Category Archives: Roadware Incorporated

Roadware 10 Minute Concrete Mender™ Best Practices

 

ROADWARE 10 MINUTE CONCRETE MENDER™

Buildings marked for demolition in Christchurch, New Zealand.
Recently, our Roadware distributor in New Zealand requested a list of best practices for using Roadware 10 Minute Concrete Mender™.  Contractors in Christchurch are using Concrete Mender to repair many meters of cracks following recent earthquakes.   
Best
Practices
Storage
and Transportation
1.
Keep cartridges in original foil bag and store in
an upright position.
2.
Store on a cool dry place between 10-28 degrees
C (50 – 80 F). If cartridges are allowed to freeze below – 10 C (14 F) some material separation
can occur.  Return material to 25 C (75 F)
and shake or mix to re-blend before use.
3.
Handle with care. Punctures to the bag can cause
moisture contamination. Rough handling can cause cartridge cracking and
leakage.
4.
Ship in upright orientation in original shipping
containers.
Usage
1.
Read and follow illustrated instructions.
2.
Use gloves and safety glasses.  Concrete Mender is very thin and can
splash back if applied erratically.
3.
Make sure the flow-restrictor and mixer seat
properly.
4.
Use a new flow-restrictor and mixer every time.
5.
Small cracks less than 2mm should be cut open to
5mm for best results.  The 5mm cut
will form a, “well” for the product to accumulate as it soaks down into the
crack and will reduce material spreading on the surface away from the repair
area.
6.
Once material is flowing from the mixer, keep the
tip pointed down.  Use the thumb
release on the gun to stop the flow.
7.
Discharge the material from the cartridge
firmly.  Working too slowly can
cause poor mixing.
8.
Always apply a coating of Concrete Mender into the crack or spall before adding sand. This will give you better penetration and bonding.
9.
When applying with sand, make sure the sand and
repair area are completely saturated with Concrete Mender.
10.  Use a shop vacuum or compressed air to remove as much dust and contaminates from the
repair area.
11.  If you suspect there is water on the bottom of the crack that you cannot remove, repair the bottom half first and allow it to cure (turn grey) before repairing the top half.
12.  When working at below 0 degrees C, use a propane torch or similar method to remove any surface frost from the concrete before applying the material. Keep Concrete Mender and sand at room temperature before use.

13.  Needle tip mixers are great for better control and pinpoint application. They also can easily clog up when left filled with mixed product. Do not try and force a mixer or tip to clear by adding more force to the gun. You can blow out the rear seals and cause a mess.  Get a new mixer or tip and start over.

Concrete Mender™ is injected into cracked walls in Christchurch, New Zealand.

Ten things about Concrete Mender

Ten things you probably didn’t know about Concrete Mender.
  1. A little Concrete Mender goes a long way.  A gallon of polyurea or epoxy makes a gallon of repair material. A gallon of Concrete Mender mixed with 2 gallons of manufactured sand makes 2.2 gallons of repair material. That makes polyurea and epoxy more expensive to use even at half the price.
  2. All Roadware 10 Minute Concrete Mender is manufactured and packaged in South St Paul, Minnesota, USA.  We do not private label the product to other companies. The, “patent” did not run out allowing other companies to make Concrete Mender.  That was a just an amusing rumor we heard at the World of Concrete put out by an unscrupulous exhibitor.
  3. Microdoweling is more than a funny word.  Microdoweling is the process of using very low surface tension materials that penetrate the surface of damaged concrete and bonding to the aggregate within the concrete mix.  It is an exclusive Roadware technology. You can see the scanning electron microscope photos in our website by clicking here.
  4. Concrete Mender is a structural repair. Concrete Mender is the flagship product for a new class of materials called structural polyurethanes. It is tough enough to be a structural repair, but never brittle like epoxy.
  5. The color of a finished Concrete Mender repair is more influenced by the sand color than anything else.  White silica sand will make a light grey repair. Brown sand will make a darker and warmer tone.  We do offer Concrete Mender in Grey, Off-white, Safety Yellow, Target Red,  Ikea Black and WalMart red/brown.
  6. Concrete Mender is sold all over the world and most overseas exported product is shipped via air.  When your concrete needs to be fixed in ten minutes, you don’t want to wait eight weeks for ocean freight.
  7. When repairing polished concrete floors, you can use polishing dust from the floor, sand and aggregate to give your repairs the same,  “texture,” and look of the surrounding concrete.
  8. Contractors in New Zealand developed simple techniques to repair hairline cracks in walls damaged by earthquakes near Christchurch.
  9. In Japan Concrete Mender is known as, “Crack Bond.”
  10. Every cartridge of Roadware 10 Minute Concrete Mender is packaged by hand and inspected by Amanda.

 

Microdoweling™ and Concrete Mender™ are trademarks of Roadware Incorporated © 2012.

