Industrial Flooring – PennCoat Does Patch Work

Floor Repairs For Industrial Facilities.

Industrial facilities can be a brutal environment.  Fork lifts, cranes, machinery, compressors, balers, etc. can all do serious damage to the facility.  And the biggest receiver of this brute force is typically the floors.

I was contacted by a banana plant to look at a large floor repair.  We’ve dealt with floor repairs before, and have a good understanding of the amount of work and material is required to adequately fix the area.

Firstly, it’s not a decorative finish.  The purpose of a floor repair is to try and return the floor to its original strength and integrity.  This requires excessive demo, and material stronger than epoxy.

So, I went on my appointment knowing that this was the purpose of a floor repair.  And when the customer showed me what was beneath the steel plate, it reinforced my theory.

The customer had recently installed a drain pipe.  However, there must not have been enough fill put in with the drain, because as you can see in the picture, the floor started to sink.  Now, when the original installer did the original patch, there was probably enough fill.  But he must have forgotten to tamp down the fill.  So over time, as the fork lifts drove over the area, it was tamping down the fill, causing the new patch to sink.

Which is why the the customer that large piece of steel over the failing concrete.

Flooring Solution

As I stated earlier, when dealing with floor repairs, the objective is to return the area to its original strength and integrity.  So the correct method is the following:

  • prep: jackhammer and removed failed concrete.  It is detrimental that all the failed floor is completely removed from the area.  You will need to demo until you achieve sound concrete.
  • Prep: For this particular area, because the floor is sunk so low, you’ll need to drill rebar into the surrounding floor.  Rebar is important for concrete flooring, because it helps the liquid material form over something solid.
  • Install: In case the demo goes through the floor, you will need to infill the floor with stone.  And if that’s done, then we’ll need to tamp the area, so that the floor actually settles.
  • Install: Then apply resurfacing material that can be installed to a depth of atleast 2″.  Considering how sunken this floor is, and how much material will need to be removed, then it’s likely that more than 2″ will be removed.

Overall, that is the solution that customer will need.

PennCoat, Inc. has been providing industrial painting, commercial painting, epoxy flooring, and polished concrete services for nearly 30 years.  Our experienced installers are trained and equipped with the proper knowledge and tools to ensure that every installation is installed efficiently and safely.  PennCoat, Inc. provides service to Pennsylvania, New Jersey, Maryland, and Delaware.  And we cover York, Lancaster, Philadelphia, Chester, Montgomery, Baltimore, Harrisburg, Dauphin, Bucks, Berks, and other counties in the surrounding area.

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