An open control joint in a forklift warehouse is a slow-motion failure. Wheels drop in on every pass, the edges spall a little each time, and within a year it becomes a crater. Abbotsford Concrete fills control joints with semi-rigid polyurea that turns the joint solid and stops the spall cycle. Every project starts with a free written estimate.
Concrete slabs need control joints so they crack where they should. The joint itself is a planned weak point in the slab; the crack runs down the saw cut and the slab moves slightly with temperature. Without filler, every forklift wheel that crosses the joint drops into the gap, applies pressure to the joint edge, and chips the corner microscopically. Multiplied across thousands of crossings per day, the joint becomes a crater.
Semi-rigid polyurea filler bonds to both joint edges, fills the gap full-depth, and provides a supported surface the wheels roll across. The slab can still move slightly (the filler flexes), but the edges are protected. Done as part of a new warehouse floor coating install or forklift-rated epoxy project, it is what makes the system actually last.
Same approach across our warehouse services and the wider industrial concrete work. Retrofit joint filling on existing floors before the spall cycle starts is one of the highest-ROI maintenance moves a warehouse can make; see warehouse floor repair if joints have already failed.
Recent work
How it works
How We Fill Joints in Abbotsford
Clean the joint to depth
Each control joint is cleaned out with a saw or specialty blade to full depth, removing existing debris, old fillers, dust and contaminants so the new filler can bond to clean concrete on both sides.
Prime joint edges
A bonded primer is applied to both joint edges where the filler will adhere, ensuring the polyurea bond is permanent and the filler cannot work loose under forklift load over time.
Inject filler full-depth
Semi-rigid polyurea filler is injected into the joint to full depth, slightly proud of the slab surface, allowed to set up to the manufacturer's working window before the next step.
Shave flush with slab
The set filler is shaved flush with the slab surface using a specialty blade so wheels roll across a continuous surface without any bump or transition at the joint.
Maintenance vs install
Joint Filling Pays Back Fast
Joint filling on a previously-unfilled warehouse floor is one of the highest-ROI maintenance investments available. The work itself is fast and minimally disruptive (a single visit for most warehouses), the cost is low compared to floor coating, and the prevented spall cycle saves the cost of spall repair several times over within the first few years.
We install joint filler as a standalone retrofit on existing floors or as part of new floor projects. Coordinate with adjacent forklift-rated epoxy or standard floor coating install if both happen in the same project.
Semi-rigid polyurea, joint depth, retrofit vs install and forklift wheel impact.
Sealant is for weather barrier; semi-rigid filler is for load support. Joints need the filler to be hard enough to transfer wheel load across the joint without compressing, soft enough to flex slightly with slab movement. Polyurea hits that target; flexible sealants do not.
Yes, and it is one of the best investments any forklift warehouse can make. The retrofit install is fast, minimally disruptive, and prevents the next several years of joint-edge spalling for a fraction of the cost of repair.
Then warehouse floor repair on the spalled edges first, then joint filling to prevent it from happening again. We can do both in one project to address the failures and prevent recurrence.
Zone by zone over a single visit or two, with forklift traffic routed around the work zone for a few hours while each joint cures. The cure is fast (hours, not days) and operations resume in each zone as soon as cure completes.
A properly installed polyurea fill lasts the life of the slab in most warehouses. Re-fill at specific joints may be needed if a joint experiences exceptional movement, but full-floor re-fill is rarely required.
Client reviews
What Abbotsford Operations Say About Their Joint Filling
Retrofit joint fill on our existing floor before opening a new operations zone. The spalling we had been seeing every quarter has completely stopped. Best maintenance dollar we spent.
Z. U4
Warehouse Manager, Abbotsford
★★★★★
They explained the difference between sealant and filler clearly; the wrong material had been used before. Polyurea fill installed properly, forklift wheels roll across joints smoothly now.
Y. U4
Distribution Director, Chilliwack
★★★★★
Installed during a single weekend across our entire warehouse. Operations resumed Monday morning, joints have held perfectly through two years of daily forklift traffic.
Q. U4
Logistics Operations, Mission
★★★★★
Combined joint filling with floor coating in one project. The combined system has held with zero failures. Coordination saved scheduling time and the result is bulletproof.
X. U4
Operations Lead, Langley
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