Coo-Var Floor Pack Repair Mortar - Heavy Duty Epoxy Concrete Repair for Industrial & Commercial Floors

• Repair potholes, cracks, and broken bays in concrete, grano, or asphalt floors with a heavy duty epoxy mortar

• Use a repair mortar that bonds stronger than the original concrete (76 MPa compressive strength)

• Get floors back in service quickly — traffic ready in just 3 hours

• Apply in cold or damp conditions — cures down to 5°C and on damp substrates

• Use a solvent-free, zero VOC, non-flammable repair mortar safe for use in enclosed spaces

• Apply a repair mortar with negligible shrinkage that won't crack or pull away from repair edges

• Follow up with floor primer and floor paint for a complete professional floor system

• Repair surfaces other than concrete, grano or asphalt.

Coo-Var Floor Pack Repair Mortar is a solvent-free two-component epoxy mortar designed to repair potholes, cracks, and broken bays in concrete, grano, and asphalt floors — bonding stronger than the original concrete and getting floors back in service in just 3 hours. Unlike cementitious fillers that shrink, crack, and fail under heavy loads, Floor Pack's 100% volume solids epoxy formulation cures with negligible shrinkage and delivers compressive strength of 76 MPa — significantly stronger than standard concrete.

Developed by Coo-Var with over 100 years of British coating expertise, Floor Pack is the trusted choice for repairing industrial and commercial floors in warehouses, factories, loading bays, car parks, runways, and any environment subjected to heavy machinery, forklift traffic, chemical exposure, and abrasive conditions.

A key advantage of Floor Pack is its ability to cure in cold and damp conditions — down to 5°C and on damp substrates. This means emergency repairs don't have to wait for ideal conditions, minimising downtime and keeping operations running. Pot life of 1 hour gives sufficient working time for most repairs, with initial cure in 3 hours and full cure in 3 days.

The 5 kg kit is pre-weighed (2.5 kg base + 2.5 kg hardener) with gloves and instructions included — open, mix, and trowel with zero waste or guesswork. Apply with a steel trowel and smooth with a cloth dampened in Coo-Var GP Thinners Q265/1S. Apply additional layers within 2–4 hours if required for deep repairs. Coverage of 0.5 m² at 5 mm depth per 5 kg kit.

Once cured, follow with the complete Coo-Var floor system — floor preparation products, floor primer, and floor paint — for a fully protected, professional floor finish.

Key Benefits:

• Bonds Stronger Than Concrete – 76 MPa compressive strength, 18 MPa tensile strength, 32 MPa flexural strength. Bonds stronger than the original concrete. 100% volume solids with negligible shrinkage — no cracking or pulling away from the repair edges.

• Traffic Ready in 3 Hours – Initial cure in just 3 hours at 20°C. Pot life of 1 hour gives sufficient working time. Minimises downtime and gets floors back in service fast. Full cure in 3 days.

• Cures in Cold & Damp Conditions – Cures down to 5°C and on damp substrates. Emergency repairs don't have to wait for ideal conditions. Reliable performance in challenging environments where cementitious fillers fail.

• Zero VOC — Solvent-Free – Solvent-free formulation with zero VOC and non-flammable. Safe for use in enclosed spaces without specialist ventilation. Environmentally responsible choice for industrial floor repair.

• One Kit Convenience – Pre-weighed 5 kg kit (2.5 kg base + 2.5 kg hardener) with gloves and instructions included. Open, mix, and trowel with zero waste or guesswork. Everything you need in one kit.

• Universal Surface Compatibility – Adheres to concrete, grano, and asphalt. Suitable for interior and exterior industrial floors, loading bays, warehouses, runways, beams, and precast units. One product for all concrete repair needs.

• Complete Floor System – Follow Floor Pack with Coo-Var floor preparation products, floor primer, and floor paint for a fully protected, professional floor finish. Complete system available from Specialist Paints Online.

• Coo-Var Heritage – Over 100 years of British coating expertise. Trusted by facilities managers, contractors, and industrial operators for heavy duty concrete floor repair.

Repair your floor today and get it back in service tomorrow. Add to basket now for next-day UK delivery.

Coo-Var Floor Pack Repair Mortar is the professional epoxy repair solution for a wide range of industrial and commercial floor environments:

• Warehouses & Distribution Centres – Ideal for repairing potholes, cracks, and broken bays in warehouse floors subjected to constant forklift traffic, heavy loads, and abrasive conditions. Traffic ready in 3 hours — minimal disruption to warehouse operations. Bonds stronger than the original concrete for long-lasting repair.

• Loading Bays & Dock Levellers – Great for repairing damaged loading bay floors and dock leveller surrounds subjected to HGV loading, impact, and abrasion. Cures in cold and damp conditions — repairs can be completed in all weather. Follow with floor primer and floor paint for a complete professional finish.

• Car Parks & External Yards – Perfect for repairing potholes and cracked concrete in car parks, external yards, and hardstandings. Cures on damp substrates — ideal for outdoor repairs after rain. Excellent resistance to vehicle traffic, chemicals, and weathering.

