Category Archives: concrete mender

When the busses have to keep rolling, Concrete Mender gets going.

When a city bus garage in the Pacific Northwest needed a fast concrete repair solution, crews turned to Roadware 10 Minute Concrete Mender™.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™

Mission critical concrete repairs is what we do here at Roadware. Facilities like city bus garages have areas that are required to be open and operational 24/7 365 days per year. Roadware 10 Minute Concrete Mender™ is your best choice for fast repairs that have to last.

January 18, 2014
Dear Roadware,
“I am writing this letter in regards to Roadware Incorporated, in particular their 10 minute mender concrete repair product. I have been involved in the concrete industry for 28 years. I am a former Certified American Concrete Institute field testing technician and have been an ACI Concrete Flatwork Finisher and Technician for more than 10 years. For the past 15 years, I have been working to perfect the art of concrete rehabilitation on structural concrete and Architectural concrete. Other repair textures include masonry, slate. granite, clay artworks and architectural stone works.At the 2011 World of Concrete Convention, I met with The Roadware sales staff. I was quite intrigued and impressed with their 10 minute concrete mender product line. I was given some test samples which ultimately persuaded me into using Roadware product.
Our first project using Roadware products was a complicated repair contract with a bus transit authority and I had to include a two-year warranty. There would be limited time access during the repair and I needed a product that would withstand heavy bus traffic within hours of application. I submitted my bid using the specifications and MSDS for the 10 minute mender product line and believe this may have been the reason I was awarded the job. End result 10 minute mender works! Fractured concrete, spalled concrete, cracked concrete. Concrete deficiencies e.g. all surface and deep restoration repairs. Microdoweling works period! 

While I was confident in the product, it is always reassuring to experience it first hand. I am quite familiar with what it takes to provide world class service to demanding customers. Roadware Employees deliver excellent customer service and unmatched product support.”

Sincerely,

William F. Neal
Bothell, WA

Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
The process starts with removing dirt and debris from the cracks and preparing them for repair.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Sometimes, remove and replace is not an option. Roadware 10 Minute Concrete Mender™ can have this back in service in minutes, not hours or days.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Roadware 10 Minute Concrete Mender™ mixed at a one to one ratio and blended with two parts sand. Each gallon of Concrete Mender makes about 2.2 gallons of repair material.

 

Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Roadware 10 Minute Concrete Mender™ can be mixed in bulk with simple tools and equipment.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Manufactured sand or quartz is added to the Concrete Mender to make a trowel-able mortar.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Roadware 10 Minute Concrete Mender™ is available in 10 gallon kits or convenient 2 gallon jug kits.
The Roadware 10 Minute Concrete Mender™ blended with silica sand is poured into the cracks and troweled flat.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Repairs can be made in all seasons with an ambient temperature range of -20F to 100F.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Roadware 10 Minute Concrete Mender™ repairs are ready for bus traffic in about 10 minutes at 70 degrees F.
Repairing concrete cracks with Roadware 10 Minute Concrete Mender™
Customer letter to Roadware

 

 

All about Roadware 10 Minute Concrete Mender™

At Roadware, we see lots of two-component polymer concrete repair products that claim to be just like Concrete Mender™. One even calls it self, “Quick Mender.”  They are all basically polyurea based products that are too thick to effectively penetrate concrete surfaces and are so reactive, they become too sticky and gooey to trowel in just a minute or two after mixing.  When you dig a little deeper, you will see a very distinct difference in genuine Roadware 10 Minute Concrete Mender™.

  • What is Concrete Mender? Proprietary Polyurethane Blend
  • Formulation: Classified
  • Manufacturing: South Saint Paul, Minnesota, USA
  • Origin: NATO program for rapid bomb damage repair on runways.
  • Function: To penetrate deep into concrete cracks, joints, and spalls creating a structural repair in 10 minutes.
  • Military Use: Classified
  • Civilian Use: Repair cracks, joints and spalls in commercial, industrial and civil applications.
  • Service Life: Indefinite
  • Cure Time: 10 Minutes at 70°F (21°C)
  • Distribution: Worldwide Distributor Network

Surface Tension:

Surface Tension is a measurement of the ability of a liquid to overcome its own internal friction and penetrate into a material like concrete. Roadware 10 Minute Concrete Mender™ has a surface tension One third of water. It will penetrate concrete cracks and fissures quicker and deeper than water. This low surface tension lets Concrete Mender™ penetrate normal bond lines and allows structural bonding with the aggregate in the concrete. See the electron microscope slide below.

