Category Archives: crack repair

The Concrete Mender One Page Pitch

Here is the  Roadware Concrete Mender One Page Pitch. Things you need to know when considering, recommending, specifying, and using Roadware 10 Minute Concrete Mender™

Download the PDF here:

Roadware 10 Minute Concrete Mender One Page Pitch.

Amazon Warehouse – Full depth crack repair without sawing.

Full depth crack repair in warehouse floors usually involves cutting open the cracks with dry diamond saws. This is a slow process and creates a lot of hazardous silica dust that needs to be mitigated. Repair contractors at an Amazon Warehouse project are using an innovative way to repair cracks in the floor without the traditional cut and fill methods. 

The problem:

Some people question why these types of cracks should be repaired. Cracked floors in industrial and commercial settings are a liability.  The cracks will continue to get larger as wheeled traffic starts to crush the sidewalls. (More) Cracks will also fill with dirt and debris creating a hard to clean surface. Roadware 10 Minute Concrete Mender™ is a structural polyurethane that will restore load transfer and can bring a floor back to original serviceability. 

Thre level Amazon Warehouse with cracks in the floor.

This three level Amazon Warehouse developed thousands of linear feet of shrinkage cracks prior to being places into service. Roadware 10 Minute Concrete Mender will be used to repair them.

 

Crack in warehouse floor.
This floor presented thousands of feet of shrinkage and stress cracking. The cracks were all fairly clean without excessive foreign debris or dirt at time of repair. 

The Plan:

Use sacrificial vinyl weatherstrip to make a dam parallel to the cracks that will hold Roadware 10 Minute Concrete Mender™ in place while it soaks down into the cracks. Concrete Mender™ is nearly water thin when mixed and will flow easily deep into open cracks. Since Concrete Mender™ will start to gel up in 5-7 minutes, it will naturally self-seal the bottom of the crack as it cures. It sometimes takes three of four light pours of material, but it will fill the crack completely and start the structural Microdoweling™ process. Microdoweling™ is how Concrete Mender™ uses low surface tension and molecular attraction to penetrate concrete surfaces and locking into the aggregate and rock matrix. 

 

No cut full depth crack repair with Roadware 10 Minute Concrete Mender™.
No-cut crack repair with Roadware 10 Minute Concrete Mender™ uses removable peel-and -stick weatherstrip to form a temporary well that holds the Concrete Mender in place while it soaks down into the crack.

 

Roadware 10 Minute Concrete Mender injected deep into cracks using the Roadware Easy Injection System.
Roadware 10 Minute Concrete Mender injected deep into cracks using the Roadware Easy Injection System.

 

Amazon Warehouse full depth crack repair without cutting.
Wehtherstrip is used to hold Roadware 10 Minute Concrete Mender in place while it soaks deep into cracks.

Application:

With Concrete Mender™, expensive pumps and equipment is not needed. Once cracks are vacuumed and the surface is cleaned. The weatherstrip dam can be applied. Roadware 10 Minute Concrete Mender™ can be mixed on one gallon batches by hand in a bucket and poured directly into the cracks.  Additional manufactured sand can be added for larger cracks, but it is not recommended for this type of repair.  See more here: Concrete Mender Bulk Application Instructions 

Pour equal parts A and b into a mixing container and mix for about 15 seconds with a mixing stick.

 

Amazon Warehouse full depth crack repair without cutting.
Crack repairs are filled with Roadware 10 Minute Concrete Mender to refusal and the excess is removed.

When the Concrete Mender™ cures in about 10 Minutes at 72 degrees F (21C) , the weather stripping and excess material can be shaved clear or ground smooth with standard equipment. 

Amazon Warehouse full depth crack repair without cutting.
Roadware 10 Minute Concrete Mender filles hairline cracks completely using the dam and flood method. No cutting is needed.

 

After buffing and clearing excess material, floors can be returned to service immediately. 

Amazon Warehouse full depth crack repair without cutting.

Finished concrete crack repair blend in nicely at an Amazon warehouse using full depth Roadware 10 Minute Concrete Mender™.

Additional buffing and service traffic will blend the repairs even more into the surrounding concrete. 

Roadware 10 Minute Concrete Mender Technical Data Sheet

Download PDF:  

Concrete Mender™ TDS

Product used in the project:

80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit
80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit

80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit

80050 Roadware 10 Minute Concrete Mender Ten-Gallon Kit
80050 Roadware 10 Minute Concrete Mender Ten-Gallon Kit

80050 Roadware 10 Minute Concrete Mender Ten-Gallon Kit

 

COVID19 Operations

Roadware stands ready to supply immediate concrete repair needs for warehouses, cold chain logistics, manufacturing,  and supply. Repairs can be made with almost no downtime and under operational conditions. Please call 1-800-522-7623 or 1-651-457-6122 to be connected with our worldwide network of distributors waiting to assist. Or, send email to sales@concretemender.com

We ask that visitors to Roadware Headquarters in South St Paul, MN, or any of our Roadware Distributors, call the location ahead to verify operating hours and local conditions.