• Factories & Production Facilities – Suitable for repairing factory floors in food production, manufacturing, and processing facilities. Solvent-free, zero VOC formula safe for use in food production environments. Traffic ready in 3 hours — minimal disruption to production schedules.

• Runways & Hardstandings – A must-have for repairing concrete runways, hardstandings, and heavy-duty external surfaces. 76 MPa compressive strength withstands the most demanding loads. Cures in cold conditions — repairs completed year-round.

• Beams & Precast Concrete Units – Ideal for repairing damaged beams, precast concrete units, and structural concrete elements. Bonds stronger than the original concrete. 100% volume solids with negligible shrinkage for structural integrity.

If you need further advice on using Coo-Var Floor Pack for your project, contact our experts now via the live chat for personalised guidance!

Coverage: 0.5 m² @ 5 mm depth per 5 kg kit

Coverage is fixed by repair depth — the deeper the repair, the more product required per m².

Coverage at Different Depths (per 5 kg kit):
• 5 mm depth: Covers approx. 0.5 m²
• 10 mm depth: Covers approx. 0.25 m²
• 20 mm depth: Covers approx. 0.12 m²
• 25 mm depth: Covers approx. 0.10 m²

Example Calculations:

Small Repair (single pothole or crack — approx. 0.25 m² @ 10 mm):
• Product required: 1 x 5 kg kit

Medium Repair (several potholes — approx. 0.5 m² @ 10 mm):
• Product required: 2 x 5 kg kits

Large Repair (broken bay — approx. 1 m² @ 10 mm):
• Product required: 4 x 5 kg kits

For accurate project planning, measure the surface area and depth of each repair. Order 10% extra for irregular repair profiles and surface variation.

Important: Pot life is 1 hour at 20°C — mix only what you can apply within the pot life. Apply additional layers within 2–4 hours of the previous layer. Traffic ready in 3 hours. Full cure 3 days.

Recommended System Products:
• Floor Preparation Range – Prepare the floor surface before priming and painting
• Floor Primer Range – Prime the repaired floor before applying floor paint
• Floor Paint Range – Apply professional floor paint over the repaired and primed surface

Important Notes:

Solvent-free, zero VOC, non-flammable. Wear appropriate PPE including gloves (included in kit) and eye protection during mixing and application. Two-component epoxy — mix thoroughly before use.

Pot life is 1 hour at 20°C — mix only what you can apply within the pot life. Pot life will be shorter at higher temperatures.

Surface Preparation:

• Remove all loose concrete, debris, dust, and contamination from the repair area
• Cut back crumbling or delaminated concrete to a sound substrate
• Ensure repair edges are clean and square — undercut edges improve mechanical bond
• Remove all standing water — surface can be damp but must not have standing water
• Do not apply to frozen substrates
• No primer required for most applications — Floor Pack is self-bonding to prepared concrete, grano, and asphalt

Mixing:

• Ensure both components (base and hardener) are at room temperature before mixing
• Pour the entire contents of Part B (hardener) into Part A (base)
• Mix thoroughly for minimum 3 minutes until completely combined and uniform in colour
• Do not mix partial quantities — the kit is pre-weighed for correct ratio
• Use immediately — pot life is 1 hour at 20°C

Application:

• Apply in temperatures above 5°C
• Trowel mixed mortar firmly into the repair area using a steel trowel
• Press firmly to fill all voids and ensure full contact with the substrate
• Build up to the required depth — apply additional layers within 2–4 hours if required for deep repairs
• Level and smooth the surface with a steel trowel
• Smooth the surface finish with a cloth dampened in Coo-Var GP Thinners Q265/1S if required
• For deep repairs (over 25 mm), apply in layers — allow each layer to reach initial cure before applying the next

Drying & Curing Times (at 20°C):

• Pot life: 1 hour
• Initial cure (traffic ready): 3 hours
• Overcoat window for additional layers: 2–4 hours
• Full cure: 3 days

Curing times may be extended in cooler temperatures. Cures down to 5°C.

Recommended System Products:
• Floor Preparation Range – Prepare the floor surface before priming and painting
• Floor Primer Range – Prime the repaired floor before applying floor paint
• Floor Paint Range – Apply professional floor paint over the repaired and primed surface

• Finish / Texture: Smooth, trowel-finished concrete grey
• Base: Solvent-free two-component epoxy mortar
• Available Colours: Concrete Grey (others to order)
• Pack Sizes: 5 kg kit (2.5 kg base + 2.5 kg hardener)
• Coverage: 0.5 m² @ 5 mm depth per 5 kg
• Drying Times @ 20 °C: Pot life 1 h; initial cure 3 h; full cure 3 days
• Re-coat Interval: Apply additional layers within 2–4 h if required
• Minimum Application Temp.: 5 °C
• VOC Content: 0 g/L (solvent-free)
• Flash Point: Non-flammable
• Application Method: Steel trowel; smooth with cloth dampened in Coo-Var GP Thinners Q265/1S
• Surface Suitability: Concrete, grano, asphalt; interior & exterior industrial floors, beams, precast units, runways
• Volume Solids: 100 % (negligible shrinkage)
• Compressive Strength: 76 MPa
• Tensile Strength: 18 MPa
• Flexural Strength: 32 MPa

Unsure about the right thickness or prep? Chat with our experts now!

