Sometimes, the floor in a hall, warehouse, or production facility is crooked, puddles form, and water stagnates instead of disappearing. This problem is not only annoying but also dangerous: it's slippery, dirty, the subfloor deteriorates more quickly, and hygiene is more difficult to maintain. The solution is floor reprofiling, which means giving it the proper slopes towards the drains and channels, so that water and liquids have a place to drain.
When to order it and why
When "lakes" remain after floor cleaning. When technology changes and forced drainage is necessary (e.g., in wet production, car washes, processing plants, breweries, garages). When the old concrete industrial floor was made without slopes or the building has "settled." When a sanitary inspection or HACCP audit requires better hygiene and easier cleaning. When you want to reduce slipperiness and the risk of accidents.
What substrates can be improved?
Concrete, including cracked, missing, and dusty floors. Polymer epoxy or polyurethane resin floors, worn, cracked, with a peeling coating. In both cases, there's no need to completely remove the entire surface—often, proper substrate preparation and the addition of a profiling layer to create a slope are sufficient.
What is reprofiling step by step?
1. Reconnaissance and plan
Laser measurements are taken to determine the required slope and where. A slope of 1–2% (1–2 cm per meter) is most common, ensuring water drains quickly and forklifts can safely operate on the industrial floor repair.
Verification of drainage points before floor repair, inlets, grates, and troughs. Sometimes these need to be raised or lowered to fit the new geometry. Assessment of floor condition, load-bearing capacity, cracks, moisture, and contamination (oils, grease, chemicals).
2. Preparing the old floor
Mechanical cleaning, grinding, concrete milling, shot blasting – to remove cement laitance, paint, flaking resins, and open the pores of the concrete. Degreasing dirty areas. Repairing cracks and voids, stitching cracks, filling with resin and sand, reprofiling edges. Checking and restoring expansion joints (the gaps that allow the slab to "work").
3. Priming and bonding bridge
They are selected based on the type of industrial floor repair material that will be applied. This is key to adhesion and durability. Moisture-tolerant systems (e.g., polyurethane-cement) are often chosen for damp or "difficult" substrates.
4. Execution of inheritances
Marking levels with benchmarks/guide strips and a leveler. Laying a leveling layer for the slope. Quick-setting cement mortars or thin-layer commercial cement floors – when you need to return to work within 24–48 hours. Polymer/epoxy-quartz mortars – abrasion and chemical resistant. Polyurethane-cement systems (PU-cement) – for harsh conditions, hot water, thermal shocks, aggressive cleaning agents (e.g., food industry).
The thickness is selected based on needs. Real-world slope shaping typically requires several to a dozen or so millimeters of concrete grinding. Self-leveling materials won't create the slope themselves – the slope must be applied manually, using patches and trowels. Smooth transitions without "feathers" (very thin edges), which are weak and chip quickly – the edges are trimmed and reinforced.
5. Top layer
Depending on the function: epoxy, polyurethane, PU-cement coating, and in very difficult conditions – resin mortar with aggregate 6–9 mm thick. The anti-slip class (e.g., delicate texture in dry halls, stronger in wet areas), color and any markings, as well as the number of safety barriers are selected.
6. Expansion joints and grates
The cuts are recreated in the new layer and elastically sealed. The grates and drains must be flush with the new surface and "work" with the polished concrete floor (frames, flanges).
7. Reception
Water test after industrial floor repair – whether and how quickly it drains. Check for smoothness, slip resistance, thickness, and adhesion. Care and first-time cleaning instructions.
What about time and costs
Downtime can be reduced by using fast-acting systems – often pedestrian traffic can be restored after 6–12 hours, and forklift traffic after 24–48 hours (depending on temperature and material). The price depends on the layer thickness, extent of substrate preparation, material type, and number of inlets. Patching multiple small slopes can be more labor-intensive than patching a uniform surface. It's worth planning industrial floor repairs in stages to maintain production.
The most common mistakes that a good contractor avoids
The slope is too small (water stagnates) or too high (uncomfortable and dangerous for wheelchairs). Lack of continuity of flow – water stops at the "thresholds." Poorly positioned grates and inlets – not at the correct height, missing flanges. Neglected priming or a damp, greasy substrate – separation and blisters. The edges of the new layer are too thin – they crumble. Failure to recreate expansion joints – industrial flooring cracks.
How to choose a material system
"Wet" environments + chemicals + hot water: PU-cement (highest resistance) for industrial floor repairs. Vehicular traffic and abrasion, without high temperatures: epoxy-quartz mortars or high-build epoxy. Quick renovations and medium loads: fast-setting cement mortars with appropriate coating. Damp substrates: moisture-tolerant systems (not every epoxy resin is suitable).
What to pay attention to when ordering a service
Request a sketch of the slopes, indicating the heights and flow directions. Ask about the substrate preparation method and the primer to be used. Determine the target slip resistance and chemical resistance. Check the timeframe for reopening and the warranty. Ensure the contractor includes a water test upon acceptance.
Grading is one of the most effective and cost-effective industrial floor repairs. It eliminates puddles, improves safety, makes cleaning easier, and extends the life of the floor. Well-chosen materials and thorough subfloor preparation ensure a quick and long-lasting renovation. If you have a facility with nowhere for water to drain, this is the solution.