Local distributor information can be found here:

Find your Distributor

Thank you and be safe,

Roadware, Inc.

Smart floor repairs for AGV’s and warehouse robots.

AGV’s or Automated Guided Vehicles are the reliable workhorses of the modern warehouse. They are designed to run smoothly and predictably all day and everyday. AGV’s are great at repetitive tasks moving freight as needed day in and day out. These repeated trips over the same path can be very punishing to concrete floors. The small hard wheels of an AVG can crush control joint sidewalls and grind the concrete surface to dust. This leads to rough, uneven floors that can cause premature breakdowns of AGV drive systems, wheels, and even damaged freight.

“If your AVG could talk, it would ask for Concrete Mender. ” Richard King, Roadware, Inc.

AGV carrying beer on a preset path in a warehouse.
AGV’s move thousands of pounds in a single trip over the exact same path hundreds of times per day.

Roadware 10 Minute Concrete Mender with Microdoweling™ penetrates into concrete surfaces repairs concrete cracks, joints and spalls where others fail. Over the years we have noticed some conditions needed for successful repairs in the path of AVG’s.

  1. Repairs need to be as tough as the concrete itself. But not too tough. Let’s say your concrete is a typical 4000 psi in compressive strength. The AGV wheels are grinding away the surface of the concrete and spalling the control joints. You repair the “bad” sections of the path with fairly brittle 10,000 psi epoxy. Now you have sections of the original concrete and sections of much harder epoxy. As the original concrete continues to grind away, the hard epoxy remains and you just created more speed bumps for the AVGs. Concrete Mender will wear with the concrete and deflect with the concrete under load. Your AVG’s favorite path will be smoother longer.
  2. Stop your repairs from popping out. Did you ever notice common warehouse floor repairs popping out in chunks? This can happen when you put a super hard epoxy patch in a not as hard concrete floor. The epoxy is so brittle that it fractures the bond-line when a load is applied. Epoxy repair products have a modulus of elasticity that is so high, it will fracture the concrete before deflecting under load. Concrete Mender has a modulus of elasticity that is slightly less than concrete so it will deflect with concrete concrete under load and gently transfer load from the repair to the surrounding concrete.
  3. Time is money! Closing down aisles or sections of a warehouse is a disruption for everyone including AVG’s. With minimal prep requirements and less invasive techniques including Roadware Easy Injection, 10 Minute Concrete Mender can have your AVG pathways back in service in minutes, not hours or days. You can even make repairs in operational freezers down to -30F.
Concrete repairs for AGV’s need to bond under heavy traffic as well as deflect with the concrete and transfer loads to the surrounding concrete without fracturing.

AVG’s like to take the same path every time. This can prematurely wear out concrete floors.
AGV drive system in an Automated Guided Vehicle.
The drive system in a typical AGV can haul a lot of weight, but the floor needs to be smooth.
Warehouse and AGV floors can be repaired and open for traffic in about 10 minutes after application with Roadware 10 Minute Concrete Mender.

Products used in this application:

80300 Roadware 10 Minute Concrete Mender 600ml Cartridge
80300 Roadware 10 Minute Concrete Mender 600ml Cartridge

80300 Roadware 10 Minute Concrete Mender 600ml Cartridge

80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit
80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit

80020 Roadware 10 Minute Concrete Mender Two-Gallon Kit

 

Bridge crack repair in the Philippines.

Make Roadware 10 Minute Concrete Mender part of your bridge preventative maintenance program. Repair cracks as they develop when they are small. Don’t let small cracks turn into big problems. Roadware 10 Minute Concrete Mender™ is extremely tough and will withstand even the harshest punishment. Use all year long… may be applied at temperatures as low as -20° F with excellent results.

The Gilbert Bridge in the Philippines.

Crack repairs on the Gilbert bridge in the Philippines with Roadware 10 Minute Concrete Mender.

Roadware 10 Minute Concrete Mender is great repairing surface cracks in a bridge deck. The flow-and-go application along with the 10 minute cure time allow repair crews to get on and off the bridge quickly. Traffic can be returned to the bridge in just 10 minutes after application.  In the Philippines, crews often work at night when traffic is low and working conditions are cooler.

