Concrete spalling in warehouses isn’t just cosmetic; it signals deeper problems like joint edge failure, surface delamination, or freeze-thaw breakdown. Left untreated, spalling can grow rapidly; damaging forklifts, undermining racking legs, and triggering further slab degradation.
This guide walks you through how to identify different types of spalling and the best repair methods for restoring durability and safety to warehouse concrete floors.
Not all spalling is the same. Light surface flaking is often caused by abrasion or poor curing; deeper damage may indicate freeze-thaw cycles, corrosion of embedded steel, or impact stress at joints. Tap around the affected area with a hammer; hollow sounds mean delamination. Record how deep the damage goes and whether it spreads along a joint or corner. Accurate diagnosis ensures the right repair material and method are used.
Use a diamond blade to cut around the damaged area, forming clean, square edges. This helps contain the patch and prevents feathering, which often fails under load. Cut to the full depth of the damage; typically 20 to 50 mm; and remove all loose or deteriorated concrete. For joint-edge spalls, expose the entire face of the joint. Clean the repair zone thoroughly with vacuum or compressed air before priming or filling.
Resin-based repair mortars (polyurea or epoxy) offer the best strength and bond for warehouse use. They cure quickly, resist shrinkage, and tolerate forklift traffic within hours. For surface repairs under light loads, high-performance cementitious patch mortars may be suitable. Always match the repair product to the application: joint edges need flexibility and abrasion resistance; surface flake zones need strong bonding to avoid lifting under wheels. Read cure times carefully before reloading the area.
Use a compatible primer to ensure strong bond between new and old concrete. Apply it to all faces of the cutout. For resin mortars, pour or trowel the material into place while the primer is still tacky. For deep repairs, build up in layers if the product requires it. Compact the patch material firmly into corners and edges to eliminate voids. Overfill slightly and strike level with the surrounding slab while wet.
After the patch has cured, grind or sand flush with the surrounding surface for smooth forklift transitions. If the repair is in a coated or sealed area, reapply the finish to blend it in and protect from moisture ingress. Keep an eye on the repair during the first few weeks of traffic; repeated damage may indicate joint movement, slab curling, or inadequate load capacity. Document repairs for warranty and maintenance records.
If you'd rather skip the stress and get a flawless concrete floor polished by professionals, we’ve got you covered. From precision prep to polished perfection, we handle it all.
Get in touch today for a no-obligation quote on polished concrete flooring:
Or fill in the form below and we’ll get back to you with honest advice and a competitive quote.