BECOSAN® UK Ltd is a company specialising in the repair of cracks in concrete floors in warehouses, factories, distribution centres and other industrial facilities throughout the UK and Europe.
We assess the cracks on site, classify them according to their width and condition, and repair them. This includes both cracks running the length of the slab and those whose edges are crumbling or flaking away. The repairs minimise further surface deterioration and restore safe conditions for the movement of forklift trucks, pallet trucks and automated guided vehicles (AGVs).
We plan the work around your operations and carry out repairs in sections where necessary, so that your premises can continue to operate.
Cracks in warehouse and factory floors rarely stay the same. Under daily traffic from forklift trucks and vehicles, they tend to lengthen and widen, and their edges begin to splay. These are the two most common reasons why facilities managers contact us.
If cracks are spreading across your warehouse floor, they are usually still active: the slab is still moving due to loads, temperature changes or shrinkage. Every time a forklift passes over it, it exerts pressure on the crack, making it longer or wider. An active crack must be assessed before it is filled, as the appropriate repair material depends on whether the crack is still moving.
What to do: locate and measure the cracks, check whether they are active or inactive, and repair them before they reach the stage where the edges start to spall.
When the edges of a crack crumble or flake off, the crack has begun to spall. Forklift wheels strike the unsupported edges and chip away pieces of concrete. The opening widens with each pass, and a small crack can turn into a hole that damages wheels and loads.
What to do: cut into the crack until you reach sound concrete and fill it with a repair resin that bonds to the edges. Surface sealing alone is not sufficient once the edges are spalling.
Forklift trucks or pallet trucks jolt or make a noise when driving over the crack.
Dirt, dust and debris accumulate inside the crack.
Liquids or cleaning water seep into the crack.
Loose pieces of concrete appear around the crack.
The damage runs in a straight line at regular intervals. In this case, it may be a damaged joint rather than a crack.
Repairing cracks and fissures in concrete floors in industrial facilities
Cracks and fissures are common in concrete floors subjected to daily industrial and commercial traffic. Over time, loads, shrinkage, temperature changes and forklift wheels cause weak spots to appear in the slab.
BECOSAN® repairs these cracks as soon as they are detected, as a crack repaired in good time is cheaper and quicker to fix than one that has already started to spall. The repair restores the continuity of the slab’s surface and prevents the edges of the crack from deteriorating further.
Following the repair, the floor can undergo the patented BECOSAN® treatment: grinding, densification and polishing, which hardens and seals the surface. This makes the surface more resistant to wear around the repaired areas. Cracks caused by sub-base movements or insufficient slab thickness may still require a structural assessment.
Consult with one of our technicians to discuss the details and find solutions.
The BECOSAN® crack classification groups cracks in industrial concrete floors into four types by width and condition: S-Crack (under 2 mm), L-Crack (2 to 9 mm), XL-Crack ([9 to 30 mm]) and XXL-Crack (30 mm or more). Each type has its own risk and repair method.
Minor crack (<2mm) that can be straight, curved or zigzag-shaped. It needs
to be repaired to prevent crumbling, which generally converts an S-Crack into an L-Crack.
Medium sized crack (2-9mm) that can be straight, curved or zigzag- shaped. It needs to be repaired as the existing crumbling will lead into a detachment of concrete parts within the crack. The consequence will be major damage of the surface due to concrete spalling.
A large crack (9 to 30 mm) that usually appears near contraction or construction joints. It can hinder or prevent the passage of forklift trucks and automated guided vehicles (AGVs), and causes severe erosion of the floor surface.
Very large crack (≥30mm) as a consequence of a not timely repaired XL-Crack to prevent further surface damage. These areas are very dangerous as they can cause heavy accidents. Areas with XXL-Cracks should not be used at all in warehouse or logistics operations≥
There is no single repair for every crack. The right method depends on crack width, whether the crack is still moving, the traffic it carries and how long the area can be closed.
| Method | Best for | Limitations |
|---|---|---|
| Epoxy resin filling (e.g. BECOSAN® J+C Repair Kit) | Dormant cracks in interior floors with forklift traffic | Not suitable for exterior use; active cracks need assessment first |
| Polyurea filling | Exterior areas and cracks with some movement | Lower rigidity than epoxy at crack edges under heavy wheel loads |
| Crack injection (BS EN 1504-5) | Restoring continuity in deeper structural cracks | Needs specialist equipment; does not repair spalled edges |
| Cementitious repair mortar | Wider damaged areas and patch repairs | Slower curing; poor bond in narrow cracks |
| Slab replacement | Slabs with failed subgrade or extensive structural damage | Highest cost and longest downtime |
In most warehouses and factories, cracks can be repaired without replacing the slab. BECOSAN® recommends the method after assessing each crack on site.
