top of page

Warehouse Control Joint Filling for New Builds

  • Writer: seanpond1
    seanpond1
  • Oct 1
  • 2 min read

Updated: Nov 10


Cracked concrete in a warehouse that needs joint filler or concrete repair.

Why Warehouse Control Joint Filling Matters in New Build Warehouses


With Warehouse control joint filling, modern logistics and manufacturing demand concrete floors that handle forklifts, AGVs/AMRs, and 24/7 traffic. Unfilled or poorly filled control joints (contraction joints) lead to:


  • Edge spalling

  • Impact damage

  • Debris intrusion

  • Costly downtime


GSA Slabs installs semi-rigid joint fillers (polyurea/epoxy) to protect edges, support load transfer, and keep surfaces smooth for robotics.


What Are Control Joints?


Control joints are intentional saw cuts that guide shrinkage cracking. Per industry guidance (e.g., ACI 302):


  • Cut depth = ¼–⅓ of slab thickness

  • For 6–8 in. slabs, that means 1.5–2.5 in. deep


Correct filling restores continuity at the joint while still allowing limited movement.


When to Fill (New Builds)


In new construction, allow initial shrinkage and curl to stabilize before final filling—commonly 60–90 days after pour (or per project specifications). This reduces debonding and “picture-framing.”


Our ACI-Guided Process for New Builds


1. Assess & Plan

  • Survey joint depth, width, and lineal footage

  • Confirm slab maturity

  • Check moisture and contaminants


2. Clean & Route

  • Dust-controlled routing/sawing to a consistent profile (often ¼ in. wide)

  • HEPA vacuum for a debris-free bond surface (ICRI surface prep)


3. Backer Control (If Required)

  • For deep joints, install closed-cell backer rod

  • Controls fill depth and prevents three-sided adhesion


4. Install Semi-Rigid Filler

  • Polyurea or epoxy (Shore A ~80–85 for heavy traffic)

  • Placed full-depth using metered, dual-component pumps

  • Slight overfill offsets shrinkage


5. Shave Flush

  • After cure (polyurea: hours; epoxy: 1–3 days)

  • Razor-shave or grind flush for a seamless, robot-friendly floor


6. QC & Maintenance Plan

  • Inspect for voids or soft spots

  • Touch-up as needed

  • Set inspection/maintenance intervals to extend service life


Materials & Equipment We Trust

  • Semi-rigid fillers: Polyurea or epoxy matched to load profile (forklifts, narrow-aisle, robotics)

  • Prep tools: SASE grinders/joint saws with OSHA-compliant HEPA dust extraction

  • Placement: Automated dual-component pumps for precise ratios and uniform fill


What You Gain

  • Reduced spalling & chipping at joint arrises

  • Smoother travel for forklifts and AGVs (less vibration & maintenance)

  • Better load transfer and joint edge support

  • Cleaner floors (less debris intrusion, easier housekeeping)


Why GSA Slabs

  • Industrial focus: New build warehouses, distribution centers, and manufacturing floors

  • Standards-driven: Processes aligned with ACI/ICRI guidance

  • Scalable crews & gear: Fast mobilization, dust-controlled prep, consistent quality

  • Local expertise: Based in El Paso with regional reach (West Texas, Southern New Mexico, and select national projects)


FAQs

Polyurea vs. epoxy—what’s better?

Polyurea cures faster and is more flexible at low temps. Epoxy has longer work time. We specify based on traffic, temperature, and schedule.


How soon can we drive on it?

Polyurea can often handle light traffic within hours. Epoxy typically needs 1–3 days. We phase work to minimize downtime.


Ready for a Robot-Ready Warehouse Floor?


📞 Call: (915) 233-3322

🌐 Web: gsaslabs.com

📍 Service area: El Paso, TX & surrounding markets

 
 
 

Comments

bottom of page