Category Archives: Concrete Repair

Polishing un-polishable Concrete

Polishing and honing concrete to smooth shiny surface is a great way to give an old warehouse floor new life. Sometimes, warehouse floors are too damaged and worn to make polishing practical. Floors that are full of cracks and spalls will require a large amount of grinding and polishing to achieve an acceptable surface. Roadware 10 Minute Concrete Mender™ may be used to restore the concrete surface and reduce the time and expense of heavy grinding. The Microdweling™ action of Roadware 10 Minute Concrete Mender™ can penetrate the surface of the cracks and spalls, fill in all the low spots, and make the floor ready for polishing.

Click on photos for a larger image.

Pitted, spalled and cracked surfaces may be unpractical to polish.

 

The first step is a light surface grinding to open up the cracks and remove any loose materials.

An initial grinding with metal resin pads reveals cracks and spalls.

Roadware 10 Minute Concrete Mender™ and fine silica sand mixed in bulk is troweled into the surface over the entire area and allowed to set.

Workers trowel Concrete Mender into place.

In about 10 – 30 minutes, the surface is polished using standard techniques. Roadware 10 Minute Concrete Mender™ will not gum-up polishing pads or smear into the surrounding concrete.

Surface polish using standard techniques.

After grinding, all pitting, cracks and spalls are filled and a smooth surface is quickly restored.

Concrete Mender repairs hold up perfectly during the polishing process.

After polishing, hardening and sealing, a beautiful polished floor is revealed.

Concrete Mender restored floor after polishing, hardening, and sealing.

Click here to learn more about polishing with Roadware 10 Minute Concrete Mender™

Special thank you to International Roadware Distributor Join K&C in Seoul, Korea for submitting this project.

Repairing Railings and Posts with 10 Minute Concrete Mender™.

How often have you run into this problem?  Industrial railings that have been split apart due to age, abuse, or weather damage. With a few special techniques, you can repair these problems with Roadware 10 Minute Concrete Mender™.

Clean the repair area with a wire brush or by sandblasting. Remove as much of the rust as possible. It is also a good idea to spray the the steel railing with a rust neutralizer.

 

Make a simple form out of blue foam board, and duct tape or most anything plastic. Do not use wood, Concrete Mender will permanently bond the wood to your railing base.I made that mistake years ago and had to chip, grind and sand the wood off the face of the concrete.

Make your repair by pouring 10 Minute Concrete Mender™ bulk mixed with sand in from the top. Allow to cure and finish the surface with a stone or grinder.

 

Add a quick coating of a latex cement coating and your finished. You may also make repairs around railings with Roadware Flexible Cement II™ if the railing is made aluminum and requires more thermal contraction and expansion properties.

Airport terminal deck repair after 5 years.

Here is a crack repair project at the CVG Airport in Cincinnati, Ohio. The upper terminal deck developed cracks parallel to the  construction joints. Roadware Flexible Cement II™ was used to repair the cracks in 2005. Here are some pictures of the project over the years.

Here is a photo of the CVG terminal deck as of June 2010.

 

Roadware Flexible Cement II™ was used the repair the crack on the right in 2005.  The crack on the left was repaired with Roadware 10 Minute Concrete Mender™ for comparison.

 

Finished repairs in 2005. Roadware Flexible Cement II™ on the left. Roadware 10 Minute Concrete Mender™ on the right.

 

Repairs as they appeared in 2006 after one year on service. Both are holding well. The Roadware 10 Minute Concrete Mender™ on the right shows yellowing, but is still performing well. The Flexible Cement II™ is slightly lighter on color, but looks perfect.

 

Here is the same repair in June 2010. After 5 years on service, everything looks good.

This is a close-up shot of the Flexible Cement II™ after 5 years of service. The repair is still holding like the day it was installed. Roadware Flexible Cement II™ is a good choice for outdoor repairs in structural concrete. The semi-flexible properties strike a good balance between road toughness and just the right amount movement absorption.

Concrete repair under decorative coatings.