 

Low surface tension has another little hidden benefit.  It allows Roadware 10 Minute Concrete Mender™ to be combined with more than two parts sand and still be workable and trowel-able.  Try that with a polyurea and you will have a gooey mess on your hands.

 

 
Roadware Microdoweling™ Technology:
Slab to slab micro-doweling action, provided by Roadware 10 Minute Concrete Mender, links concrete slabs together, locks them in place and allows for full-traffic, dynamic-load transfer, in 10 minutes. This micro-doweling action is more compatible with concrete and less re-active in harsh environments than even Poly-coated re-bar. Millions of micro-dowels penetrate, then bridge and bond, side by side, broken and jointed slabs. Hairline cracks, trench wide cracks, irregular cracks, cured control joints and variable depth spalls are candidates for this amazing technology.
In 10 minutes, at 70°F (21°C) , this micro-doweled bond has the same compressive and shear strength as poured and fully cured concrete. This makes bond-line failures a thing of the past. Parallel re-cracking, often experienced when epoxies cure out, are eliminated with Roadware’s micro-doweling technology.

Structural Polyurethane

Roadware 10 Minute Concrete Mender™ is a polyurethane based material that restores structural integrity and aggregate interlock to distressed concrete by using low surface tension and low viscosity to penetrate concrete surfaces and cross -linking polymer chains to bond directly to the concrete-aggregate matrix.  This bonding action utilizes capillary forces to self-inject polymer chains into the surrounding concrete. This material should have a modulus of elasticity less then the surrounding concrete and should not become brittle over time. This material may be combined with manufactured sand to form a PCC compatible polymer concrete that can structurally repair concrete cracks  and spalls.

Advantages– Due to the very low surface tension of the material and low viscosity, complete saturation bonding of cracks can be easily achieved. Minimal prep to remove lose debris is all that is normally required.  This can be considered a structural repair if the material is allowed to gravity flow to the full depth of the crack. Manufactured sand or quartz may be introduced into the repair as necessary to prevent under slab ponding and martial waste. For repair greater than 0.125 inches, specified sand may be added at a ratio of two parts sand to one part mixed polyurethane as the crack is filled to extend the material and add strength. The sand also brings the thermal coefficient of expansion of the repair material closer in-line with surrounding concrete. Polyurethanes of this nature may be applied in a wide range to substreight temperatures making them useful in frozen and cold storage warehouse applications or cold weather application below -20F (-23C). Repairs are typically ready to accept traffic in approximately 10 minutes at 72F (22C).

Toughness:

Roadware 10 Minute Concrete Mender™ mixed with sand gets about as hard as concrete, yet it’s modulus of elasticity is slightly less than concrete so it will move with the slab, not work against it.

Common uses for 10 Minute Concrete Mender™
 
Spalled control joints and cracks.
Spalls and holes.
Delamination Repair

 

Uneven slabs and thresholds.
Crack Injection using gravity:
Typical crack injection repair techniques involve epoxy, ports, pumps, and pressure to force thick epoxies into a crack.  Roadware 10 Minute Concrete Mender™ with its low surface tension can do same job in less time, less mess, and better performance.

Polishable:

Polishing your floor to a mirror like finish? Repairs made with Roadware 10 Minute Concrete Mender™ will not smear into the surrounding surface or gum-up diamond polishing pads.  You can even add natural sand to match the grain and color of the surrounding concrete.

The repair pictured above shows  Roadware Concrete Mender™ Off-white blended with plain concrete sand and a small amount of portland cement. This water-thin polyurethane is almost translucent. When we add nearly any type of dry sand or aggregate, we get a fast-curing polishable repair that blends beautifully with the surrounding concrete. Since this material is almost translucent, it resists shadowing effects due to over-banding when applied.

Lower Cost:

By adding two parts silica or quartz sand to a gallon of Concrete Mender™ you will yield about 2.2 gallons of repair material.

A gallon of polyurea or epoxy will yield a gallon of repair material.  That makes polyurea more expensive to use even at half the material cost! This does not even factor in the hidden costs of short repair life, damage to the surrounding concrete caused by pre-mature failure, or the cost of redoing the the repairs when they fail.

 

Packaging:

Roadware 10 Minute Concrete Mender™ hand packed with state-of-the-art packaging materials.  They have to be good. The very low viscosity and surface tension require it.

Bulk Application:
Due to the the extended working time formula, bulk mixing of Concrete Mender™ is easy.  Unlike polyureas that start to gel up instantly, Concrete Mender will remain workable and flowable for several minutes before curing begins.  Much less wasted product setting up in buckets.
Pin-point Application:
With a Roadware needle tip mixer, you can apply Concrete Mender™ within-point accuracy delivering product to where it is needed most. Our needles come as small as 1.2mm in diameter.  If you can get a finger nail in the crack, we can get some Concrete Mender in there as well.

