We have solutions for your current defect floor which will last much longer, is cost effective and saves time. Floor repair is very much important for proper functioning of work . Epoxy floors are durable, easy to clean and maintain. Moreover, it looks great with the seamless appearance and ability to customize in various colours. However, issues such as chipping or cracking may occur.

The extent of repair will depend on the type of cracks. First, let us look at the causes of floor cracks.

Causes of floor cracks

• Presence of water or damp can cause existing resin coating to bubble and result in debonding from the substrate. When heavy loads come into contact with the affected surface, the bubble may crack. Machine vibration can also cause the epoxy coating to debond from the substrate. 
• Impact from falling objects and point load can cause depression or floor surface to be chipped off. 
• Crack originates from the substrate. Shrinkage cracks in the substrate during curing process decrease the volume of concrete mass due to evaporation of water content, and force the concrete to develop cracks in the weaker parts.
  

  Once we have determined whether it is a surface crack or one that originates from the substrate, we can implement the appropriate repair method.

  Repair methods

  In all cases, mechanical surface preparation has to be done before fixing any holes, joints and surface defects. The first step is to detect any hollowness around the crack and isolate the area by placing a tape. Hollowness on the floor can be detected using a mallet or any other tool such as a metal or steel object to tap on the floor. The sound produced from a hollow substrate is different from the bonded substrate. If there is hollowness, the affected areas have to be removed and grinded off and proceed with localized repair. 

  If it is just a surface crack (e.g. crack in the coating), repair can be done by removing loose/weak particles and coating from the cracks and joints, and then made sound. This is followed by grinding off the existing coating and then applying a primer and finishing coat.

  If the crack arises from the substrate, all loose particles around the crack have to be removed and made sound. The cracks are then patched and fixed with fluid epoxy resin such as Eporip or an epoxy resin such as Primer SN mixed with Additix PE. An option is to embed a fiber mesh to help avoid or reduce capillary crack in case of micro-contractions.

  For dynamic cracks that come from the concrete substrate (i.e. screed has debonded from the concrete substrate), a localized repair can be done by removing all friable weak parts from the cracks and joints. If necessary, enlarge the cracks with a cutting tool and clean with a vacuum cleaner. Next, perform “stitching” or cross cuts along the cracks. The stitch can be further reinforced with steel bars to reduce their contraction or expansion width. Steel bars are placed into the opening and embedded with fluid epoxy resin to close the crack. Subsequently, the surface has to be grinded flat.

  If the surface needs to be further reinforced, a fiber mesh can be applied such as Mapenet 150. The surface is then embedded and fixed with a primer (for instance, Primer SN added with Additive PE) to smoothen the floor. This is followed by sanding and then applying a finishing coat. For holes and joint edges having higher thickness, these can be repaired or patched with heavy-duty epoxy mortars such as Mapefloor EP 19 MT with a minimum thickness of 5mm.

  CONCRETE SOLUTIONS

  Concrete Floors and subfloors can be repaired using some common methods. Concrete floors should be repaired with a surface topping only when the concrete slab contains surface, or hairline, cracks or has cosmetic surface flaws. If the concrete floor to be repaired is heaving, has large or wide cracks, or is damaged due to freeze damage, then other alternatives should be considered instead of resurfacing.

  Concrete Repair and Maintenance System

  As a first step to increase the likelihood of a successful repair, it is paramount to use a consistent, systematic approach to concrete repair. Reclamation’s concrete repair and maintenance system consists of seven basic steps:

  1. Determine the cause(s) of damage
  2. Evaluate the extent of damage
  3. Evaluate the need to repair
  4. Select the repair method and material
  5. Prepare the existing concrete for repair
  6. Apply the repair method 
  7. 7. Cure the repair properly 

  Different methods for Repair of damaged concrete floors

  Sealers and Coatings

  Concrete sealing and coating compounds are applied to cured, dry concrete as a maintenance and repair procedure to reduce or prevent penetration of water, aggressive solutions, or gaseous media. They help to reduce or prevent associated deterioration such as corrosion of rebar, freeze-thaw, carbonation, or sulfate damage. These materials are not suitable for repairing badly damaged or deteriorated concrete, but they are suitable for sealing concrete surfaces and cracks in concrete that is in overall good condition. 

  Cracks in concrete are widely regarded as long-term durability and maintenance problems because they increase the permeability of the concrete. Cracks can allow the ingress of moisture and other compounds into concrete, leading to further deterioration. Cracking is a problem that occurs in most geographical locations and climates, and many types of concrete structures. Reclamation has a large inventory of aging concrete that is experiencing deterioration resulting in cracking or exacerbated by cracking. Effective sealing and coating compounds for smaller cracks could slow or halt deterioration in some cases.

  Thin Repairs 

  Thin repairs are generally from about ¼- to about 2 inches deep and do not encompass any existing reinforcing steel. Typical examples of thin repairs include surface grinding, Portland cement mortar, some coatings and surface sealers, dry pack mortar, packaged cementitious and chemical repair mortars, and polymer mortars (including epoxy mortars). Unfortunately, insufficiently thick repairs to some concrete should not be considered permanent. In some circumstances, thin repairs may lead to accelerating deterioration behind or adjacent to the repair.

  Thick Repairs 

  In general, thick repairs refer to repairs that are about 3 inches thick and that completely encompass at least some reinforcing steel from the existing structure. If the repairs do not encompass any steel from the existing structure, they are typically at least 6 inches thick. In such cases, consideration should be given to anchoring additional reinforcement (that will be embedded in the repair material) to the existing concrete. Typical examples of thick repairs include replacement concrete, preplaced aggregate concrete, shotcrete, and silica fume concrete.

  Crack and Water Leak Repairs 

  Crack and leak repair methods are described below. They are treated separately from other concrete repair methods because they are significantly different from methods for thin or thick repairs. In many ways, properly repairing cracks and leaks can be the most difficult type of repair. In many Reclamation structures, if the concrete cracks, there is also a water leak. Reclamation’s seven-step process should be followed for crack repairs. In other words, the cause and extent of the cracks or leaks should be determined, including whether the cracks are dormant or active (moving); exposure conditions should be considered, wetting and drying, etc. 

  There are two basic types of crack repair: (1) resin injection, and (2) adding additional reinforcement. These two methods can be performed separately or in combination. Additional reinforcement is typically added if the shear or tensile capacity of a structural element has been, or might be, exceeded.