The advances in decorative concrete coating and finishes for patios, sidewalks, driveways and pool decks are amazing. All of these systems have one common element. They are all affected by the condition of the concrete underneath. We recommend and use Roadware Concrete Mender™ Off-white to repair cracks, spalls and surface defects prior to decorative concrete treatments and coatings.  Off-white Mender is just like the Roadware 10 Minute Concrete Mender™ except it cures to a neutral off-white color that has less chance of affecting the color of the decorative coatings applied over the repairs.  Take a look at the project below.

P5101449

Here is a church with a spalled and rough looking entrance.

 

Prior repair materials were removed revealing worn, but sound concret

Concrete Mender Off-white

Roadware Concrete Mender™ Off-white and sand mixed in bulk is applied and troweled smooth. The material appears brown due to the brown colored manufactured sand added to the mix.

 

 Cracks are cleaned and repaired with cartridge applied Roadware Concrete Mender™ Off-white and sand.

After about 15 – 30 minutes, the repairs are ground smooth and flat. The concrete is now ready to accept most types of decorative concrete treatments.

 

NC4

Roadware  Concrete Mender™ Off-white is compatible with most high-build overlay or coating systems. It is also recommended by several top coating system manufacturers.

 

Making Cracks Disappear

One question we get asked all the time is if we can make a crack disappear.  For the most part the answer has always been no. We can make a good repair and finish it as close as we can to the original color and surface texture. That was before Roadware MatchCrete™ Clear came along.  The photos below were sent in by a concrete polishing contractor. By using MatchCrete™ clear and sand that matches the surrounding concrete, the polished repair blends in very nicely with the concrete slab. When the floor is in service, you will have to look very carefully to find the repairs.  Try some Roadware MatchCrete™ Clear on your next polishing job. With a little technique and experimentation, you can get results like this.

dalton.008
Polished concrete repair with Concrete Mender™ Off-white.
Polished concrete repair with Concrete Mender™ Off-white.
 Did the crack disappear? If you don’t notice it anymore, what’s the difference?

Roadware compared to look-alikes.

Recently a customer sent me several cut sheets from other manufactures of look-alike concrete repair products and asked me to compare them with Roadware 10 Minute Concrete Mender™.  Here is how it played out.

Dear Dave,
 
We here at Roadware are familiar with the knock-off and look-alike products you submitted for our review. These products fall into the category of a low viscosity polyurea. Basically, what they have done is modify a standard polyurea joint filler and added a solvent to make it appear as a high-penetration Concrete Mender™-like product. They are all missing the key property and process that makes Roadware 10 Minute Concrete Mender™ unique and superior in overall performance. This process is called Microdoweling™.
 
Roadware’s Microdoweling™ process uses a proprietary formula of polyurethanes and additives to achieve a measured surface tension of 0.026 N/m. (1/3 of water) Surface tension is a measurement of a liquids ability to break free of its own molecular friction and flow into something else. Microdoweling™ is why Roadware 10 Minute Concrete Mender™ can penetrate easily into a concrete surface under adverse conditions, as is the case in distressed, broken and cracked concrete.
Other advantages for Roadware 10 Minute Concrete Mender™ are:
 
  • The lowest viscosity for easier mixing and blending.
  • Easy, one-step polishing and grinding. This material will not melt, smear, or gum up diamond polishing pads. An excellent parging compound.
  • Experienced and advanced packaging. Roadware cartridge packaging is reliable and works well in the field.
  • End-user color blending. New MatchCrete™ Concrete Mender can easily be manipulated into many colors by modifying the sand or adding pigments.
  • A modulus of elasticity that is slightly less then the concrete so repairs will move with the concrete and not against it.
  • Needle tip application. A complete system of needle-tip cartridge mixers for pin-point application and hairline crack repair.
It’s all in the data. Roadware backs up the Microdoweling™ process with independent testing data and publishes it on our website, www.roadware.us.
Thank you for continued support and please call us any time if you have any questions.
Best regards,
 
 
Kelton Glewwe
Vice President of Operations

 

Rebuild of a Damaged Step Corner

A common concrete repair problem is broken steps. Roadware 10 Minute Concrete Mender™ is a good choice for repairing steps and curbs. Here is a repair sent in by Roadware distributor Minitman Supply in Colorado.

