Specialist concrete floor rehabilitation for cracked, spalled, worn, and chemically damaged industrial floors. Crack injection, spall repair, joint sealing, surface grinding, and epoxy overlay using CIPY repair systems by Pidilite Industries. Fast turnaround — minimising production downtime.
Industrial concrete floors are among the most demanding structures in modern construction — expected to withstand constant heavy forklift traffic, point loads from racking systems, chemical spills, thermal cycling, and years of abrasive wear — all while maintaining a flat, safe, and serviceable surface. It is perhaps not surprising that even well-constructed concrete floors eventually show signs of deterioration. What matters is recognising the cause of deterioration accurately and applying the correct CIPY repair system to address it before it progresses from a surface issue to a structural one.
Abrasion is the most universal cause of concrete floor deterioration in industrial settings. Forklift wheels — particularly polyurethane tyres — exert concentrated contact pressures that gradually wear the weaker surface laitance layer from the concrete, exposing the aggregate below. Over time, the aggregate itself is worn flush and then removed, leaving hollows that create noise, vibration, and accelerating deterioration. Areas of high traffic concentration — aisle ends, turning areas, ramp bases, and dock leveller approaches — show disproportionately high wear compared to lower-traffic zones. Surface hardeners applied during construction reduce but do not eliminate this wear mechanism.
Concrete shrinkage cracking is practically universal in industrial floor slabs — it occurs as the concrete cures and loses water, causing volumetric contraction that exceeds the tensile strength of the young concrete. Construction practices — such as inadequate curing, excessive water-cement ratio, or incorrect joint spacing — can significantly increase the extent and severity of shrinkage cracking. While plastic shrinkage cracks that form in the surface layer during the first days of curing are typically superficial, mid-depth or full-depth cracks that reflect structural behaviour require more careful assessment and may require epoxy injection repair to restore structural continuity.
Chemical attack on concrete floors is particularly aggressive in battery manufacturing, electroplating, pharmaceutical, food processing, and chemical plant environments. Even cleaning chemicals — particularly acidic descalers and alkaline degreasers — can attack unprotected concrete over time, softening the cement matrix and creating a porous, contaminated surface layer that absorbs further chemical attack and harbours bacteria. CIPY chemical resistant coatings over properly repaired concrete provide the defence that unprotected concrete cannot offer.
Overloading — whether by racking systems exceeding design capacity, forklift axle loads heavier than the original design assumption, or point loads from new process equipment — causes structural cracking that must be distinguished from non-structural shrinkage cracking. Structural cracks require engineering assessment before repair, to ensure the underlying load-bearing capacity is adequate and that repair is appropriately designed.
Sri Sai Technologies deploys a comprehensive range of CIPY concrete repair systems — from crack injection to full-surface overlay — with each system precisely matched to the cause and extent of the floor deterioration identified during our diagnostic survey.
Low-viscosity CIPY epoxy injection grout is pressure-injected into cracks through packers installed at regular intervals, completely filling the crack and restoring structural monolithicity. For cracks less than 0.3 mm width, surface-applied low-viscosity epoxy penetrant sealer is used. For active (moving) cracks, flexible CIPY polyurethane injection foam provides a seal that accommodates ongoing movement without re-cracking.
Concrete spalls and breakouts are repaired by saw-cutting clean vertical edges around the damaged area, removing loose concrete to sound substrate, treating exposed reinforcement with CIPY rebar treatment coating, applying CIPY bonding primer, and filling with CIPY structural repair mortar. Rapid-set epoxy repair mortars allow return to traffic in as little as 2–4 hours — critical in live operational facilities.
Construction joints and control joints are the most vulnerable areas of any industrial floor — they experience the highest stress concentrations, the most abrasion from wheel crossings, and are the primary route for water and chemical ingress. Joint repair involves saw-cutting the joint to the correct profile, removing old sealant, cleaning, priming, and installing fresh CIPY epoxy or polyurethane joint sealant to restore a functional, watertight joint.
Worn, dusty, or contaminated concrete surfaces are mechanically prepared using diamond grinding machines (single-head to large ride-on planetary grinders) or shot-blast equipment to remove the weak surface layer, existing coatings, contamination, and high spots. This creates a uniform, profiled, sound surface (CSP 2–5) for the application of repair overlays or floor coating systems. Also used to level minor surface irregularities and remove trip hazards at joint lips.
For floors with widespread surface deterioration that is beyond spot repair but where the substrate structure is sound, a thin bonded concrete overlay — cementitious or epoxy-based — provides an economical alternative to complete floor replacement. CIPY epoxy overlay systems at 3–6 mm, applied over a properly prepared substrate, can extend the floor's service life by 10+ years while providing a significantly improved surface quality.
