Concrete is one of the most widely used construction materials in the world, but it is far from indestructible. Heavy loads, vibration, chemical exposure and mechanical impact can lead to cracks, voids and surface deterioration.
Using a high-performance epoxy concrete repair system offers several advantages over traditional cement-based repairs:
- High compressive strength
- Excellent adhesion to concrete
- Fast return to service
- Chemical and mechanical resistance
- Long-term durability
In this blog, we explore five key applications where epoxy concrete repair offers a fast and durable solution, with short clips demonstrating Belzona concrete repair products in action.
Five Key Epoxy Concrete Repair Applications
1. Epoxy Concrete Repair of Concrete Voids
When concrete contains hidden gaps or hollow areas, loads can cause cracking and structural instability.
Concrete voids can form due to poor consolidation, long-term deterioration, trapped moisture or corrosion of reinforcing steel. If left untreated, these voids leave air pockets, which reduce load transfer and can lead to further cracking. Filling concrete voids helps prevent ongoing damage and restores the structural integrity of the substrate.
Using epoxy to repair concrete voids allows them to be filled permanently, restoring load-bearing strength and long-term structural support. Belzona 4111 (Magma-Quartz) acts as a durable epoxy concrete patch, bonding to existing substrates and restoring the original profile. This method eliminates the need for costly demolition and reduces downtime while reinforcing foundations for long-term service.
2. Securing Loose or Damaged Anchor Bolts
Loose anchor bolts pose a serious threat to the safe and reliable operation of equipment, often caused by vibration, concrete cracking, repeated mechanical stress, or voids and honeycombing around the bolts and nearby rebar. These voids can occur due to inadequate consolidation during the original concrete pour, leaving gaps that reduce load-bearing capacity.
Industrial facilities often need a solution that fixes loose anchor bolts in concrete without removing the equipment. Using epoxy repair mortar to rebuild the concrete around the bolt provides superior mechanical anchoring strength. Belzona 4111 (Magma-Quartz) ensures long-term stability by re-anchoring bolts and filling voids, maintaining alignment and load transfer under operational conditions.
3. Epoxy Chocking / Liquid Shim Solutions
Unlike traditional metal shims or chocks, pourable epoxy chocking systems such as Belzona 7111 form a solid, seamless interface that fully supports the equipment footprint. By filling surface irregularities and distributing loads evenly, they help minimise vibration, reduce the risk of loosening caused by thermal cycling, and eliminate the corrosion issues commonly associated with steel components.
The result is long-term equipment stability, with reduced vibrations, achieved without the need for precision machining or extended downtime.
4. Epoxy Concrete Repair of Unlevelled Equipment
Uneven concrete floors can create alignment issues and place damaging stress on machinery. For facilities looking at how to fix uneven concrete, epoxy concrete repair products such as Belzona 4111 (Magma-Quartz) provide a practical, long-term solution.
Typically used as a high-strength epoxy repair mortar, Belzona 4111 (Magma-Quartz) has a flexible mixing ratio as a three-component system and can also be mixed to a slurry consistency where required. This allows worn or sunken concrete to be rebuilt back to its correct profile, often without the need to remove equipment. The result is effective, even concrete repair that restores load support, reduces vibration and helps protect assets from premature failure.
5. Epoxy Concrete Repair of Walls
Vertical surfaces often experience cracking due to impact, reinforcement corrosion and structural movement. Using a high-build epoxy wall filler solves this problem quickly by bonding tightly to the substrate and restoring the original contour.
Belzona 4141 (Magma-Build) is a lightweight epoxy repair material for concrete, designed for vertical and overhead repairs, which prevents further moisture ingress and degradation. It provides a long-lasting, cost-effective method of concrete wall crack repair and lintel repair without replacing large sections of concrete.
Learn More
How to Repair Concrete Expansion Joints with a Polyurethane Sealant Solution
How to Fix Uneven Concrete Floors
How to Repair Overhead Spalling Concrete
Frequently Asked Questions
What is the best epoxy concrete repair product?
This varies depending on the application. A high-strength concrete epoxy patch such as Belzona 4111 (Magma-Quartz) is often considered the best option for concrete crack repair epoxy solutions, particularly for floor and foundation repairs. It acts as a durable epoxy filler for concrete, providing excellent adhesion and resistance to vibration, chemicals and heavy loading.
For overhead and vertical concrete repairs, Belzona 4141 (Magma-Build) is the preferred solution, offering similar long-term strength and bonding performance for wall and structural applications.
Can epoxy fix uneven concrete?
Yes, epoxy repair mortars like Belzona 4111 (Magma-Quartz) can fix uneven concrete and offer a long-lasting solution for machinery bases and epoxy resin floor repair applications. These epoxy concrete repair products help create a precise, level surface that supports critical equipment alignment.
How do I secure anchor bolts into concrete?
For a loose anchor bolts, epoxy mortar can rebuild the damaged concrete and strengthen the fixing point. Belzona materials provide high load-bearing capability when securing bolts, making them ideal when you need to anchor bolts into concrete reliably, even in areas exposed to vibration.
What is epoxy chocking?
Epoxy chocking is used to transfer load and reduce vibration between machinery and its foundation, rather than simply correcting alignment. Unlike thin metal shims, which are typically used to align misaligned equipment, an epoxy chock forms a solid, load-bearing interface that fully supports the equipment footprint.
A liquid shim epoxy system cures into a rigid, precisely fitted chock that distributes loads evenly and minimises movement under operation. Belzona 7111 is an epoxy resin chock designed to maintain alignment under high loads and vibration, making it well suited for rotating machinery and foundation epoxy applications.
Do I need to use a conditioner for epoxy concrete repair?
Yes. A conditioner is used with Belzona epoxy concrete repair solutions to promote adhesion and seal the concrete substrate, helping to prevent outgassing and pinholing during application.
To select the correct conditioner for your application, please refer to the Instructions for Use (IFU) for your chosen Belzona epoxy concrete repair material.
Contact Belzona to Learn More About Epoxy Concrete Repair
Content Creator, Belzona Inc., Harrogate, UK.
Responsible for writing a range of content including blog posts, press releases and a range of marketing material.
