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Understanding Concrete Cracks
Although concrete is a durable and widely used material, cracks can develop due to various factors. Cracks are signs that stresses in the concrete exceed its strength and are frequently harmless, albeit unattractive. However, they can also indicate a more significant problem or something that could develop into one if ignored.
Cracks in concrete can range from hairline fractures to significant structural damage, compromising its strength and appearance. Addressing these cracks promptly with the right concrete repair methods is important, which might leave you wondering what the best concrete crack filler is. Epoxy resin is a great remedy as it can extend the lifespan of the concrete and prevent further weakening. Correspondingly, if you plan to install resin flooring, tackling crack repairs in concrete is essential before starting the job.
In this article, we take a look at the various types of cracks found in concrete, where they typically occur, when it is essential to perform concrete repair and why using epoxy resin can be the perfect solution.
Where and Why do Concrete Cracks Occur?
Cracks can appear on just about any concrete surface, and the causes often depend on where the concrete is located. For example, a concrete driveway is especially prone to cracking because of the constant exposure to temperature changes and heavy vehicle traffic. Basement and garage flooring often suffers because of foundation settling or moisture seeping in over time. Industrial and commercial floors often bear heavy loads, which can create a lot of stress on the surface. Even concrete walls and foundations aren’t immune—structural shifts and changing environmental conditions can easily lead to concrete cracking there as well.
What are the Different Types of Cracks in Concrete?
Understanding the differences between different types of cracks is key to determining whether the concrete floor repair you need to undertake is cosmetic or critical. Each crack tells a story about the stresses acting on the concrete, and knowing how to interpret them is essential for long-term durability and maintenance planning.
It’s essential to repair cracks in concrete in preparation for installing epoxy flooring, even if what you diagnose is only minor, to ensure a strong, long-lasting, and aesthetically pleasing finish. Here are some of the most common types of concrete cracks you might encounter:
Hairline concrete cracks
These are very fine surface-level fractures that usually don’t indicate serious structural issues. They are mostly related to minor movements or temperature fluctuations during the curing process and are generally aesthetic. As the name suggests, hairline concrete cracks appear as very thin (usually less than 0.1mm), barely noticeable fissures that can be continuous lines or create a map-like pattern on the concrete surface. Although they are very narrow in width, they can extend deep into the concrete slab, so proper assessment and management of them are essential, as we discuss in the next section.
Shrinkage concrete cracks
Shrinkage cracks are similar to hairline cracks in that they also develop during the curing process, but are a result of moisture loss as the concrete shrinks. They are also fairly common and usually non-structural. Proper mix design and curing practices can minimise their occurrence. But if you aren’t performing this part of the process, and are either implementing epoxy concrete repair or prepping for a resin floor installation, this is largely out of your control.
Settlement cracks
These occur when the ground beneath the concrete shifts, compresses, or decomposes, causing the slab to move unevenly. This shifting or movement below can cause weak spots or voids beneath the concrete, leaving it more prone to cracking. They can also be symptomatic of too much weight bearing, although this is less common. Settlement cracks can be more serious because they can lead to uneven surfaces and trip hazards.
Structural cracks
A major red flag – structural cracks are typically wider, deeper, and run through the entire slab or wall. Causes are usually due to overloading, design flaws, or foundation issues. These cracks compromise the integrity of the concrete and can become unsafe if left untreated. Consult a qualified structural engineer if you suspect any cracks are structural.
Expansion cracks
Temperature changes are the cause of expansion cracks. As concrete heats up, it expands. Control joints should be included in the design of concrete structures to manage and direct cracking, which minimises structural damage. They accommodate the stresses caused by temperature changes and drying. Unplanned expansion cracks can form if there’s no room for movement in a concrete slab, such as a control joint.
Why is Using Resin for Concrete Repair a Perfect Solution?
Epoxy resin is a go-to choice for crack repairs in concrete because of its exceptional adhesive strength and long-lasting durability. One of its most valuable advantages is how well it performs as a crack filler, penetrating deep into cracks, ensuring a thorough fill that helps stop the damage from spreading.
