If you are noticing concrete flakes or chips coming loose on the top layer of concrete you have a problem, and unfortunately it is not going to get better with time, rather it will get much worse. Luckily, there are ways to fix this without pouring all new concrete.
When the surface of concrete starts flaking, peeling, or coming loose, it is often referred to as concrete scaling. Scaling typically affects the upper layer of the concrete and can range from light surface flaking to deep areas of exposed aggregate.
Scaling can happen shortly after a floor is installed or develop years later. In commercial and industrial environments, exposure to chemicals, grease, oils, cleaning products, and heavy traffic can accelerate the deterioration. Factors such as improper finishing, excess water at the surface, inadequate air entrainment, and freeze-thaw exposure all can cause scaling.
One of the most common reasons we see concrete start scaling relatively soon after it was poured is a problem with the original installation. Concrete that was improperly mixed, finished, or cured can have a weak surface layer that begins breaking apart months or years later.
This is especially frustrating because the floor may have looked perfectly fine when it was first installed. Unfortunately, problems with the original concrete can eventually show themselves as flaking, dusting, pitting, or chipping.
Adding too much water to concrete can weaken the finished surface. Extra water increases the amount of space left behind as the concrete hardens, which can leave a weaker, more porous surface that is more susceptible to wear and deterioration.
Water added at the surface during finishing can create similar problems. Finishing concrete while excess water is present at the surface can reduce its resistance to scaling and abrasion.
Concrete needs proper curing conditions to develop the strength and durability expected from it. If concrete dries too quickly or is not properly protected while it cures, the surface can be weaker than the concrete underneath.
This can leave the top layer more vulnerable to chipping, abrasion, and scaling as the floor is exposed to everyday use.
Outdoor concrete and unheated areas can also experience scaling from repeated freezing and thawing. Water can enter the pores of concrete, freeze, expand, and create pressure within the material. Repeated cycles can eventually cause the surface to break apart.
Properly air-entrained concrete is more resistant to this type of damage, but poorly designed or improperly installed concrete can still be vulnerable.
Concrete can also deteriorate when it is repeatedly exposed to harsh chemicals, cleaners, grease, oils, or other aggressive substances.
We see this in commercial environments such as restaurants around fryers, creameries where floors are exposed to milk and cleaning chemicals, and agricultural facilities such as apple orchards or dairy/milking parlors. Large vats, strong cleaning products, and constant washing can gradually eat away at the concrete surface.
The best way to repair scaled concrete depends on how deep the damage goes. Light surface scaling may only require aggressive surface preparation and a new coating, while severely deteriorated concrete may need to be repaired and filled before a coating can be installed.
For commercial and industrial floors, the goal is to remove the damaged material, repair the surface, and create a clean, properly profiled surface that the new coating can bond to.
Before any repairs begin, the floor needs to be evaluated to determine how extensive the scaling is. The important question is whether the damage is limited to the surface or whether the concrete underneath has also deteriorated.
Signs that the damage may require more extensive preparation include:
The extent of the damage will determine the depth of grinding needed to get back to solid concrete.
The next step is removing loose, weak, and deteriorated concrete. The goal is to get past the damaged layer and expose a sound surface underneath.
Shot blasting is one method we commonly use for all of our concrete floors before we begin any sort of coating process. It uses abrasive media propelled at the concrete surface to remove weak material and contaminants while creating the surface profile needed for the coating to adhere.
Depending on the condition of the floor, mechanical grinding may also be used. However, severely scaled concrete can sometimes be open enough that extensive grinding is not necessary.
Once the damaged material has been removed, the concrete needs to be thoroughly cleaned and prepared.
Proper preparation helps ensure that contaminants do not interfere with the new coating.
At this stage, the floor should be:
When scaling has left behind pits, voids, or other significant imperfections, a urethane slurry can be used to repair and fill the damaged areas.
The slurry helps create a more consistent surface while filling imperfections that would otherwise remain visible through the finished coating. This is especially useful when the concrete has deteriorated enough that simply grinding the floor smooth is not practical.
We recommend a urethane slurry for any industrial or commercial concrete floors that see chemicals on a regular basis.
After the urethane slurry is installed, blasting sand can be broadcast into the surface. This serves an important purpose beyond simply adding texture.
The aggregate creates a textured surface that can provide additional slip resistance, which is particularly valuable in commercial environments where floors may regularly become wet or contaminated with oils and other substances.
It also provides additional texture for the epoxy coating installed over the repaired surface to mechanically bond to.
Once the repaired surface is ready, an epoxy coating can be installed over the concrete.
The coating essentially creates a new sealed surface over the repaired concrete, helping protect it from the day-to-day conditions that contributed to the original deterioration.
For commercial and industrial floors, a quartz epoxy provides the strongest layer of support over your concrete. This can be particularly helpful in areas exposed to:
The specific coating and thickness needed will depend on the environment and how the floor is used. A basement floor and a commercial dairy operation would require very different levels of coating.
If you are noticing concrete scaling, do not just throw a coating over top and think your floors are good-to-go, because they won’t be. Proper grinding, cleaning, and sealing steps need to be taken before an epoxy topcoat can adhere to the flakey concrete. Contact Elite Floor Coatings today if you have damaged concrete in your home or business or are simply looking to upgrade your existing concrete to be better looking and more durable.