Damaged concrete repair with epoxy in Kanpur

Concrete in many of Kanpur's older factories has been fighting a slow chemical battle for years. In tanneries, food units and chemical plants, liquids have eaten away the cement, exposed the aggregate and in places reached the steel reinforcement. Once steel starts to rust, it expands and cracks the concrete around it, and the damage speeds up. Repairing these floors properly takes more than filling holes.

Chemically eroded floors

Acidic liquors, salts and some cleaning chemicals dissolve the cement paste that binds concrete together. The floor surface turns sandy, then gravelly, and then potholes form. Before repairing, we:

1. break out all weakened and chemically contaminated concrete, going back to hard, sound material
2. neutralise the exposed surface if acids were involved
3. let it dry, because epoxy won't bond properly to wet, contaminated concrete
4. rebuild with epoxy mortar or a suitable repair mortar

If the chemicals will keep reaching the floor, the repaired area needs protection afterwards, such as PU concrete or a chemical resistant lining. Otherwise the same damage will return.

Rusting reinforcement

Where steel bars are exposed and rusting, patching over them just traps the corrosion. The correct sequence is:

• break out concrete around and behind the steel, not just in front of it
• clean the steel back to bright metal
• replace or add steel if too much has corroded away, following engineering advice
• apply a corrosion-protective primer to the steel
• rebuild the section with a repair mortar suited to the depth

In suspended slabs, beams or columns, a structural engineer should assess the damage before repair.

Broken drain channels

Tannery and food unit drain channels carry chemical-laden water all day, and their edges and bases erode first. We rebuild channel edges and inverts with epoxy mortar, cut anchor details along the edges, and where needed line the channel afterwards so the repair lasts.

Potholes and trolley routes

In warehouses and dry production areas, potholes along trolley routes are repaired with square-cut epoxy mortar patches that can take loads within about a day.

Kanpur's heat and repair materials

Epoxy mortars cure faster in heat. On a hot May afternoon, working time can be very short. We mix small batches, work early or late in the day, and keep materials and tools shaded. In some very hot conditions we choose repair materials formulated for high temperatures.

Why the cause matters

We ask what reaches the floor, how it's cleaned and how water drains. Repair without addressing the cause is money spent twice. Sometimes a small change, such as better drainage or a drip tray under a leaking pump, is as important as the repair itself.

FAQs

Can you repair a tannery floor while production continues?

Yes, in sections. Each section must be dry and out of use while it's prepared, repaired and cured.

Is epoxy mortar resistant to tannery chemicals?

Epoxy mortar resists many chemicals better than concrete, but strong acids can still attack it over time. For those areas, a protective lining over the repair is recommended.

How deep can epoxy mortar repairs be?

Epoxy mortar suits shallow to medium depth repairs. Deep repairs, especially around reinforcement, often use a different repair mortar, sometimes with epoxy at the surface.

Call +91-8755475716 or send photos of the damage on WhatsApp. More details are on our damaged concrete repair epoxy page.