Rebuild of a Damaged Step Corner
A repair like this one starts with cleaning the concrete with a wire brush or diamond blade. Use blue Dow board to make a form and hold it in place with duct tape.

 

Fill the repair area with Roadware 10 Minute Concrete Mender™ combined with silica sand. Pull the form after the material sets in about 10 – 20 minutes depending on temperature.

 

 

 

After you remove the forms, you will see something like this.

 

Use a finishing stone to bland and contour the repair into the rest of the steps.  A finish coat of a latex cement finishing coat over the entire stairway will have your steps looking good as new.

 

 

Emergency Concrete Repair at Wal-Mart Garden Center

Recently Dave Wilson, of Roadware Distributor Fowler Supply received this email on behalf of a East Tennessee Construction Services.

From: Retail Facilities Maintenance Call Center
 
Subject: concrete repair
 
Possible safety hazard in garden center patio. Please dispatch concrete repair specialist to evaluate and remedy the situation as soon as possible. Customer safety is a top priority.
Store Manager 
Store #XXX
Georgia

 

Emergency repairs are common for Roadware contractors.  When safety is on the line and a store needs something repaired quickly and permanently, Roadware Concrete Repair Products are the clear choice due to minimal down time and minimal intrusion to facility operations.

When Dave Wilson arrived on site, this is the trip hazard condition he found.

Plan of Action:

  1. Repair bottom portion of spalled joint with Roadware 10 Minute Concrete Mender™.
  2. Repair top portion of spalled joint using new Roadware MatchCrete™ Clear (MCC) colored with Davis Colors pigment to match the surrounding concrete. MCC is used because it will not change color when exposed to UV sunlight as is the case in a garden center.
  3. Finish to grade.

Roadware 10 Minute Concrete Mender™ and silica sand is added to the bottom of the repair. This provides a tough  Microdoweling™ repair and seals off and moisture in the substrate.

Roadware MatchCrete™ Clear and a mixture of silica sand blended with about one teaspoon of powdered Davis Color is added to the repair.

The Roadware MatchCrete™ Clear and sand mixture is troweled in place and allowed to cure for about 45 minutes.

After curing, the surface is ground smooth and the control joint is re-sawn with a diamond blade.

 

Traffic is restored immediately.  Danny, the associate who requested the work order was, “Amazed.”

When the job has to be done quickly and correctly. Roadware Concrete Repair products are always at the ready.

Special thanks to Dave Wilson at PatchMyConcrete.com for sending this in!

Concrete slab under wood floor crack repair.

Today I received several photographs of a large crack that developed under a hardwood floor in a slab-on-grade application. The crack buckled the hardwood flooring. The home owner consulted several contractors and engineers to solve the problem. No cost-effective solution could be found until Roadware contractor, Clay Kenny, (Manderville, Lousiana) arrived on the scene.

Using Roadware 10 Minute Concrete Mender™ and silica sand, Clay repaired the crack to full depth and re-bonded the slabs back together using Roadware’s Microdoweling™technology.

The repairs cured in just 10 minutes and Clay was on and off the job in just 3 hours. The home owner was amazed. Clay and 10 Minute Concrete Mender™ did what couldn’t be done. The hard wood flooring was re-installed and the floor was put back in service faster then anyone could imagine. This repair took nine 600ml cartridges of #80300 Roadware 10 Minute Concrete Mender™ and a 40 lbs bag of silica sand to complete. The Concrete Mender™ turned a flooring disaster into an opportunity.
Anyone in the concrete business knows that concrete can be unpredictable and even a well thought-out project can develop cracks. Some are minor, and some can cause a real problem. Roadware 10 Minute Concrete Mender™ can help make the problems manageable.

 

Concrete Polishing: Crack, Joint and Spall Repair Are Critical To Lasting, Quality Jobs



By: Joe Noble

The days of super-sized everything arrived about a decade ago, making large concrete-floored buildings common in a sea of commercial applications, including box-retailing, airports, malls, convention halls, and more. It also created demand for concrete polishing unlike anytime in the past. Today, professionally polished or decorated concrete floors are coveted for their clean, low maintenance finish, their dust-free, smooth feel, and for their aesthetically pleasing look. Managers report how polished floors boost morale among employees, improve light reflectivity (reducing light usage) and garner positive customer comments.