Freezers:

Working in the cold?  We’re from Minnesota. We know first hand what it takes to work in freezing temperatures. Roadware 10 Minute Concrete Mender™ can be applied at temperatures below -30 F ( -34C).  That is really cold.  Exposed flesh will freeze in seconds.  That is almost too cold to go ice fishing. Most repair products would freeze solid before curing and quickly fail.  Roadware 10 Minute Concrete Mender™ generates its own heat. Curing will take several hours, but you will still get the same great performance.

 

 

Colors:
Roadware Concrete Mender™ comes in two standard colors.  Concrete Grey and natural off-white. Since a typical repair is made up of two parts sand to one part liquid, the color of the sand will determine the color of the finished repair.  By adding colored quartz sand to off-white Concrete Mender, you can make custom colors as needed.
Specialty Applications:
We also custom make Concrete Mender in Safety Yellow, Red, Blue, and Black.  Use Concrete Mender Yellow to create permanent safety lines and marks in difficult areas like cooler and freezer floors.
Safety:
Roadware 10 Minute Concrete Mender™ is completely self-reacting and does not out-gas solvents or VOC’s when curing.  This material meets FSIS guidelines for work is federally inspected meat and poultry plants.

History:

For over twenty years, Roadware 10 Minute Concrete Mender™ has performed without fail in thousands of applications. Many times outliving the facility itself.

Concrete Mender repair in a cold storage warehouse after 15 years of heavy forklift traffic.

Utilizing technology developed to repair bomb damaged runways for NATO, Roadware 10 Minute Concrete Mender™ was reformulated and brought to commercial markets in the early 1990’s.  You can find us in nearly every industry that has concrete floors, decks, slabs or surfaces.

Links:
Roadware 10 Minute Concrete Mender™

Availability:

Roadware 10 Minute Concrete Mender is made in the USA and is available from Roadware authorized distributors and dealers worldwide. Call 1-800-522-7623 or 1-651-457-6122 to find a dealer near you.

Specifications:

For complete specifications, ASTM testing data, and usage guidelines, please visit the Roadware Website.

Repair polished concrete with Concrete Mender™

Stop repairing polished concrete with polyurea joint fillers. They look like plastic, do not bond well, and do not hold-up over time. Concrete polishing lets the natural beauty of stones, sand, and rock shine through.  Your repair product should as well.

cbec1b48d1534cf9a2862736e4d80d23

We took the proven Microdoweling™ properties of Roadware 10 Minute Concrete Mender™ and combined it with natural sands, aggregates and pigments to make repairs that not only look great, but perform better than epoxies and polyureas.

polished-repair450

The repair pictured above shows  Roadware Concrete Mender™ Off-white blended with plain concrete sand and a small amount of portland cement. This water-thin polyurethane is almost translucent. When we add nearly any type of dry sand or aggregate, we get a fast-curing polishable repair that blends beautifully with the surrounding concrete. Since this material is almost translucent, it resists shadowing effects due to over-banding when applied.

Uncontrolled Epoxy Injection

Question: How do you epoxy inject cracks in floor slabs on grade when you do not have access to the bottom of the slab? What keeps the product from running out the bottom and all over the place?Answer: We make these type of repairs all the time. The first thing to do is dump the epoxy.  It is too thick, too brittle, and takes too long to set.  Fast setting materials like 10 Minute Concrete Mender allow you to control set points deep in the crack and prevent material seepage.

Roadware 10 Minute Concrete Mender™ has an ultra low viscosity of 8cps and will gravity inject into the smallest of cracks. We make the repair in stages adding fine silica sand into the crack as necessary to prevent the material from running out the bottom. The product can be injected with needle tip mixers as small as 18 gauge. With careful technique and experience you can make structural repair that will restore aggregate interlock and restore the slab.

Start out by adding a small amount Concrete Mender to the prepared crack and noting where material in running beyond the slab.  Add a light dusting of silica sand or fine quartz to the crack and some more Concrete Mender. The Concrete Mender will combined with the particles of sand to form a quick setting, “mud” at the bottom of the crack. Repeat as necessary and repair the full depth of the slab.

This will be a structural repair with no ports, no pumps, and almost no down time.

 

 

Extreme Concrete Repair and Polish

How do polish a floor when your concrete is like this?