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Safety Yellow Line Marking with Concrete Mender™ Yellow

Roadware Concrete Mender™ is available in safety yellow.

 

Permanent safety yellow line marking with Concrete Mender™

Use for creating permanent yellow safety lines in concrete floors.
• Integral color will not peel or chip-off.
• Apply in temperatures as low as -20°F.
• Cures forklift traffic ready in 15 minutes at 70°F.
• Easy to clean and maintain.
• High chemical resistance.
• Based on Roadware’s proven Microdoweling™ technology.

Yellow Concrete Mender™ cures to a bright safety yellow color in minutes.

Yellow safety marking can be permanently installed in concrete floors with this material. The photo above shows Concrete Mender™ Safety Marking after a year of commercial service.


Bill Smith, US Food Service, Wixom, Michigan.

After years of frustration trying to keep safety line marking in place in a cold storage warehouse, Bill Smith of US Food Service in Michigan started looking for a better way. Installing safety line marking in a 38°F cold storage warehouse is especially challenging. With the 24/7 operations and the heavy fork lift traffic, there was never enough time to let traditional marking paint to cure without the forklift tires marking up the paint. At cool temperatures, the cure times were even slower. Marking tape fared no better. The cold concrete was hard to adhere to and the heavy traffic would quickly damage the marking tapes.

Bill was using Roadware 10 Minute Concrete Mender™ to repair cracks, joints, and spalls in the warehouse floor. He liked the fast cure times at low temperatures and he noted the repairs hold up very well to forklift traffic. Bill thought, “What if we could fix our safety line issue with Concrete Mender?” After experimenting with different types of Yellow sand and a request into Roadware for MatchCrete™ Concrete Mender factory colored in Safety Yellow, the line marking MatchCrete™ system was born.

After much experimentation, here is the system that works the best.
1. Scarify a shallow recess in to the concrete the length of the line marking. This can be done any number of ways. Stacking several diamond blades together and placing a temporary saw guide works best. Cut the recess about 1/4 inch deep and 1 inch wide.
2. Vacuum all dust and debris from the saw cut area. Mask off the recess with duct tape.
3. Carefully flood the recess area with Safety Yellow MatchCrete™ Concrete Mender. A small amount of safety yellow quartz sand may be used to choke-off any material that flows too far into any cracks or joints. The top of the material should be slightly recessed and smooth.

The lines will be ready for full traffic in about 15 minutes at room temperature. Give them a few hours to cure if working in a cold room or freezer. No special maintenance is required.
Ordering:

Call Roadware at 800-522-7623

Item 70300-y (300x300ml cartridge) Concrete Mender™  in Safety Yellow

Item 70020-y (2 gallon kit) Concrete Mender™ in Safety Yellow

New Concrete Mender™ Mini Cartridge for precise application.

For the first time, Roadware 10 Minute C5150-mender-verticaloncrete Mender™, the industry’s only Microdoweling™ concrete repair polyurethane, is available in 50ml mini cartridges. The mini cartridge offers precise application control that is perfect for repairing hairline cracks. Each mini cartridge comes with a needle tip mixer and is simple to use. Use the 50 ml cartridge with the Roadware 5150 application tool. Each cartridge will repair about 10 feet of hairline cracks or 3 feet of 1/4 x 1/4 inch cracks.

 

Roadware 80105 50ml 10 Minute Concrete Mender™ mini cartridge with mixer and needle tip.

 

 

Use Roadware 10 Minute Concrete Mender to repair and re-bond delaminated concrete slabs.

Use Roadware 10 Minute Concrete Mender to repair and re-bond delaminated concrete slabs.

Roadware delimanition repairs are featured in the July 2008 issue of Concrete International. This is the official publication of the American Concrete Institute. The article was written by Nelson Tonet, President of Express Polymers and a Roadware distributor.

ABSTRACT
“Delaminations in concrete floor slabs can be difficult to repair in a cost-effective and timely manner. A newly developed product (Roadware 10 Minute Concrete Mender™) that uses a two-part hybrid polyurethane with a viscosity similar to water can significantly reduce the difficulty of performing delamination repairs by easily flowing up to 10 ft (3 m) from an injection point and penetrating deep into concrete surfaces. The product also speeds up repair by setting in only 10 minutes, allowing the repair to be checked by sounding only 30 minutes after product placement.”

View full article in PDF format Delamination Repairs PDF

Here is a Roadware synopsis.

Roadware 10 Minute Concrete Mender™ is an excellent choice for repairing concrete slab delaminations. The very low viscosity of less then 8 cps and the exclusive Microdoweling™ penetration properties of the material allow it to flow deep into delaminated concrete voids. The Concrete Mender will restore aggregate interlock and will allow dynamic load transfer under heavy traffic. The expense and mess of pressure injection with epoxy can be avoided.