For severely deteriorated floors requiring comprehensive rehabilitation — crack repair + spall patching + joint treatment + surface grinding + full epoxy or PU overlay — Sri Sai Technologies can deliver a complete floor rehabilitation programme using CIPY repair and coating systems, transforming a failed floor into a fully functional, coated industrial floor with a new 10–15 year service life.
Successful concrete floor repair begins with accurate diagnosis. Sri Sai Technologies carries out a thorough diagnostic assessment of every floor before specifying or pricing any repair work.
A systematic visual inspection of the entire floor area is conducted, mapping all visible defects — cracks, spalls, joint damage, surface wear, delamination, and contamination. A floor plan is marked up with defect locations and severity classifications, providing the basis for the repair specification and cost estimate. Photography documents all significant defects for the client record.
Tensile pull-off strength is measured at representative locations across the floor using a calibrated pull-off tester. This determines whether the existing concrete substrate is strong enough to receive bonded repair materials and overlay systems, or whether areas of weak substrate require more extensive remediation before repair can proceed. Results are compared to the minimum 1.5 N/mm² typically required for CIPY repair systems.
Cracks are assessed for width (using a crack width gauge), depth (using a hammer-tap sounding and visual probe), and activity (dormant vs. active — using tell-tale monitoring). This classification determines whether cracks require rigid epoxy injection (dormant structural cracks), flexible PU injection (active cracks), or surface sealing (non-structural surface cracks). Structural cracks are reported to the client for engineering review.
Floor moisture content is measured using a calibrated moisture meter or calcium chloride test at multiple locations. Excessive moisture (>4% by weight) will prevent epoxy repair materials from bonding properly. If moisture levels are too high, the cause — rising damp, water ingress from above, or high residual construction moisture — must be identified and addressed before proceeding with repair.
For floors where surface regularity is critical — logistics facilities, high-bay warehouses, and automated guided vehicle (AGV) applications — a precision floor levelness survey is conducted using a floor profiler (F-number method) or traditional levelling instrument. Deviations from specification are quantified, and the repair plan addresses high spots, low spots, and ramps to bring the floor back within tolerance.
Based on the complete diagnostic survey, a detailed repair specification is produced — identifying the repair system for each defect type, the extent of works, the CIPY products to be used, estimated completion time, and warranty provisions. This is presented with a full quotation that allows the client to make an informed decision on the repair programme.
Repair areas are isolated with safety barriers and dust containment screens. Adjacent operating areas are protected from dust and repair material overspray. All necessary power, water, and waste disposal facilities are established. Personnel are briefed on safety requirements.
Diamond grinding, scarifying, or shot-blasting removes weak surface layers, contamination, existing coatings, and high spots. Spall boundaries are saw-cut to clean vertical edges. Crack channels are chased if required. All dust and debris is removed by industrial vacuum.
Where corrosion-affected reinforcement bars are exposed during spall repair breakout, loose rust and corrosion products are removed by wire brushing, and CIPY rebar treatment compound is applied to passivate the bar surface and inhibit further corrosion before the concrete patch is applied.
Injection packers are installed at 100–200 mm intervals along each crack. CIPY low-viscosity epoxy injection grout is pumped into each packer at low pressure, filling the crack from the bottom up until grout is seen emerging from the adjacent packer. Packers are progressively moved along the crack until full length is filled. Packer holes are plugged after cure.
CIPY bonding primer is applied to the prepared break-out area. CIPY structural repair mortar is placed, compacted, and trowel-finished level with the surrounding floor surface. For depth >50 mm, mortar is placed in layers. Rapid-set repair mortars allow traffic return in 2–4 hours; standard cementitious mortars in 24 hours.
Joint profiles are prepared by routing or saw-cutting to the correct width-to-depth ratio. CIPY joint primer is applied. CIPY polyurethane or epoxy joint sealant is installed using a gun applicator and tooled to the required profile. The sealant surface is finished slightly below the floor level to protect from wheel traffic damage.
Following all crack, spall, and joint repairs, the overall floor surface is prepared by diamond grinding to achieve the required profile for the selected CIPY coating or overlay system — epoxy, PU, or specialist finish. The full floor system is applied per the CIPY application guidelines, restoring the complete protective floor surface.
| Condition | Repair Appropriate | Replace Recommended |
|---|---|---|
| Substrate pull-off strength | > 1.5 N/mm² (bonded repairs possible) | < 1.0 N/mm² (widespread substrate failure) |
| Crack extent | Defined areas, dormant, <10% area | Widespread, active structural cracks throughout |
| Surface condition | Worn surface, pitting, delamination in patches | Complete surface failure, pervasive spalling |
| Slab thickness | Adequate for repair overlay bond (>100 mm) | Too thin for repair bonding or loading requirements |
| Floor levels | Acceptable geometry, minor corrections | Major level correction required throughout |
| Economics | Repair cost <50% of replacement cost | Repair cost approaches replacement — replace for new life cycle |
Sri Sai Technologies provides an honest, independent assessment of repair vs replace options — our recommendation is always based on what gives the client the best value over the floor's lifecycle, not on which option is higher-value for us.
