks that you are seeing are in relatively straight uniform lines then this is probably the answer.
The only other reasons that epoxy floors crack is down to thermal shock that some systems are not designed to handle. We supply and install specialist resins that can handle extreme temperature fluctuations, but it is always important to consider this information before choosing the correct resin system for your application.
Which is the most common method of crack repair?
The most common method of crack repair is to chase and fill. As described above, this is the least time consuming and value for money method that can be used. This epoxy floor repair can however be expensive if the crack that you are filling is leading to a void below the surface.