BECOSAN® has carried out crack repair work on concrete floors in warehouses and industrial facilities of all sizes, ranging from structural cracks caused by heavy forklift traffic to shrinkage cracks in freshly poured slabs and damage resulting from years of intensive industrial use.
In all cases, crack repair formed part of our comprehensive concrete floor refurbishment programme, which restored the integrity of the slab prior to diamond disc grinding and the application of the patented BECOSAN® treatment.
Below are examples of crack repair work carried out on industrial flooring projects across the UK.
Floor area: 1,500 m²
Challenge: The project started as a localised floor repair. Once the real condition of the concrete slab was assessed, the scope was extended to a full intervention. Among the issues identified were structural cracks across the slab that needed to be repaired before the floor could receive the BECOSAN® treatment.
Solution delivered: BECOSAN® repaired 100 linear metres of cracks across the concrete slab, restoring structural continuity ahead of the surface treatment. This work was carried out as part of a wider floor refurbishment project, which also included joint resealing, surface grinding and other localised repairs.
Result: The crack repair work removed a key source of surface weakness and edge deterioration, contributing to a stronger, more uniform floor. The entire refurbishment project, from the initial assessment to the completion of the work, was carried out in 16 weeks; the repair of the cracks itself took just a few days.
BECOSAN® is a company specialising in industrial concrete floors, ideal for warehouses, factories and logistics centres that need to repair cracks without disrupting their operations.
Own crack classification. Each crack is assessed and classified (S, L, XL, XXL) before the repair method is selected.
Own repair product. We use the BECOSAN® J+C repair kit, a two-component epoxy resin filler with comprehensive technical documentation.
Cracks, joints and surface in one project. We repair cracks and joints and can then apply the patented BECOSAN® treatment, meaning a single contractor takes care of the entire floor.
Work around your operations. Repairs carried out in sections and outside working hours where necessary.
Local team. BECOSAN® UK Ltd operates throughout the UK, with specialist technicians and over 15 years’ experience.
For cracked indoor concrete floors in warehouses, factories and industrial facilities, particularly where the floor is subject to forklift or automated guided vehicle (AGV) traffic and must remain in use during the works.
When the slab is subsiding or the sub-base has failed: in such cases, you must first consult a structural engineer, and we can then repair the surface. For external cracks, we use polyurea, not the J+C repair kit.
Before deciding on a repair solution for your cracks it is important to understand why the cracks are there in the first place.
Cracks are mainly caused by:
Repairing cracks in concrete floors is a laborious and complicated job.
Even so, at BECOSAN®, we know that this is no reason to stop a client from carrying out their work; and therefore, we adapt to it promptly. We work by zones and in the hours required to not paralyze the company’s production.
In the case of interconnected cracks, there is a risk of spalling. That is, pieces of concrete can detach from the flooring, creating holes and leaving the concrete aggregate exposed.
Therefore, spalling is the next step after the cracks, as these begin to deteriorate mainly due to vehicle circulation.
The treatment of this type of damage is slightly similar, but due to its complexity, it requires eliminating the entire damaged area. Once this is done, it is possible to prepare the area where a sanding, polishing, and hardening treatment will subsequently be applied.
It consists of rebuilding the pavement, eliminating the loose material, and replacing it with a new one with improved characteristics.
Once we are aware of the problem, we will proceed to repair cracks in the concrete floors by milling, cleaning, and sealing.
These tasks are part of the set of renovation activities, through which superficial flooring problems are solved.
We start by milling the cracks or fissures and subsequently cleaning them. Next, concrete cracks are sealed with a resin component for interiors or polyurea for exteriors.
Sealing cracks in concrete floors avoids water and any other external substance to penetrate the concrete, thus helping to maintain its support capacity.
Structural crack repair in the UK typically falls under BS EN 1504-5, the British and European standard covering the injection and filling of cracks, voids and interstices in concrete. Unlike patch repair, which replaces missing concrete, crack repair works with the existing slab, sealing and restoring continuity without adding new concrete. When comparing repair proposals, ask your contractor which method and product category they are applying and request the Declaration of Performance for the product used.
BECOSAN® only uses original, first quality material for crack repair. The BECOSAN® J+C Repair Kit is a two-component epoxy resin filler with reduced viscosity, some flexibility and no solvents, with a cycloaliphatic hardener. It prevents crumbling once cured and provides high sealing performance with strong penetration into the capillaries and porosity of the substrate. It can be pigmented to match the surrounding floor. Recommended for interior use only.
Full technical documentation, including material specification and test data, is available on request for facility managers and contractors evaluating this repair method.
Whether cracks are spreading across your warehouse floor or their edges are breaking away under factory traffic, BECOSAN® UK Ltd can assess the damage and recommend a suitable repair approach. Contact our team to discuss your floor and arrange a free, no-obligation assessment.