Understanding and Repairing Cracks in Concrete Floors Before Epoxy Coating
At Epoxy Plus Pro, every epoxy floor installation begins with a critical first step: addressing and repairing cracks in concrete. Whether you're dealing with jagged cracks in an old concrete floor or hairline fractures in a newly poured slab, ignoring these flaws can compromise the performance, appearance, and durability of your epoxy coating. This guide explores why concrete floors crack, how we fix cracks before coating, and why concrete crack repair is essential for a successful finish.
Why Do Cracks in Concrete Floors Form?
Cracks are often an inevitable part of concrete's lifecycle, but understanding their root causes helps us apply the best solution. Here are the main culprits behind cracked concrete:
1. Shrinkage During the Curing of New Concrete
All types of concrete shrink as they cure, and this volume change can create fine hairline cracks. Even with proper concrete mix ratios, this natural process can produce imperfections that need a concrete patch before epoxy is applied.
2. Subsurface Settlement and Poor Compaction
If the subgrade under a concrete slab isn’t adequately compacted, it may settle over time, placing uneven stress on the surface of the concrete. These conditions result in deep cracks or larger cracks that need immediate repair.
3. Thermal Expansion and Contraction
Temperature fluctuations can cause concrete to expand and contract. Without properly placed joints, this thermal cycling leads to cracks that eventually split across the surface.
4. Heavy Loads on Concrete Floors
Garages, warehouses, and driveways often bear heavy loads that exceed what the concrete was originally designed to handle. Over time, this causes damage to the concrete floor, including structural cracking.
5. Poor Concrete Installation Techniques
Improper troweling, poor mixing, or failure to use a proper concrete patching compound at the right time can leave the slab vulnerable to early damage.
How Epoxy Plus Pro Repairs Cracks in Concrete Before Epoxy Coating
1. Detailed Inspection of Existing Concrete
We begin by identifying all forms of damaged concrete, from jagged cracks and air pockets to structural splits. Using our expertise in concrete repair, we determine the depth, movement potential, and appropriate crack filler for each damaged area.
2. Cleaning the Area and Crack Preparation
Before any repair, we clean the surface of the concrete using a pressure washer and a concrete cleaner. We remove loose gravel, dust, and any debris using a wire brush, broom, or vacuum. The surface must be completely dry before proceeding.
For larger cracks or masonry crack issues, we use a masonry chisel to open up the sides of the crack slightly. This allows the crack filler to bond securely. We remove any excess material with a putty knife and use soap and water or a cleaning solution to scrub away residual dirt. Safety gear like long sleeves, long pants, and a dust mask are always worn during this process.
3. Filling Cracks in Concrete with the Right Material
We select from a range of concrete crack repair products depending on the severity of the damage:
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Self-leveling sealant for hairline or flexible cracks
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Concrete patching compound or pre-mixed concrete patch for non-structural cracks
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Backer rod and flexible sealant for deeper or wider gaps
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Sika or polyurethane caulk for cracks that may move with temperature or load shifts
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Grout or epoxy mortar for repairing cracks in concrete that are deep and wide
The filler is worked into the crack using a caulking gun or by troweling compound into the crack. For larger cracks, we insert a backer rod first to provide a base. Once applied, we smooth the compound and remove any excess using a putty knife or trowel.
4. Leveling and Smoothing the Repaired Area
Once the filler cures, we use grinding tools to self-level the area and create a seamless transition between the repaired crack and surrounding concrete. This step is critical for adhesion and aesthetics.
5. Priming and Surface Preparation
After all cracks are filled, we apply a concrete primer to enhance bonding. If moisture is detected in the slab, a moisture vapor barrier is applied to prevent future adhesion failure of the epoxy floor coating.
The Risks of Skipping Crack Repair Before Coating
If you don't fix cracks in concrete before installing epoxy, you risk:
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Delamination: Coating may peel due to poor adhesion
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Aesthetic issues: Cracks show through high-gloss or metallic epoxy
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Chemical and water infiltration: Unsealed cracks allow liquids to penetrate
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Structural instability: Big cracks worsen over time under heavy loads
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Warranty voids: Manufacturers require a sound substrate for warranty validation
Testimonials from Satisfied Customers
"I had deep cracks all over my driveway and garage. Epoxy Plus Pro didn’t just coat it—they repaired every single crack and made it look brand new. Truly the best way to fix cracks in concrete floors!" — Alex R., Paramus, NJ
"We had jagged cracks and loose pieces of concrete. Their team used self-leveling compounds and flexible sealants, and now you can’t even tell there were issues. Highly recommend them!" — Grace L., Staten Island, NY
"Our old concrete slab had multiple masonry cracks. Epoxy Plus Pro filled the cracks, smoothed the surface, and gave us a flawless epoxy finish." — David N., Newark, NJ
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Frequently Asked Questions (FAQ)
What’s the best way to fix cracks in concrete?
The best way depends on the size and type of the crack. For hairline cracks, use a self-leveling sealant. For structural or large cracks, use a concrete patching compound and backer rod.
Can I use epoxy over cracked concrete?
Only if the cracks are first repaired with the right filler or patch compound. Otherwise, the epoxy won’t adhere properly.
How do I clean the area before repairing cracks?
Use a pressure washer or soap and water to clean the area. Remove loose material with a broom or wire brush. Let the concrete completely dry.
What tools do I need to repair cracked concrete?
You’ll need a masonry chisel, trowel, caulking gun, putty knife, broom, pressure washer, and safety gear like gloves and a dust mask.
What’s the difference between a concrete patch and crack filler?
Concrete patching compounds are typically used for larger cracks or damaged areas, while crack fillers are designed for narrow, non-structural cracks.
Final Thoughts: Repair Cracks First for a Flawless Floor
Repairing cracks in concrete is the foundation of a durable, smooth, and long-lasting epoxy floor. Whether you’re dealing with hairline cracks, large structural separations, or deteriorating cement in old concrete, Epoxy Plus Pro has the tools, experience, and products to deliver flawless results.
Don’t coat over damaged concrete—repair it first. Fill the cracks, clean the surface, apply the patch compound, and self-level before your epoxy goes down. That’s the Epoxy Plus Pro difference.
Contact Us Today to Schedule a Free Crack Repair and Epoxy Floor Evaluation
Visit www.epoxypluspro.com or contact us here now to get started.
We turn cracked, damaged concrete into strong, smooth, and stunning epoxy masterpieces.