Concrete repair & resurfacing
Spalling, pitting, joint failure and salt damage put right before a coating goes near it.
What it is
What repair & resurfacing actually is.
Structural and cosmetic repair to concrete that has broken down — spalled surfaces, failed joints, cracks, and the salt damage that is endemic on a New England slab. Sometimes it is preparation for a coating. Sometimes it is the whole job, and we will tell you which.
Where we are the right call
- Slabs with spalling, pitting or surface breakdown from de-icing salt
- Failed joints in warehouse and industrial floors
- Repair ahead of a coating, a polish or a racking installation
- Owners deciding between repair and replacement, who want a straight answer
Where we will tell you something else
- Structural failure, which needs an engineer before a contractor
- Slabs so far gone that replacement is genuinely the cheaper answer
- Active water ingress, which is a drainage problem first
Specification
What it is rated for.
| Spall repair | Broken concrete cut out to sound material and rebuilt with a polymer-modified repair mortar |
|---|---|
| Joint repair | Saw-cut, cleaned and filled with semi-rigid filler, so the joint carries wheel loads instead of spalling outward |
| Crack repair | Routed and filled. Moving and structural cracks identified and flagged rather than covered |
| Salt damage | Chloride-damaged surfaces removed to sound concrete before anything is laid over them |
| Moisture remediation | Vapour barrier primers where readings require them; drainage problems referred rather than coated over |
| Warranty | Written workmanship warranty, terms by system |
How a commercial job runs
Four stages, and you know when you get the space back.
Stage 01
Site assessment
We walk the building, test the slab for moisture and dew point, review chemical exposure and agree the shutdown window. You get a written scope, not a number on a card.
On site, no obligationStage 02
Preparation
Diamond grinding or shot blasting to profile, crack and joint repair, and HEPA extraction so the rest of the building stays open.
Dust contained · CSP 2–3Stage 03
Installation
Base coat, broadcast and topcoat, phased by bay or zone. Overnight and weekend work where production cannot stop.
Phased by zoneStage 04
Return to service
Foot traffic the following morning, vehicles and racking the day after. Cold slabs cure slower and we tell you the real number.
10–14 hrs foot · 24–48 hrs loadCommon questions
What people ask about this system.
Repair or replace?
Depends how deep it goes. Surface spalling from salt is repairable and usually worth repairing. Breakdown through the full depth of the slab, or cracking that traces a structural pattern, is not — and we would rather lose the job than take money for a repair that will fail. We will say which you have at the walk-through.
Why do the joints keep failing?
Because a joint left open or filled with a soft sealant has no shoulder support, so every wheel that crosses it chips the edge a little more. A semi-rigid filler carries the load across the joint instead, which is why it is the detail we treat separately on every industrial floor rather than coating over.
How much of my building has to stop?
As little as we can engineer. Almost all of our commercial work is phased — one bay, one zone or one room at a time — so the whole facility is never down at once. We agree the sequence and the hand-back times at the walk-through and put them in the proposal, which means you can plan around a number rather than a promise.
How quickly can we use the floor again?
Foot traffic roughly 10 to 14 hours after the last coat, vehicles, racking and equipment after 24 to 48 hours, both at 70°F. A cold slab is slower and we will tell you the real figure for your building rather than the data-sheet one.
Do you work nights, weekends and shutdowns?
Yes, and on most commercial jobs that is how we prefer to run it. Off-shift work is normal scheduling for us rather than an exception we charge extra to accommodate. Holiday and summer shutdown windows are the easiest of all to plan against.
Can you install in winter?
In a heated interior, year-round — and winter is often the best time to book institutional and municipal work, because the building is quiet and our calendar is not competing with the summer rush. Polyaspartic systems install down to about 30°F with the slab 5°F above dew point. You may see −40°F claimed elsewhere in this industry; it is not supported by any manufacturer data sheet we work from.
The last coating failed. Why would this be different?
Nearly every failure we are called in to replace comes down to one of three things: the slab was acid etched or not prepared at all, nobody tested it for moisture, or the joints were coated over instead of being repaired. We grind or shot blast to a measured profile, we test and record moisture and dew point before anything goes down, and we treat joints as a separate detail.
What does a site assessment involve?
About an hour on site. We test the slab for moisture, look at the joints, the drains and the thresholds, ask what gets spilled on the floor and what cleans it, and talk through when the space can realistically be released. You get a written scope with a system recommendation and a phasing plan. There is no obligation and no pressure to decide on the spot.
Next step
Book a site assessment.
We walk the building, test the slab, and put a written scope and a realistic shutdown plan in front of you. No obligation, and if the timing or the system is wrong for your space we will say so.