The market for concrete polishing and design continues to flourish and evolve. What hasn’t changed is the need to repair cracks, chips, joints and spalls in the floor prior to polishing. Without the proper repair material, the repair will fail, sometimes quickly costing time and money.

Curtis Venable is president of C&C Construction Co., a concrete repair and polishing services provider. Venable said that cracks, spalls and other deformities in the concrete must be properly repaired before polishing. Use of an inadequate repair product, or improper use of a repair product can cause more problems than they solve.
“I don’t want to get a call from a client at midnight wondering why a chip repair popped out in the middle of his floor,” said Venable. “Improper or poor repair prior to polishing is bad service and undermines my credibility with my clients.”
While Venable utilizes various repair products depending on the job, he often relies on 10-Minute Concrete Mender™ by Roadware, Inc (www.concretemender.com). Concrete Mender combines with sand to form a tough instant polymer concrete.


Reliability
Venable uses Concrete Mender for several reasons. First, he said, Concrete Mender penetrates deep into concrete to establish a permanent bond with the host concrete, producing repairs that absorb the shock and transfers the load of heavy traffic without cracking or disbonding. Its chemical resistance means it can be applied in a wide range of temperatures.

“I know that it won’t melt, smear or come out of a repair when my polishing machines are run over it,” he said. “And I can apply it in cold temps found in freezers.”
Concrete Mender accomplishes its unbreakable bond through a process called Microdowling™. Microdowling drives the repair deep into the micro-fissures of the crack, joint or spall, where it forms an unbreakable bond with the existing concrete.

“The Microdowling capabilities eliminate the anxiety caused by the liability that I and all contractors must carry for each job,” he said. “I know of jobs that are going on six and seven years without Concrete Mender failing in any way.”


Application Efficiency
Besides performing for years, it cures in only 10 minutes. At a recent job in which Venable repaired and then polished an 110,000-square-foot concrete floor for a national grocery retailer, he used Concrete Mender for efficiency reasons.
Venable inspected every chip, crack and spall before the job began, looking for joints where the filler has come out, anchor bolt holes, corner chips and spalls. He assessed each repair, and then made recommendations that clients repair each one.

“I put six people on polishing machines to work at the site for almost three weeks,” he recounted. “It becomes expensive if I have to wait for the repair material to set. Concrete Mender takes only 10 minutes.”
 

Blending
Finally, Venable said his customers require that the shade of the repair material match the existing concrete for aesthetic reasons. Large retailers, such as Home Depot and Sam’s Club, understand that today women are making many of the purchasing decisions for the home, including home repair. Because women prefer shopping in light and well-kept stores, shiny, clean floors are important to a retailer’s image. A patchwork of different repair shades and colors has become unacceptable among peer retailers.

After hardening, Concrete Mender blends flawlessly with surrounding concrete, resulting in a near perfect color match. After polishing or coloring, a repair made with Concrete Mender is indistinguishable from the original floor.
“Having various shades and colors of repairs on the floor is unacceptable in the concrete polishing industry,” said Venable. “Today, to meet the expectation of women shoppers, repairs must blend to give the appearance of a single, neat and clean finish.”

Concrete Mender can serve many demands in the concrete polishing industry. It hardens within 10 minutes, after which it can be treated like the surrounding concrete. It can be cut and polished, and won’t smear or come out in the process. It’s efficient for use on large jobs, including where heavy machinery is operated, airport hangers, freezers, retailers and more.
“Concrete polishing is an expanding market and becoming more competitive,” said Venable. “I have confidence in Concrete Mender to help me meet customer expectations of looks, performance and efficiency.”
For more information 10-Minute Concrete Mender, contact Roadware, Inc. at www.concremender.com.  For more information about C&C Construction, visit www.candcconst.com.

Contact Information:
Richard E. King 800-522-7623 or 651-457-6122
Kelton E Glewwe 800-522-7623 or 651-457-6122
Roadware Incorporated
381 Bridgepoint Way
South Saint Paul, MN 55075

Microdoweling™, Roadware 10 Minute Concrete Mender™, and respective logos are trademarks of Roadware, Inc. Copyright 2008.