What is Coo-Var Floor Pack Repair Mortar and when should I use it?

Coo-Var Floor Pack is a solvent-free two-component epoxy mortar designed for heavy duty repair of potholes, cracks, and broken bays in concrete, grano, and asphalt floors. Use it when you need a structural repair that bonds stronger than the original concrete and gets floors back in service in just 3 hours.

How strong is Floor Pack compared to concrete?

Floor Pack delivers 76 MPa compressive strength, 18 MPa tensile strength, and 32 MPa flexural strength — significantly stronger than standard concrete. 100% volume solids with negligible shrinkage means no cracking or pulling away from repair edges.

Can I use Floor Pack in cold or damp conditions?

Yes — Floor Pack cures down to 5°C and on damp substrates. This makes it ideal for emergency repairs that cannot wait for ideal conditions. Do not apply to frozen substrates or surfaces with standing water.

How long before I can use the floor after applying Floor Pack?

Traffic ready in just 3 hours at 20°C. Full cure in 3 days. Curing times may be extended in cooler temperatures.

What is the pot life of Floor Pack?

The pot life is 1 hour at 20°C. Mix only what you can apply within the pot life. Pot life will be shorter at higher temperatures. The kit is pre-weighed — do not mix partial quantities.

Can I apply additional layers for deep repairs?

Yes — apply additional layers within 2–4 hours of the previous layer. For very deep repairs (over 25 mm), apply in layers and allow each layer to reach initial cure before applying the next.

What surfaces can I apply Floor Pack to?

Floor Pack is suitable for concrete, grano, and asphalt — interior and exterior industrial floors, loading bays, warehouses, car parks, runways, beams, and precast concrete units.

What coverage can I expect from Floor Pack?

Coverage is 0.5 m² at 5 mm depth per 5 kg kit. Coverage reduces proportionally with depth — at 10 mm depth, one kit covers approximately 0.25 m². Calculate the number of kits required based on the surface area and depth of your repair.

Is Floor Pack solvent-free?

Yes — Floor Pack is solvent-free with zero VOC and is non-flammable. Safe for use in enclosed spaces without specialist ventilation. An environmentally responsible choice for industrial floor repair.

What do I need to do after applying Floor Pack?

Once Floor Pack has fully cured (3 days), apply the complete Coo-Var floor system — floor preparation products, floor primer, and floor paint — for a fully protected, professional floor finish. All products are available from Specialist Paints Online.

How do I smooth the surface of Floor Pack?

Apply and level with a steel trowel. Smooth the surface finish with a cloth dampened in Coo-Var GP Thinners Q265/1S if required.

Does Floor Pack require a primer?

No — Floor Pack is self-bonding to prepared concrete, grano, and asphalt. No primer is required for the repair mortar itself. However, once the repair is complete and fully cured, apply Coo-Var Floor Primer before applying floor paint for the complete floor system.

Safety data sheet

Method Statement

Complete Your Floor Repair & Finishing System:

• Floor Preparation Range – Prepare and clean the floor surface before priming and painting

• Floor Primer Range – Prime the repaired and prepared floor before applying floor paint

• Floor Paint Range – Apply professional floor paint over the repaired and primed surface for a durable, attractive finish

Need help specifying the right floor system for your project? Contact our experts via live chat!

Fast, Reliable & Fully Tracked UK Delivery

Every order is dispatched from our warehouse using a fully tracked DX or FedEx service, so you always know when your paint will arrive.

Delivery Options

• FREE Standard Delivery (orders over £75) Arrives in 2–3 working days
• Standard Delivery – £7.95 Arrives in 2–3 working days
• Express Delivery – £13.95 Next working day delivery when you order before 12:00 noon (Mon–Thu)
• Spending £75+? Select Express Upgrade at checkout and only pay the difference

Dispatch & Delivery Times (What Happens After You Order)

• Express delivery (order before 12:00 Mon–Thu) Dispatched same day, delivered next working day
• Standard delivery (Mon–Wed orders) Dispatched next working day, delivered 2–3 working days later
• Orders placed Thursday (standard delivery) Dispatched Friday for Monday delivery
• We do not dispatch or deliver on weekends or UK bank holidays

What to Expect on Delivery

Please provide a contact telephone number at checkout. This allows the courier to share tracking updates or contact you if there are any delivery issues.

Most orders require a signature on delivery. If you may not be available during the day, we recommend delivery to a workplace, business address, or another location where someone can sign.

Outside the UK Mainland?

Delivery prices shown apply to UK Mainland only.

For the Highlands, Islands, Northern Ireland, or non-mainland addresses, please contact us for a quick personalised quote via live chat, by calling 01482 222 421, or emailing info@specialistpaintsonline.co.uk.

Bottom Line

Order today, get fast and reliable delivery, track every step, and get painting without delays.