Tag Archives: concrete mender

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.

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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.

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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.

Roadware 10 Minute Concrete Mender™ needle tip application.

 

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.
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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.

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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.
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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.
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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.

 

Freezer threshold repair with Roadware 10 Minute Concrete Mender™.

Freezer, chiller and cooler thresholds have been an ongoing challenge to floor repair contractors and the USDA since the 1950’s. Recognizing the need to keep refrigerated and frozen food storage areas clean and sealed so they will not harbor lichen, fungus and pests, the USDA has issued zero tolerance guidelines for floor cracks and spalls in all food processing and refrigerated food lockers. Unsealed and opened joints also come under the watchful eye of those charged with keeping America’s food supply safe. Because thresholds are freezing cold on one side and at room temperature on the other, the thermal stress on the concrete is unrelenting and unforgiving. Couple this with forklift and wheeled cart traffic and you have a formula for disaster.

 

Fortunately, 10 Minute Concrete Mender™ has become the accepted repair material for these very harsh conditions. The agency itself is forbidden from recommending one product over another, but the personal choice among active USDA inspectors is Roadware 10 Minute Concrete Mender™. It’s thin, it gets in, it won’t pop out.

Some minimal prep work is required when working in the cold. Have the cracks and spalls as clean and dry as possible. This may not be easy, but it’s a step professionals know better than to ignore. Next, apply Mender to the base and sidewalls to seal off any free moisture movement into the repair area. Immediately follow by filling the spalled area or crack, almost to the top, with manufactured sand or approved quartz. Flood the sand to refusal, making sure the Mender saturates each grain. For larger areas, a bulk mixed mortar of Mender and sand may be easier to handle and install. Keep all materials at room temperature or warmer to speed up cure time. Even then, one should plan on an hour or more if temperatures are extreme. However, since all conditions vary, onsite testing is the best way to insure the time at which freezer floors and thresholds will be traffic-ready. Contractor field reports are very solid in reporting that 10 Minute Concrete Mender is the only thing that works in these tough repair situations. Click here for step by step bulk application instructions.

 

1. Remove existing concrete to wood base.

2. Saw key-way at a 45° downward angle on the cold side of the

threshold toward the freezer.

3. Using a diamond shaped pattern, drive sheet rock screws into

the base leaving 3/8″ of the screw sticking up, to act as a

dowel pin for the finishing lift of 10 Minute Concrete

Mender and sand aggregate.

4. Place 10 Minute Concrete Mender to grade. When fully cured

(about an hour at 32F, 0C) sawcut the warm side joint and fill

with Roadware Flexible Cement II™.

5. Reopen to traffic when Flexible Cement II is fully cured.

Continue reading Freezer threshold repair with Roadware 10 Minute Concrete Mender™.

New Roadware Estimator App

UPDATE: The new online Roadware product estimator runs on most browsers and mobile devices including iOs and Android. Click here for the Roadware Online Product Estimator.

Announcing the Roadware Product Estimator App for iOS devices.

 

Users of iOS devices such as the iPhone or the iPad now have a convenient way to estimate the amount of Roadware 10 Minute Concrete Mender™ needed to repair a concrete crack, joint or spall.  Since Concrete Mender may be extended with sand at a ratio of two parts sand to one part liquid, estimating product usage is more challenging. The Roadware App eliminates the guesswork and gives users an estimated usage in 600ml cartridges and gallons of material. Sand ratios can be adjusted from none, 2:1 and 3:1 for special applications. An internet connection is not necessary when using the App so you can make an estimate from anywhere.

The Roadware App can be downloaded for free at the iTunes store by searching for Roadware or by clicking here.

 


Enter the crack dimensions in English feet and inches or metric meters and millimeters.

Set sand ratio. Default is two parts sand two one part mixed Concrete Mender.

Click the Calculate button at the top.

 

The resulting screen shows:

Total cubic centimeters need to fill the repair area.

Total gallons of mixed repair material needed.

Number of 600ml cartridges of Concrete Mender needed.

Number of gallons of Concrete Mender needed.

 

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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