A professional repair programme using CIPY systems, followed by protective epoxy or PU coating, can extend the service life of a deteriorated concrete floor by 10 to 15 years — at a fraction of the cost of slab replacement.
CIPY rapid-set repair mortars allow repaired areas to return to foot traffic in 2 hours and vehicle traffic in 4–24 hours. Sri Sai Technologies plans repair work in sections to keep maximum floor area operational throughout the works.
Eliminates trip hazards, loose concrete, and protruding aggregate that create workplace safety incidents. Repaired joint edges and smooth surfaces reduce forklift tyre damage and improve workplace safety compliance.
Sri Sai Technologies' thorough diagnostic process identifies the actual cause of floor deterioration — not just the visible symptoms. This ensures the correct repair system is specified and that the same deterioration mechanism does not recur prematurely.
All repair works use genuine CIPY repair products from Pidilite Industries — India's most trusted construction chemicals brand — ensuring consistent quality, batch-to-batch reliability, and full technical data sheet support.
Timely repair of cracks and surface damage stops the ingress of water and chemicals that would otherwise accelerate deterioration of the concrete substrate and reinforcement — preventing a minor repair need from becoming a major structural issue.
Our team has extensive experience carrying out repair works in live, operating industrial facilities — sectional working, rapid-cure materials, dust control, and after-hours scheduling all combine to minimize disruption to facility operations.
Comprehensive concrete floor repair is the essential foundation for successful floor coating or overlay application. CIPY floor coatings and overlays applied over properly repaired concrete achieve full design service life; coatings over unrepaired concrete fail prematurely.
Sri Sai Technologies provides full documentation of all repair works — survey reports with defect maps, repair specifications, material certificates, application records, and post-repair inspection reports — supporting asset management, maintenance records, and warranty requirements.
Professional concrete floor repair using CIPY systems typically costs 20–40% of full slab replacement — delivering substantial capital savings while restoring floor serviceability and enabling the installation of a new protective floor coating system.
Challenge: A 25,000 sq. m. distribution warehouse in Chennai had developed widespread shrinkage cracking across the main storage floor and significant joint edge breakdown in forklift traffic aisles. The cracks were allowing water ingress and creating an unacceptable trip hazard.
Solution: Complete crack mapping survey and tensile strength testing. Epoxy injection of 1,800 linear metres of dormant cracks using CIPY low-viscosity epoxy grout. Joint edge repair using CIPY epoxy mortar. Diamond grinding of the full floor area followed by application of CIPY 2 mm epoxy floor coating.
Result: All cracks sealed, joints restored, floor fully coated in 14 days. Zero operational shutdown — works conducted in sections allowing continuous warehouse operations throughout.
Challenge: Extensive forklift impact and spalling damage to 450 m² of the factory floor in a high-traffic loading area of an automotive manufacturing facility. Loose concrete was creating tyre damage and forklift stability risks. Production could not be stopped for more than one 10-hour shift.
Solution: Saw-cut boundaries around all spalled areas. Break-out to sound concrete using electric breakers with dust control. CIPY bonding primer application. Rapid-set CIPY epoxy repair mortar placed and trowel-finished level. Return to forklift traffic after 4 hours per repaired section.
Result: All 450 m² of spall damage repaired within one extended shift. Facility returned to full operation without further downtime.
Challenge: A 3,000 sq. m. pharmaceutical production floor had failed coating, widespread cracking, and chemical attack from cleaning-in-place operations. The deteriorating floor was causing GMP deviations and was scheduled for major maintenance shutdown.
Solution: Diamond grinding to remove failed coating. Crack injection of all cracks >0.5 mm using CIPY epoxy grout. Spall patching with CIPY repair mortar. Full-area diamond grinding to CSP 3 profile. Application of CIPY 3-coat chemical resistant epoxy system (primer + 2 mm body coat + UV-stable topcoat) in pharmaceutical-compliant colours.
Result: Floor completed within 10-day planned shutdown. GMP-compliant floor system installed. Chemical resistant to all CIP cleaning chemicals. Full documentation provided for QA records.
Sri Sai Technologies recommends an annual professional floor condition survey for all industrial facilities with concrete or coated floors. Regular inspection identifies deterioration in its early stages — when repair is straightforward and inexpensive — rather than allowing problems to escalate to the point where major repair or replacement is required. Our annual inspection service includes:
Sri Sai Technologies uses genuine CIPY concrete repair products from Pidilite Industries — ensuring quality, compatibility with CIPY floor coating systems applied above, and full technical support.