Deep cracks and surface spalling can make polishing jobs costly and difficult.  A lot of the top surface has to be removed to get to a smooth finish.

Roadware 10 Minute Concrete Mender™ is a great choice for filling out all the cracks, spalls and holes before polishing.

This floor was repaired by troweling down a thin layer of Concrete Mender and sand, then ground smooth. A liquid hardener completed the restoration and the floor was polished.

 

The floor shows zero failure shown here 3 years later in 2007.  The floor continues to perform today.

 

Vertical Wall Repair at Club Warehouse Store

Use Roadware 10 Minute Concrete Mender™ and sand to repair damaged concrete block walls in an hour or less. Sent in by Dave Wilson at Myspec Integrated Concrete Repair Group in Georgia.  770-335-9123 Roadware 10 Minute Concrete Mender™ is great for repairing cracks and spalls in floors. This ultra-low 8cps viscosity material gravity flows deep into concrete and makes repairs from the bottom up.  To repair a holes in a block wall, mix the Concrete Mender™ with fine silica sand to make a trowel-able mortar.

 Step 1: Prepare the area and remove any loose block, paint or dirt.

 

 

Step 2: Mask off the area like shown. In a clean bucket, mix one part AB blended Concrete Mender with 3 parts sand to make a stiff mortar and trowel into the repair area. You may want to tape a plastic sheet over the repair area to hold the Concrete Mender mixture in place while it cures for 10 minutes. See bulk mixing instructions here.

 

Step 3: After approximately 10 minutes depending on the ambient temperature, pull the masking and blend in the repair with a rubbing brick.

 

Step 4: Roadware 10 Minute Concrete Mender™ can be painted as soon as it cures.  Paint the repair area to match the surrounding wall.

With Roadware 10 Minute Concrete Mender™ you can do a job in less than an hour that used to take two days. No more waiting for hours or days while traditional cement based materials to set and cure.

Here is a video of using Roadware 10 Minute Concrete Mender™ to repair cracks in concrete or block walls.

 

 

Roadware Contraction Joint Repair

Why are my contraction joints spalling and what can I do to stop it?

  

Contraction joints (or control
joints) are joints cut into a slab shortly after pouring. The purpose of these joints is to control the cracking of the slab as it cures. Most concrete slabs shrink and sometimes curl for the first 12 months after pouring. Contraction joints allow the
slab to crack at pre-determined intervals instead of natural random cracking. Joint filler is used to protect the joints from spalling and chipping caused by traffic on the slab.
 control-joint-filler-original

As the slab cures for the first
12 months, it shrinks in size and may even curl up at the joints. The contraction joints will expand as the slab shrinks. This causes the joint filler to split apart or dis-bond from the sides of the joint leaving them exposed to traffic.

control-joint-filler-curled
When loads are rolled over the
joint. The force of the load has to transfer from the wheel, to the concrete, and to the base. If the slab is even slightly curled and the joint is expanded, the force of the load will impact on the joint causing cracking and spalling. You may even get stress cracking parallel to the joint. You can sometimes feel the uneven load transfer across the joint if you stand with one foot on either side of the joint and have someone else roll a heavy load across the joint.
control-joint-filler-curled-dynamic-load
Eventually, you get a spalled contraction joint. The joint filler has completely failed or is missing. Wheels go “thunk, thunk” every time they go over the joint. Productivity suffers, and the joint fills with dust and debris.
 control-joint-filler-curled-spalled
A popular and effective way to repair spalled contraction joints is to lock them back up with Roadware 10 Minute Concrete Mender™. Once the slab is 12 months old, the shrinkage and curling has finished. There is no longer a need for contraction joints. Now you can use Concrete Mender™ and silica sand to bond the slab back together from the base all the way up to
the top. This will stabilize the slab, restore aggregate interlock,
and allow for complete and even load transfer from the wheels all the way down to the base. Your contraction joint problems are solved.
control-joint-filler-curled-spalled-repaired
NOTES: Locking up contraction joints
is recommended for interior controlled environment applications with sound concrete and base. Exterior applications may have different results. Always test a small section
of large repair for compatibility.
 See how this repair was made by clicking here.

 

 

Buy a gallon and make two. Good deal!

One gallon of Concrete Mender™ goes a long way.

 

Yield of Concrete Mender verses epoxy and pylurea.

 

One gallon of Concrete Mender™ will make 2.2 gallons of repair material when typically applied with 2 parts sand. That makes Concrete Mender™ a better value then most epoxies and polyureas. No other product we know of goes as far and performs as well.  Any way you look at it, Concrete Mender™ is a better value even it it was twice the price.