It also adds significant strength to the repaired area, reinforcing the structure and helping to restore its original integrity. On top of that, epoxy resin is highly resistant to water and chemicals, protecting the concrete from further deterioration caused by moisture or harsh substances. And perhaps best of all, once it’s cured, resin repair for concrete is built to last – capable of handling heavy loads, high footfall, weather exposure, and other severe conditions without breaking down.
What are the Consequences of Ignoring Concrete Cracks?
Whether you are reading this as a novice (e.g. a homeowner or building manager) or tradie and are looking for guidance on concrete cracks, know this: neglecting to repair concrete cracks may seem harmless at first, but over time, it can lead to a range of serious and costly issues.
As concrete cracks expand, they can compromise the structural integrity of a concrete slab or wall, making future repairs more complex and expensive. In reinforced concrete, cracks can even expose steel rebar to moisture, accelerating corrosion and leading to concrete spalling or delamination of the concrete.
Moisture intrusion is another major concern. Even hairline cracks can allow water to penetrate, which not only weakens the concrete matrix but can also seep into the foundation. This creates the perfect environment for mold and mildew growth, especially in basements or other enclosed areas and should be a particular point of consideration when prepping garage flooring. In colder climates, water infiltration can lead to freeze-thaw damage, where trapped water expands upon freezing, causing cracks to widen even further.
From a safety standpoint, cracked or uneven concrete surfaces, like those found in pavements, driveways, or warehouse floors, can create trip hazards, posing liability risks for property owners. These hazards are especially perilous in high-traffic areas.
Finally, unaddressed cracks can significantly reduce the market value of your property. Cracked concrete gives the impression of poor maintenance, which can deter potential buyers or tenants, or if you’re a business, customers or clients. Perform regular inspections and timely repairs not only to preserve structural soundness but also to protect your investment.
Why Repair Cracks in Concrete Before Installing an Epoxy Resin Surface?
The strength of the foundation for an epoxy resin floor installation is crucial. Before undertaking any structural or decor refurbishment, appropriate preparation should be executed, eg, laying foundations, sanding a surface, or using a primer. The same preparation applies when installing an epoxy resin surface.
Before you apply an epoxy resin floor or surface on top of concrete, you should plan to repair any existing cracks in the concrete to ensure a smooth and long-lasting finish. Let’s take a look at why…
Perfect finish
One of the most immediate benefits is achieving a smooth, uniform finish. Cracks or surface imperfections left untreated can telegraph through the epoxy coating, leading to visible flaws. Proper concrete repair is one of the ways to ensure the epoxy lays down evenly, resulting in a sleek, professional finish.
Complete adhesion
Beyond aesthetics, crack repair significantly improves the bond between the epoxy and the concrete. Epoxy resin is designed to form a strong mechanical and chemical bond with the substrate, but cracks or unstable areas can compromise that adhesion. Filling and stabilising these flaws before installation allows the epoxy resin to anchor itself fully.
Strong foundations
An epoxy floor is only as strong as the surface beneath it. If cracks in concrete are left unaddressed, they can continue to move or worsen under the epoxy surface, leading to premature failure of the coating. Reinforcing the concrete by repairing cracks ensures a solid foundation, helping the epoxy floor withstand heavy foot traffic, machinery, and chemical exposure.
Moisture defence
Moisture resistance is especially critical in basements, garages, or industrial environments. Cracks can serve as pathways for moisture to rise, which can interfere with the curing of the epoxy and lead to issues like bubbling, delamination, or efflorescence. By sealing cracks before application, you effectively block moisture migration, enhancing the overall performance and longevity of the resin surface.
Xtreme Polishing Systems - The Epoxy Resin Experts
When it comes to laying resin, we understand that concrete cracks can be an inevitable challenge, but with the correct repair techniques, they can be managed effectively. Epoxy resin is an excellent solution for restoring cracked concrete, providing durability, strength, and protection. If you need advice about products to help with your project, from concrete crack filler to epoxy mortar, or want to know how to train in epoxy resin floor installation, chat with us today – our resin experts are happy to help.