Two methods of repair have been successful. The first involved dry diamond drilling a 2 or 3 inch (5-8 cm) diameter hole into the concrete slab down to the delamination. Dust is removed with a shop vacuum. Roadware 10 Minute Concrete Mender is poured or pumped into the void. Only one or two inches (3-5 cm) of head pressure is required to push the material as far as 10 ft (3 m) into the delamination. When the material backs up to the top of the hole and the void is filled, silica sand is added and the hole is filled flush with the surface. Soundings are made with a hammer to verify the delamination is repaired in about 30 minutes after application.

Click here to see how Nelson Tonet repairs delaminated concrete slabs.

Another method is to drill multiple 3/8 inch (1 cm) holes into the concrete down to the delamination. Remove dust with a shop vacuum and inject pre-mixed Roadware 10 Minute Concrete Mender™ with a syringe tipped with a rubber gasket. With this method, you can actually see the material exit the adjacent hole and verify the material is filling the delaminated area. After filling, the holes are blended into the surrounding concrete with silica sand and Concrete Mender or re-drill 1/4″ (5 mm) deep and fill with a color matching concrete mortar.

See the movie:

Both methods will yield good results and are more cost effective than epoxy injection.

Repairing vertical cracks in concrete structures with Roadware 10 Minute Concrete Mender™.

The same Microdoweling™ properties of Roadware 10 Minute Concrete Mender™ that make the material excellent for repairing horizontal surfaces also make a good choice for vertical repairs.

Roadware 10 Minute Concrete Mender™ is a very low viscosity polyurethane that uses a surface tension one-third of water to penetrate quickly and deeply into concrete cracks. The typical process relies on self-gravity injection to fill cracks completely. What is not seen by the naked eye is the capillary action of the Concrete Mender polymer chains flowing horizontally into the sideswalls of the crack.  We call this chaining of polymers into the concrete Microdoweling™.  This chaining of the concrete together works on vertical surfaces too.
So, your saying, “How do we get this super thin material to stay in place long enough for the Microdoweling™ to take place and the repair to cure?” Over the years, Roadware contractors have come up with creative and ingenious ways to use Roadware 10 Minute Concrete Mender™ on vertical surfaces. Here are some techniques that have evolved.
1.     Vertical Crack Injection
This technique involves covering the vertical crack with transparent duct tape and injecting Concrete Mender through the tape with a needle tip meter/mix cartridge. This method will work well if the concrete surface is smooth and the tape can make a good bond with the surface. The crack should be 1/4 inch (5mm) or less in width. The tape will make the, “form” while the Concrete Mender sets. Concrete Mender will not stick to duct tape, so once the material cures, you can cleanly pull off the tape. It is best to warm the cartridges up to 80° F (26°C) before use for a faster gel time. Start filling the crack at the lowest point and work you way up.
See the video here.
2.     Bulk Mix and Trowel Applied Repair
Mix bulk Concrete Mender and 60-80 grit manufactured sand into a thick mortar. Working in small batches, use a margin trowel to make the repair. The fine sand will hold the Concrete Mender in place long enough for the Microdoweling™ effect to take place and for the material to set.
3.     Bag Mix and Apply
This method uses a heavy duty, clear plastic bag to quickly mix one part of blended Concrete Mender to two parts of 60-80 grit manufactured sand. Once mixed by kneading the bag for several seconds, the bag is opened and the whole batch is applied and held in place with the bag. This technique is used around building mechanical entry points such as refrigeration and HVAC units.
Whatever method you choose, Roadware 10 Minute Concrete Mender™ stands at the ready to perform. Finished repairs can be ground smooth and painted to match the wall if necessary.
Kelton Glewwe
VP Operations

See actual bridge deck repairs in PA on Google Maps.

See actual bridge deck repairs on Google Maps.

Google has spent the last few years mapping and photographing roads all over the world. If you know where to look, you can see actual concrete repairs with Roadware 10 Minute Concrete Mender™

The Google Map photo below shows actual bridge deck repairs with Roadware 10 Minute Concrete Mender™ on Interstate 279 in Pittsburgh, PA.  See all the lighter colored spots? Each one is a hole or spall filled with Roadware 10 Minute Concrete Mender™. The repairs here are over three years old. Thank you Roadware distributor, Express Polymers, Inc., in the Pittsburgh area for sending this project in.


View Larger Map

Roadware Commercial for World of Concrete 2011

The World of Concrete 2011 in Las Vegas is next month, January 17-21. Roadware will be in Booth S11847. If your coming to the show, I hope to see you there. You can register for the World of Concrete 2011 here.  Use source code A20 for free registration courtesy of the American Society of Concrete Contractors. 
Here is a 15 second commercial we will be running at the WOC on the shuttle busses and on screens at the show.