Confloor Industrial Concrete Repairs

At Confloor, we specialise in industrial-grade spall repairs, restoring damaged or deteriorated concrete surfaces to a safe, functional condition. Spalling—where the surface layer of concrete flakes, chips, or breaks away—is a common issue in high-traffic industrial environments due to heavy loads, impact, or moisture ingress.

Our team delivers precision repairs that not only restore appearance but also reinforce structural integrity and extend the life of your concrete assets.

Typical Causes of Spalling:

• Heavy vehicle traffic and forklift impact

• Moisture penetration

• Poor original installation or curing

• Corrosion of embedded steel

Our Spall Repair Process Includes:

1. Defect Identification – Locating and clearly marking the damaged areas.

2. Perimeter Cutting – Saw-cutting clean edges to prevent feathering and ensure strong bond lines.

3. Concrete Removal – Removing all loose or weak concrete to a minimum depth, typically 35mm.

4. Surface Preparation – Mechanically scabbling or grinding the base to provide a strong bonding profile.

5. Repair Application – Installing heavy-duty epoxy or polyurea repair mortar, well-compacted into the cavity.

6. Finishing – Grinding flush to surrounding concrete for a seamless, traffic-safe surface.

Our spall repairs are ideal for warehouse slabs, factory floors, truck loading bays, and other high-wear areas where durability and minimal downtime are critical.

At Confloor, we provide professional concrete joint sealing services designed specifically for heavy industrial environments. Properly sealed joints are essential to protecting concrete slabs from moisture ingress, edge breakdown, and costly long-term deterioration caused by traffic or chemical exposure.

We use industry-grade sealants and backing materials to ensure clean, durable, and flexible joint systems that maintain the structural performance of your floors.

Common Causes of Joint Failure:

• Age-related deterioration and drying shrinkage

• Impact from forklifts and material handling equipment

• Thermal expansion and contraction

• Poor original installation or inadequate joint fill

Our Joint Sealing Process Includes:

1. Removal of Existing Sealant – Carefully cutting out and extracting failed or degraded joint material.

2. Joint Cleaning – Removing debris and dust with compressed air and vacuum extraction for a clean, dry joint.

3. Backing Rod Installation – Inserting appropriate compressible foam backing rod to control sealant depth.

4. Sealant Application – Filling the joint with high-performance polyurea or polyurethane joint sealant.

5. Tooling and Finishing – Smoothing the surface to a flush, slightly cupped, or flat profile depending on environment and traffic type.

Confloor’s joint sealing is ideal for warehouse floors, cold storage facilities, logistics depots, and production areas—where sealed joints must handle both static and dynamic loads without failure.

At Confloor, we deliver specialised concrete crack repair solutions tailored for heavy industrial settings. Cracks in concrete floors are not only unsightly but can compromise structural integrity, create trip hazards, and lead to more serious damage if left untreated. Our repair systems are designed to restore function, prolong the life of your flooring, and prevent water or contaminant ingress.

Whether the cracks are static or moving, hairline or wide, Confloor applies the correct technique and material to ensure lasting performance.

Typical Causes of Cracking:

• Heavy traffic and point loading

• Drying shrinkage or thermal movement

• Ground movement or slab settlement

• Impact or vibration-related stress

Our Crack Repair Process Includes:

1. Crack Assessment – Identifying the type, width, and depth of the crack to determine the most effective repair method.

2. Crack Cutting – Using a V-blade or diamond saw to widen the crack for proper bonding and fill depth.

3. Void Cleaning – Removing dust, debris, and moisture using vacuum extraction and compressed air.

4. Base Preparation – Where required, filling the base with dry silica sand to provide a stable foundation for sealant.

5. Crack Filling – Installing flexible polyurea joint filler or rigid epoxy resin, depending on movement and load requirements.

6. Finishing – Tooling or grinding the repair flush with the surrounding concrete for a seamless finish.

Confloor’s crack repair systems are trusted in factories, transport depots, cool rooms, and storage facilities—where structural integrity and floor safety are mission-critical.

At Confloor, we offer specialised core-out removal of dynabolts and floor fixings, followed by precision epoxy filling, tailored for heavy industrial floors. Anchors and dynabolts left in concrete slabs from redundant racking or machinery can cause safety hazards, damage handling equipment, and disrupt floor flatness. Our method removes these obstructions cleanly, restoring a seamless, high-performance surface.

