Damaged concrete repair with epoxy in Baddi, Himachal Pradesh

In Baddi's pharma and FMCG plants, concrete repair usually comes up at one of two moments. The first is during a planned shutdown, when a production room floor is being redone and the old coating comes off to reveal cracked or hollow concrete underneath. The second is when utility areas, drains and warehouse joints have deteriorated enough to cause safety or hygiene concerns. In both cases, the repair has to be done quickly and properly, because the plant's shutdown window is limited.

Repairs under a new GMP floor

When an old epoxy or PU floor is removed, we often find:

• cracks that have reflected through the old coating
• hollow areas where the concrete topping has come loose from the slab
• small potholes and damaged areas near drains and doorways
• moisture-damaged concrete where the old floor blistered

A new GMP floor laid over these defects will fail in the same places. So we repair first. We fill stable cracks with epoxy, cut out and rebuild hollow and damaged areas with epoxy mortar, and treat moving cracks with a flexible detail. Only then is the new PU self levelling floor or coating laid.

Because the shutdown window is short, we use fast-curing repair materials and plan the repairs to finish in time for the floor system to follow.

Utility plinths and equipment bases

Utility rooms have plinths under pumps, compressors, chillers and boilers. Vibration and water damage their edges and anchor points. We rebuild plinth edges with epoxy mortar and regrout base plates with epoxy grout, which handles vibration and oil better than cement grout.

Drains and channels

Wash area drains and utility channels in pharma plants face water, cleaning chemicals and heat. Broken edges around drains let water get under floors. We rebuild these edges and set drain bodies properly before the finish floor goes down.

Warehouse joints and dock edges

Reach trucks and forklifts in pharma warehouses damage slab joints over time. Broken joints are rebuilt with epoxy mortar and filled with a semi-rigid filler. Dock edges get epoxy mortar repair and, where needed, steel edge protection.

Monsoon considerations

Epoxy repairs need dry surfaces to bond well. In Baddi's monsoon, concrete can stay damp, especially on ground floors. We check moisture before repairing, dry the area where possible, and use moisture-tolerant primers or repair materials where needed.

Documentation

For GMP areas, we can provide details of the repair materials used and a record of repaired locations for your change control or maintenance files.

FAQs

Can repairs and the new floor both fit in one shutdown?

Usually yes, if we survey beforehand and plan the sequence. Fast-curing repair materials let the finish floor follow quickly.

How are hollow areas found under an old floor?

By tapping the floor with a hammer or steel rod and listening for a hollow sound. Hollow areas are marked, cut out and rebuilt.

Do you regrout equipment base plates?

Yes. Failed grout is removed and replaced with epoxy grout, coordinated with your maintenance team.

Call +91-8755475716 or fill in the form below to plan repairs for your next shutdown. More details are on our damaged concrete repair epoxy page.