Our task was to quickly and reliably restore a level, safe floor to the operational production area. The scope of work included:
Concreting of larger floor voids, 10–30 cm deep. Spot repair of industrial floor cavities and cracks using epoxy resin. We wanted to minimize downtime and ensure operator comfort and trouble-free forklift operation.
Preparing the workplace
Before we began, we marked off the work zones with tape and barriers, installed signage, and organized alternate transportation. We coordinated a schedule with production management to conduct the noisier and more disruptive work during off-peak hours. We also provided ventilation and dust extraction equipment, as cutting and grinding concrete floors generate a significant amount of debris.
Key preparatory steps
Thoroughly cleaning and vacuuming the repair areas. Trimming the edges of the defects to ensure they are even and stable. Removing loose concrete fragments and loose layers. Drying the industrial floor substrate – this is important, especially with resins. Concreting large holes (10–30 cm). Where the defects were deep, we reconstructed them with high-strength concrete.
How we did it
Preparing the subfloor for the concrete industrial floor – we created a "frame" with even, stable edges; in places, we used reinforcing mesh to strengthen the corners. Priming – we used a preparation that improved the adhesion of the new concrete to the old slab.
Pouring the mix – we laid the concrete in layers, carefully compacting it to prevent voids. Leveling and troweling – ensuring the new surface was flush with the existing floor and avoiding any "steps."
Maintenance – Fresh concrete for industrial floor repair was protected from drying out too quickly. Pedestrian traffic was permitted after initial curing, and forklift traffic was permitted after achieving the appropriate hardness (in accordance with the technology recommendations – in stages to avoid damaging the fresh fill).
Spot repairs of dents and cracks with epoxy resin
Epoxy or polyurethane resin flooring is a two-component material that hardens after mixing and bonds strongly to the substrate. It's ideal for quick repairs because it gains strength faster than traditional mortars.
How we fixed it
The cracks. First, we slightly widened and cleaned them to ensure the resin penetrated properly. Then, we filled them with resin and sprinkled the surface with fine quartz sand, making the repaired area non-slip. Once it had set, we removed the excess sand and leveled the surface of the industrial floor repairs.
Hollows and gaps. We prepared a mortar of resin and quartz aggregate. We filled the hollows in layers, leveled them, and after curing, lightly sanded them to obtain a smooth, even surface.
Advantages of this method
Short shutdown time for the polished concrete area. Very good adhesion and durability. Resistance to loads from forklifts and machinery movement. Reduced risk of further crack "working" because the cracks are sealed.
Security and organization
Employees wore protective equipment (masks, goggles, gloves). We maintained constant ventilation while working with resin. We cleaned regularly to reduce dust and keep traffic routes clear. We ensured clear markings for areas that were temporarily inaccessible, as well as for the use of safety barriers.
Final result and quality control
After completing the floor repair, we inspected the floor and measured its evenness. We checked for any height differences that might interfere with wheelchairs and ensured the repaired areas were firm and stable. The results were excellent:
The floor is even, with no thresholds or dips. Forklifts move more smoothly, reducing vibration and noise. The risk of tripping and further chipping of cracked edges has been reduced. Industrial floor repair areas blend seamlessly with the rest of the floor.
The biggest challenges
Maintaining production without interruption – we solved this with sectional work and a flexible schedule. Temperature and humidity – we constantly monitored conditions to ensure the thin-layer commercial cement flooring and resin bonded properly.
Recommendations for the future
Regular floor inspections every 6–12 months, especially in high-traffic areas. Promptly report and repair minor cracks – the sooner, the cheaper and easier. Limiting point impacts (e.g., dropping heavy objects) and using bumpers.
Maintain cleanliness while milling concrete – sand and fine debris act like sandpaper and accelerate wear. Avoid spilling aggressive chemicals; in the event of a spill, clean up immediately.
The industrial floor repair was completed efficiently, within the agreed-upon deadlines, and with minimal impact on ongoing production. We filled the large voids with durable concrete, and sealed the cracks and smaller depressions with epoxy resin. This restored the floor's evenness, load-bearing capacity, and aesthetic appeal, and made moving around the hall—on foot and in wheelchairs—safer and more comfortable. If new minor damage occurs, it's worth responding quickly—this will help maintain the floor's good condition for years to come and avoid costly, larger repairs.
