Concrete Repair & Chemical-Resistant Flooring

Most concrete jobs start with loss. Spalled slabs, cracked walls, and deep voids expose rebar and weaken floors, channels, and openings right across a plant.

Once reinforcing bar is exposed it corrodes and swells. The swelling cracks the concrete around it and drives the next round of spalling, which is why a patch laid over rusty steel buys weeks rather than years.

BHI Coatings rebuilds and resurfaces damaged concrete cold, from crack patching to bulk-fill deep repair, using the Belzona 4000 Series of cold-cure compounds. Where rebar is exposed, the crew cleans the steel and primes it before the cover goes back on, which shuts down the corrosion cycle that caused the original spall.

We also restore weathered stone and decorative masonry to its original profile, and we reseal expansion and building joints with a flexible compound that bonds to concrete, stone, and brick and flexes with the joint. Nothing gets broken out, nothing gets recast, and nobody waits on a fresh pour to cure.

Process areas and containment zones take punishment that ordinary toppings cannot answer. Acid, alkali, and mechanical attack strip the floor and let product reach the substrate underneath.

Acid works into retaining walls, drains, and channels, thinning the concrete and opening leak paths into the ground around the unit. Bund walls spall from the inside out, expose rebar, and lose the rated volume they are supposed to hold.

We lay a chemical-resistant floor system over prepared concrete or steel, sized to the worst-case spill chemistry and to the forklift and impact load on top of it. Acid-retaining walls, drains, and channels get lined so the structure holds the acid stream with no slab break-out.

On bunds, the crew rebuilds the spalled face, caps it with a barrier coating, and adds a chemical-resistant overlay where the service calls for it. We can match the system to the exposure, including hot acid service. Where the concrete contacts drinking water, we repair and coat with materials certified safe for potable-water contact, so the tank or channel returns inside the utility's planned outage.

Concrete that carries traffic fails where the traffic concentrates. Forklift wheel paths, loading-bay edges, and joint shoulders crater under constant load, the slab breaks up, and material handling slows down with it.

Outdoors the mechanism changes. Sidewalks and exterior slabs crack and spall through each freeze-thaw cycle, widening into trip hazards and liability. Elevator pits collect groundwater, lubricant, and cleaning chemicals that pool right next to electrical components.

We rebuild worn loading bays and resurface high-traffic floors with a hard-wearing topping, and the bay reopens to forklift and pallet traffic inside the shift. Exterior slabs and sidewalks take a weather-durable composite that bonds to damp concrete and reopens within hours.

Spalled elevator pits get rebuilt and sealed with a chemical-resistant lining, and the car is back in service inside a maintenance day.

Every repair here is cold-cure work. No welding, no hot-work permit, and no heat soak on a structure that has to keep its shape. That matters most in live process areas, where a flame is the last thing anyone wants near the product.

The payoff shows up on the maintenance schedule. Floors and bunds return to service in a shift or a planned outage instead of a multi-day recast. Rebar gets protected before it can spall the patch off, so the repair holds and the asset earns more years before capital replacement.

Acid stays in the channel, product stays in the bund, and water stays out of the pit. We prepare it, rebuild it, protect it, and hand the unit back working. Twenty-four-hour on-call service covers the failures that do not wait for the next outage, and our safety record reflects a crew that gets the work done without incident.