Betonium at RZD Repair and Equipment Depot

Industrial floor repair for Russian Railways

On large infrastructure facilities, concrete floors directly impact operations. Dusting makes cleaning difficult, cracks and potholes require repairs, leading to downtime, and uneven surfaces accelerate wear on wheeled equipment. At Russian Railways (RZD) facilities, these problems inevitably turn into significant operational costs over time. This is precisely why, during any repair, it is important to assess not only the cost of the one-time restoration but also the costs of further floor maintenance. After the RZD team learned about the "Betonium" technology, we moved on to testing it at a facility. The first to be addressed was a repair and equipping depot, where our team modernized a test section.

Worn floor as an operational problem

Why local repair doesn't always solve the problem

Before the work began, the concrete was in poor condition. The surface had cracks, potholes, cavities, remnants of old coatings, and areas with a weakened top layer. Uneven floor levels added further complexity.

With general wear, local patching of defects provides a temporary result, while other weak areas continue to degrade and damage reappears. Therefore, the task was not cosmetic repair, but the restoration of the concrete foundation itself.

Test track in the repair depot

How we repaired existing concrete

On site, our team completed the full processing cycle:

Surface grinding
Handling hard-to-reach areas
Repair of cracks, potholes, and spalls;
Lithium silicate impregnation of the base
Epoxy strengthening
Coating polishing
Finish protection.

As a result, we repaired the damaged areas and formed a working surface on the existing slab, preparing it for intensive use.

Modernization instead of constructing a new floor

What is the technological principle of "Betonium"?

"Betonium" doesn't work like an additional coating on top of concrete. We mechanically process the existing slab, eliminate defects, strengthen the structure, and polish the surface.

This approach allows us to avoid dismantling the foundation and pouring a new floor. The volume of construction work is reduced, and the treatment can be organized without stopping the operation of the facility.

After the upgrade, the daily performance of the coating also changes, which in turn determines the cost of its maintenance. The absence of dusting reduces cleaning costs. A level surface provides more stable equipment movement and reduces wheel wear. A decrease in the number of defects reduces the risk of unplanned work and restrictions in individual areas.

Polished concrete also reflects light more strongly and is better suited for the movement of automated logistics systems. Therefore, the condition of the floor affects not only its maintenance but also the efficiency of processes within the facility.

Total Cost of Ownership instead of the price of a one-time repair

How does modernization affect an entity's economy

Local repairs might seem cheaper in the moment. But with systemic wear, the object returns to the same problem and continues to consume the budget.

Modernization works on a different logic: to make operating costs more predictable. presentations For Russian Railways, the technology was considered a tool for increasing operational efficiency, not just for floor restoration.

In the calculations presented, the payback period for the modernization was estimated to range from 0.45 to 1 year, and the potential increase in the facility’s operational efficiency was estimated at up to 20%. The economic benefit stems from a sharp reduction in fixed costs, less equipment wear and tear, and fewer downtimes.

Even a small reduction in regular costs yields a noticeable cumulative effect in large areas. Therefore, when assessing flooring costs, it's important to consider not only the price of the work itself but also the expenses for the entire period of the flooring's subsequent use.

Test site as the first practical stage

The inspection of the technology at the RZD (Russian Railways) facility revealed

The test section in the repair and outfitting depot allowed us to test "Betonium" on a truly heavily worn foundation. Our team successfully implemented the technology in the conditions of an RZD infrastructure facility and proved its effectiveness in practice.

Similar tasks arise in production halls, warehouse, and terminal complexes. In such facilities, the floor daily impacts the stability of operational processes.

For an infrastructure of this scale, the concrete foundation is important to consider specifically as part of the facility's operating system. The more stable the floor, the fewer additional costs and limitations it creates for core processes.

Key takeaways

What does the modernization of concrete floors in infrastructure facilities demonstrate:

When evaluating a solution, it is important to consider not only the cost of the work itself but also the subsequent expenses for cleaning, equipment maintenance, repeated repairs, and downtime.

If the damage is distributed throughout the area, fixing individual defects will not stop further deterioration.

Restoration and strengthening of the concrete base eliminate the need for its demolition and the installation of a new floor, and the work can be organized without interrupting the operation of the facility.

Dusting increases cleaning costs, unevenness accelerates wear on wheeled equipment, and defects create the risk of unscheduled work and restricted operating zones.

Even a small decrease in regular expenses over large areas has a significant cumulative effect, so the stability of the concrete base becomes part of the overall economics of the facility.

If you are looking for ways to reduce costs in the construction and operation of your facilities, contact the tConcrete team

We look forward to receiving your application. You can share your resume, portfolio and cover letter at hr@tconcrete.ru or send your project to hello@tconcrete.ru