Using Hilti coring systems and recycled water filtration units, we ensure minimal dust, environmental responsibility, and a high standard of finish on every repair.

Common Situations Requiring Dynabolt Removal:

• Redundant racking systems and shelving

• Reconfigured machinery layouts

• Safety or trip hazard elimination

• Preparation for floor coatings or grinding

Our Core-Out & Epoxy Fill Process Includes:

1. Anchor Identification & Marking – Locating and assessing all fixings to be removed.

2. Core Drilling – Using high-precision Hilti core drills with vacuum-bonded stands and water-fed filtration systems to extract bolts cleanly without slab damage.

3. Cleaning & Preparation – Flushing and drying the void using air pressure and vacuum extraction to ensure full bond.

4. Epoxy Filling – Injecting or gravity-filling the hole with high-strength epoxy filler designed to cure flush and blend with the surrounding concrete.

5. Finishing – Grinding the repair smooth using dust-extracted cup wheel grinders for a level, traffic-safe result.

Our environmentally conscious system reduces slurry waste and provides a cleaner, safer site—ideal for warehouse operators, logistics centres, and industrial developers seeking a tidy and durable floor finish.

At Confloor, we perform efficient punch-down removal of surface dynabolts, followed by epoxy filling and smooth grinding to restore floor continuity in heavy industrial environments. When full removal isn’t necessary, punching fixings below floor level provides a fast, effective solution to eliminate hazards and create a flush, repairable surface.

Using specialised breaking tools and industrial-grade dust-extracted grinding equipment, we ensure clean, accurate repairs that blend perfectly into the surrounding floor.

Common Situations Requiring Dynabolt Punch-Down:

• Decommissioned racking or equipment

• Floor safety compliance and trip hazard prevention

• Fast-tracked floor resurfacing or coatings

• Cost-effective repair where full core-out isn’t required

Our Punch-Down & Epoxy Fill Process Includes:

1. Fixing Identification – Locating all surface dynabolts and assessing suitability for punch-down removal.

2. Bolt Recession – Using jackhammers or impact tools to drive bolts just below floor level without damaging surrounding concrete.

3. Void Cleaning – Clearing debris and dust from the hole using compressed air and industrial vacuum systems.

4. Epoxy Filling – Filling the recessed cavity with high-strength, non-shrink epoxy to create a solid, durable finish.

5. Grinding & Blending – Grinding flush with specialised cup wheel grinders equipped with full dust extraction systems, ensuring a seamless and clean surface ready for traffic or coatings.

This method is ideal for warehouses, logistics centres, and production facilities where bolt heads present risks to forklifts, trolleys, and foot traffic.

Trip Hazard Rectification – Safer Floors by Confloor

At Confloor, we provide professional concrete grinding services to rectify tripping hazards and uneven slabs across industrial walkways and floor surfaces. Uneven joints and slab movement are common in high-use environments and present serious OHS risks to both staff and equipment. Our targeted grinding method ensures a smooth, level transition between slabs—eliminating hazards without costly slab replacement.

We use stand-up concrete grinders with integrated full dust extraction systems, ensuring efficient, clean, and compliant work across all industrial settings.

Common Causes of Trip Hazards:

• Slab displacement from ground movement

• Differential settlement between adjoining slabs

• Poor original installation or finishing

• Long-term wear from foot and vehicle traffic

Our Trip Hazard Rectification Process Includes:

1. Hazard Identification – Inspecting and clearly marking raised edges or uneven joints along pedestrian and forklift pathways.

2. Edge Grinding – Mechanically grinding high points using stand-up grinders equipped with precision cup wheels.

3. Dust Extraction – Operating HEPA-filtered dust extraction systems to minimise airborne contaminants and maintain clean, safe work zones.

4. Surface Smoothing – Carefully feathering the grind into the adjacent slab to achieve a flush, low-profile transition.

5. Final Inspection – Verifying smoothness and compliance with OHS and facility access standards.

This service is essential for warehouses, factories, carparks, and access walkways where compliance and safety are top priorities. It’s a fast, non-invasive solution to dangerous floor height variations.