As durable as concrete may be, even it may crack or eventually become damaged over time. Some damage is more minor (such as hairline cracks or small pitting), while other damage is far more significant and requires immediate attention to ensure the issue doesn’t persist (such as severe pitting or entire chunks of concrete becoming loose).
There are a number of reasons why concrete can become damaged. One of the primary reasons has to do with weather, and more specifically the hot and cold that concrete undergoes during thaw cycles we experience in Canada. This is particularly common in the Waterloo, Kitchener, and Cambridge area. As the concrete shrinks and expands depending on the season, there is the potential for hairline cracks, moisture erosion, and other forms of damage to occur.
That being said: Can you epoxy over cracked or damaged concrete? The answer to this question is a resounding Yes. Indeed, with the notable exception of freshly-poured slabs of concrete, it is rare that we as professionals get to work with concrete that isn’t damaged in some way or another. As a homeowner, whether you have a damaged concrete garage floor, porch, patio, a set of concrete steps, or any other space for that matter, we can help.
Before we apply epoxy coatings to any concrete surface, damaged or otherwise, we always have to grind the surface of the flooring. This ensures that the concrete is cleaned, leveled out, and has a consistent scratch pattern so that the epoxy can adhere to it properly.
It is during this stage of coating preparation that any damage to the concrete will be repaired. There are a number of materials that we use for concrete repairs, but the most common for minor repairs is a polyurethane quick repair solution that we mix with durable silica sand. This fast-curing polyurethane concrete repair product is ideal for most repairs—large or small, surface level or deep—as it penetrates deeply into the concrete, forming a permanent bond that is both durable and flexible.
Another common approach we use for larger concrete repairs involves epoxy mortar systems and cementitious repair products. Epoxy mortars are created by blending high-strength epoxy with other sorts of aggregates, resulting in an incredibly tough repair compound. These materials are perfect for rebuilding large high build damaged areas, filling larger voids, or repairing broken edges and joints. Epoxy mortars provide excellent adhesion to existing concrete and resist impact, abrasion, and chemical exposure—making them ideal for areas that endure heavy use. In addition, we also use cementitious-based repair products for restoring worn or spalled surfaces. These high-performance repair mortars are specially formulated to bond tightly to concrete substrates and restore both structural integrity and surface profile before the coating system is applied.
Once all types of repairs are complete, we go over them once again with our grinding equipment, resulting in a clean transition from previously damaged to undamaged concrete flooring. This final step ensures that the epoxy coating can be seamlessly applied to any concrete surface once repairs have been completed, leaving you as the homeowner with a floor that’s never looked better or been stronger!