Low-viscosity two-component epoxy for pressure injection into cracks. Restores structural continuity. High compressive and tensile strength exceeding parent concrete.
Expanding polyurethane for active crack sealing and water-stop applications. Seals cracks under hydrostatic pressure. Flexible — accommodates ongoing movement.
Two-component epoxy mortar for structural spall repair. High compressive strength. Rapid-set grades available — return to traffic in 2–4 hours. Excellent adhesion to concrete.
Polymer-modified cementitious mortar for spall patching and concrete repair. Good adhesion, low shrinkage, compatible with subsequent CIPY floor coating systems.
Flexible polyurethane joint sealant for construction and control joints. Accommodates dynamic movement. Chemical resistant. Suitable for industrial floors and wet areas.
Two-component epoxy bonding agent applied to substrate before repair mortars. Ensures maximum adhesion of repair materials and prevents failure at the substrate-repair material interface.
✅ All CIPY products by Pidilite Industries are fully documented with technical data sheets and are compatible with the full CIPY floor coating system range — ensuring seamless performance from repair to finished coating.
Explore All CIPY SystemsIndustrial concrete floors deteriorate from multiple causes: abrasion and wear from vehicle and foot traffic, shrinkage cracking during and after construction, chemical attack from process and cleaning chemicals, overloading beyond design capacity, poor original curing practices, carbonation and reinforcement corrosion, impact damage from dropped loads, and delamination of previous coating systems. Sri Sai Technologies identifies the specific cause(s) through a diagnostic survey before specifying the correct repair approach.
Dormant concrete cracks are repaired by pressure-injecting CIPY low-viscosity epoxy grout through packers installed at intervals along the crack, completely filling the crack and restoring structural integrity. Active (moving) cracks are treated with flexible CIPY polyurethane injection that accommodates ongoing movement. Surface cracks less than 0.3 mm are sealed with penetrating epoxy sealer. The correct method depends on crack type, width, depth, and activity, determined during the diagnostic survey.
With CIPY rapid-set epoxy repair mortars, repaired areas can be returned to foot traffic in as little as 2 hours and to forklift traffic in 4–24 hours at 25°C. This minimizes production downtime significantly. Larger-scale repair programmes using sectional working can maintain operational access to parts of the floor throughout the repair works. We plan all repairs around your production schedule.
Yes. Sri Sai Technologies regularly carries out concrete floor repairs in live operating facilities, using sectional working to maintain operations while repair works progress. We use dust-controlled diamond grinding, rapid-cure repair materials, appropriate safety barriers, and — where necessary — night-shift or weekend working to minimise disruption. Advance planning with the facility operations team is key to successful live-facility repair works.
Repair is appropriate when the substrate has adequate residual strength (pull-off >1.5 N/mm²), cracking is not widespread throughout the slab, deterioration is surface-level or limited in extent, and existing floor geometry is acceptable. Full replacement is appropriate when substrate strength has failed throughout, there is widespread structural cracking, or the floor is too thin for bonded repairs. Sri Sai Technologies provides an independent, honest assessment of which approach best serves your interests.
Diamond grinding uses rotating diamond-tipped abrasive heads to mechanically remove the concrete surface — removing weak laitance, contamination, existing coatings, and high spots. It creates a uniform, profiled surface (CSP 2–5 per ICRI guidelines) that repair materials and floor coatings bond to effectively. Diamond grinding is used both as standalone surface preparation for coating application and as part of a comprehensive floor rehabilitation programme.
Sri Sai Technologies uses CIPY's full range of concrete repair products from Pidilite Industries — including CIPY epoxy injection grout for crack filling, CIPY PU injection foam for active crack sealing, CIPY epoxy repair mortar and cementitious repair mortar for spall patching, CIPY bonding primer, and CIPY polyurethane joint sealant for joint repair. All are compatible with the CIPY floor coating systems applied over the repaired surface.
Concrete floor repair cost varies significantly depending on the type and extent of defects, the repair systems required, and the floor area. Typical ranges: crack injection from ₹200–₹500 per linear metre; spall repair from ₹800–₹2,000 per sq. ft.; joint sealing from ₹300–₹600 per linear metre; full-area grinding from ₹30–₹60 per sq. ft. Contact Sri Sai Technologies for a free floor condition assessment and detailed repair quotation.
Is your industrial concrete floor cracked, worn, or deteriorating? Contact Sri Sai Technologies — India's specialist concrete floor repair contractor and Authorized Applicator of CIPY flooring systems by Pidilite Industries. We'll assess your floor, identify the cause of deterioration, and provide a detailed repair proposal — all at no cost or obligation.
Sri Sai Techno's certified team will assess your concrete floor condition, identify root causes, and recommend the right CIPY repair system — at no cost.