Repairing Concrete Floors Before Applying Resin Coating

Repairing concrete floors before resinous flooring is applied is essential for a proper finish.  If this is not done, the damage will most likely reflect through the resin finish.

What is the Nature of the Damage?

First, the cause and the extent of the damage must be determined. Damage can be caused by wear, abrasion, impact or exposure to chemicals. It can also be due to defects in the original work, like unsuitable aggregates, honeycombing, or voids. Once the damage has been assessed, the weak or unsound concrete must be broken out mechanically, making sure that honeycombing or voids in the slab are exposed. Damaged joints and cracks must be treated in order to make sure that there will be no future cracking or contamination of the resin floor.

What Type of Material Should Be Used in the Repair?

There are several factors that must be considered in determining the best method for repair. They include:

  • The type of resin floor that is to be installed
  • The purpose of the resin floor
  • The environmental conditions at time of repair
  • The time available to complete the repairs

If time is not of the essence, large areas are usually repaired with cement based patch material. It is critical that there is enough time for them to cure to the point where the moisture content is acceptable for the resin flooring system. Generally speaking, the time needed will be at least 1-3 days. If the repair has to be done more quickly, rapid-hardening or quick curing cement could be used. Additionally, mortars of epoxy resin might be employed. This will be considerably more expensive, but the floor can be repaired and the new resin flooring system can be installed in the same day.

Moving or Non-Moving Cracks?

Cracks that will be subject to movement in the future should be treated as joints. They need to be cut square and brought through the floor finish. Then it is sealed with a floor joint sealant. If the crack is not-moving, then it is repaired and sealed before the new resin flooring is applied. The best materials and method will depend on the dimensions of the crack. Probably the surface will have to be opened and cleaned out with a diamond blade in order to get rid of any loose materials. Then a fine epoxy mortar can be pressed into the cracks to fill and seal it. The structural engineer may also advise injecting a low-pressure epoxy resin product.

It is vital that repairs to the underlying concrete be completed properly before the resin floor system is installed. Any damage left untreated will be highly detrimental to the appearance of the new floor.

Elite Crete Systems, Inc. is a world leading developer and manufacturer of specialty high performance building products for concrete surface repair and industrial high-wear protective floor coatings.