Problems with the industrial floor
The warehouse floor had suffered considerable damage after years of intensive use: cracks had created irregularities in the floor, increasing the risk of tripping or falling for operators and visitors.
If the cracks get too big, the result is further deterioration of the floor. Repairs become increasingly costly (in extreme cases, the entire floor has to be replaced).
Cracks accumulate dirt, debris and bacteria. Cleaning them is a real chore and maintaining a hygienic working environment becomes difficult (this is particularly critical in food or pharmaceutical environments).
When the floor is cracked, the surface is uneven, posing a risk to forklift trucks and industrial vehicles. Maintenance and repair costs increase accordingly. One of the worst cases is when water seeps into cracks.
In this case, there is a risk of damage to the structure of the building: the risk of mould and corrosion can become critical.
In addition to the cracks here and there, the Rugby site had entire areas that were particularly damaged, so we carried out intensive repairs in these areas. Because all the industrial shelving had to be removed, we also had to remove the screws left by the shelving racks.
The existing joints also needed to be repaired and sealed. BECOSAN® also removed the industrial floor markings and epoxy coatings.
Over time, epoxy can deteriorate: signs of wear such as chipping, cracking or discolouration appear.
This deterioration is not just an aesthetic problem. It can also compromise safety, by creating uneven surfaces that are prone to accidents.
A damaged epoxy coating no longer offers the same resistance to chemicals or the same ease of cleaning. This is a recurring problem in industrial environments. Epoxy removal can be dictated by a change in the site’s functional requirements.
For example, if an industrial site evolves towards processes requiring stricter hygiene standards, the existing epoxy coating is not sufficient.
Changes in safety or environmental standards may require a coating with different properties, such as improved fire resistance or reduced electrical conductivity. Polished concrete, for example, has undeniable qualities that epoxy does not (we discuss this in more detail below).
BECOSAN® solutions
We have therefore tackled all these problems in this order:
- Repair of cracks and damaged areas
- Removal of anchors, screws and industrial marks
- Removal of epoxy coatings and repair of joints
- Application of our patented BECOSAN® treatment, including densification, sealing and polishing of the floor. This treatment was completed in just 60 days.
Our step-by-step polished concrete finish
Our treatment comes after all repairs. It transforms simple industrial concrete floors into durable, attractive and easy-to-maintain surfaces.
Polished concrete is ideal for warehouses, workshops, car parks and other industrial or commercial areas with high machine traffic.
This first stage increases the density and hardness of the concrete surface. It is carried out using a hardener – BECOSAN® Densifier – which penetrates deep into the pores of the concrete.
This hardener reacts chemically with the calcium in the concrete to form very hard crystals. This process not only strengthens the surface, but also makes it more resistant to abrasion and impact.
Densification also helps to reduce surface dusting, a common problem with untreated concrete floors.
After densification, sealing is applied to protect the floor against the ingress of water, oil, grease and other substances that stain or damage the concrete.
BECOSAN® Protective Sealer creates a protective barrier on the surface of the concrete, while retaining its ability to breathe.
This prevents the build-up of moisture below the surface and reduces the risk of cracking or freeze/thaw degradation in cold environments.
The final stage of the BECOSAN® treatment is the polishing itself, which improves the floor’s appearance while increasing its durability. The polishing process is carried out in several passes, using progressively finer abrasive discs. This gradual polishing creates a smooth, shiny surface that is easy to clean and maintain.
