Concrete floors are bound to crack over time. They cure, and then they settle, sometimes resulting in a cracked surface or slab.
Once a crack exists, it can be worsened by routine activities and common facility conditions. Moisture seeping into the cracks, exposure to oils or chemicals, poor cleaning due to existing cracks, and vehicles driving over the cracked surfaces will all aggravate cracks in a concrete floor.
There are many reasons why concrete floors crack. Expansion cracks, for example, occur when the slab doesn’t have enough room to expand or contract in response to temperature changes and stress builds within the concrete. Regardless of the type of crack, the important thing is that when it happens, you know what you should and should not do.
Is That a Crack in the Floor or a Joint?
Let's clarify one thing: cracks in a floor and joints in a floor are two different things. Cracks appear in concrete as a result of curing, aging, abuse, thermal movement, and sometimes unseen substrate issues.
Not all concrete cracks require the same repair approach. Hairline cracks may appear narrow at the surface but can still allow moisture, dirt, or contaminants to enter the slab. Large cracks or cracks with movement, uneven edges, or widening gaps may point to deeper slab issues. These cracks often require professional evaluation before they are filled, coated, or polished.
Joints, on the other hand, are there by design to control cracking, isolate slab movement, or form clean separation points with new slab pours.
How Control Joints Help Control Cracking
Control joints are a grooved line purposefully placed in the concrete surface. They help control inevitable cracking that occurs as the concrete shrinks by directing the crack in a straight line. They also help with the management of internal stress due to thermal expansion and contraction.
How Expansion Joints Help Control Movement
Expansion joints extend throughout the slab and are designed to give concrete space to move without creating uncontrolled cracks across the slab. They help absorb movement caused by thermal expansion, vibration, and changes in the surrounding environment.
When joints are missing, damaged, or filled with the wrong material, cracks can form in or around the joint. These joint-related cracks should be inspected before any coating or surface repair is applied.
How Do You Repair a Cracked Concrete Floor?
A simple solution for cracked concrete floors is the use of control joints, but only during the initial slab pour. Control joints help concrete floors to crack along straight lines.
Once cracks already exist, repair options depend on the type of crack, the size of the opening, the condition of the joint, and the activity your floor endures.
Repairing Cracks in Concrete Joints
Cracks can occur in the expansion joints themselves when joint edges break down, when fillers fail, or when movement exceeds what the joint material can handle. In industrial environments, forklifts, pallet jacks, moisture, and chemical exposure can make these issues worse over time.
Joint repairs may involve removing failed material, cleaning the joint, rebuilding damaged edges, and installing a specialized filler that can support the expected movement and traffic.
Using Caulks and Specialized Fillers
Some repair solutions include caulks and specialized fillers. The properties of caulks and fillers range from rigid to flexible, allowing them to expand and contract or fill the void.
Depending on the type of activity your floor endures and the nature of the cracks themselves, CPC may recommend a specialized filler. Facilities that deal with corrosive chemicals or recurring cracking usually require specialized fillers, whereas high-traffic facilities may need a filler designed to simply restore strength and even out the surface.
When Cracks Require Deeper Repair
Sometimes the right repair solution for bad cracks and broken joints requires a deeper repair, not just a surface fix. Unless handled properly, these damages will only grow over time.
Large cracks, active expansion cracks, uneven slab edges, and recurring joint failure should be evaluated before repair. Covering these issues without addressing the underlying cause may lead to continued cracking or coating failure.
How Do You NOT Repair a Cracked Concrete Floor?
Many people think that if their concrete floor cracks, they can just cover it with an epoxy coating... right?
Maybe. It depends on the current condition of the crack as well as some of the conditions it is (or will be) subjected to.
Do Not Rely on Epoxy Alone to Hide Cracks
Just coating over cracks with epoxy may not be enough to cover the crack or abate the issue. We've witnessed owners and contractors trying to coat over cracks to hide or fix an issue, only to have the coating seep through the crack before drying. And they never solve the issue.
Before applying a coating, cracks should be evaluated to determine whether they’re stable, active, moisture-related, or connected to joint movement.
Do Not Use Standard Over-the-Counter Caulk
Contrary to what you may have found online, another method you should not use to repair your cracked concrete is applying standard over-the-counter caulk. Industrial concrete floor cracks require special materials selected for traffic, movement, moisture, chemical exposure, and long-term performance. CPC uses specialty caulks made for the industry, but you won’t find them in big box stores.
Do Not Ignore Cracks in Joints
Cracked or deteriorating joints should not be ignored. When joints fail, traffic can chip the edges, increase vibration, and create safety or maintenance issues across the facility. An expert can determine whether the joint needs cleaning, refilling, edge repair, or a more extensive concrete floor repair solution.
Do Not DIY
Lastly, it's best not to try to repair your concrete floor on your own. Call in a flooring professional to at least give you a consultation.
How CPC Floor Coatings Can Help Repair Cracked Industrial Concrete Floors
CPC Floor Coatings work with industrial and commercial facilities to evaluate cracked concrete floors, damaged joints, and expansion cracks before recommending the right solution.
Maintaining a safer, more durable concrete floor starts with understanding what caused the cracking, how the slab is moving, and whether the damage requires filling, joint repair, or a deeper concrete floor repair approach.
Contact our team today to schedule an assessment and learn how the right repair solution can protect your facility’s concrete floors long term.
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