Crack repairs on the Gilbert bridge in the Philippines with Roadware 10 Minute Concrete Mender.

Crews work in teams. One person shoots the Concrete Mender from 600ml cartridges, one person applies filler sand, and one person trowels the repair smooth.

Sunset photo of the Bantum Bridge in the Philippines.

Workers repairing cracks in the Bantum Bridge in the Philippines using Roadware 10 Minute Concrete Mender.

Workers repairing cracks in the Bantum Bridge in the Philippines using Roadware 10 Minute Concrete Mender.

What are the reasons DOT’s Roadware?

1) “Safety for the driving public.” Roadware repairs are ready for traffic in 10 minutes. Lane closure time is dramatically reduced.

2) “Safety for my crew.” The interstate is a dangerous work environment, the quicker repairs are made, the less exposure to the hazards of working on a heavily traveled interstate.

3) “Saves a lot of money.” Quick cure times, easy mixing, straight forward application, and good long term performance makes Roadware 10 Minute Concrete Mender a good value. After a few days of training, the crew was able to repair a bridge in half a day. One district in Wisconsin saved about $1500 per bridge over conventional repair methods. No overnight lane closures are needed and crews are more productive with less equipment requirements.

Full Depth Crack Injection with Concrete Mender.

A 24″ deep core sample shows 100% injection repair with Roadware 10 Minute Concrete Mender.

For many years, engineers have looked for ways to fully inject repair polymers into cracked concrete structures. The general consensus is to seal off the crack with a sacrificial epoxy and install injection ports every few inches. Then thick epoxy is injected under high pressure into the crack with expensive resin injection pumps. The process is time-consuming, the epoxy is brittle, the equipment is expensive and the skill level is highly specialized. This makes epoxy injection slow, expensive and not really effective in the field.

At Roadware, we look for ways to make concrete repair fast, effective and easy.  

Fast is better. When injecting Roadware 10 Minute Concrete Mender into concrete, the fast gel and cure time allows you to make a full depth repair from the bottom of the crack up to the top. If the crack you are injecting has a large hidden void, Concrete Mender repairs will start to gel and plug up the void in several minutes. Injection epoxy that takes several hours to cure will sink to the bottom of your crack and pool in the base before it has a chance to cure.

Effective. Concrete Mender is a Structural Polyurethane**.  It is about as hard as typical concrete with much greater tensile and bonding strength. It is super thin at 8cps with a surface tension 1/3 of water. It can to penetrate concrete cracks and surfaces. Concrete Mender does not need to be forced into cracks with high pressure pumps and extraordinary methods.  Concrete Mender can easily flow into cracks and fissures with just simple manual tools and a specially designed application mixer. You can repair more cracks in less time with less waste then ever before. Repairs are structural in nature and will move with the concrete, not against it like very hard epoxies.

Easy Application. For a repair to be effective in the field, it has to be simple enough for crews to apply efficiently. Installation productivity saves money.

Diagram showing Concrete Mender Soft-tip mixer injection into a concrete slab.

  1. To start, simply drill a 3/8″ diameter hole about one inch deep into the crack at several points along the crack. Clean the crack and holes with a vacuum.* (Click here to learn how to work safely around silica dust).
  2. Tape off the top of the crack and around the holes you just drilled with clear duct tape or Gorilla Clear Repair Tape. These tapes have a good adhesive that will stick to the surrounding concrete. Do not use packing tape or other tapes without testing them first.
  3. Assemble a cartridge of Roadware 10 Minute Concrete Mender using out specially designed Soft-tip static mixer. Purge the cartridge of air as directed and insert nozzle into the first hole you drilled earlier.
  4. Gently squeeze the handle of the gun and slowly inject Concrete Mender into the crack. Work product into several holes at a time, moving the cartridge back and forth among them. Allow time for  the Concrete Mender to start gelling in the bottom of the crack.  As the crack starts to fill completely, you will see Concrete Mender flow under the clear tape from one drilled hole to the other. You may see air bubbling up from one hole as you inject Concrete Mender into adjacent holes.
  5. Once the crack is filled to refusal, move on to the next few drilled holes until the whole crack is filled.
  6. After 10 minutes at 70 degrees or 23 C, pull the tape. You can use a razor scraper, grinder or polishing device to remove and excess material and blend in the repair.

Drilling a pilot hole into a crack to prepare for injection with Roadware 10 Minute Concrete Mender.
Drilling a pilot hole into a crack to prepare for injection with Roadware 10 Minute Concrete Mender.

A pilot hole drilled into a concrete crack and ready for injection with Roadware 10 Minute Concrete Mender.
A pilot hole drilled into a concrete crack and ready for injection with Roadware 10 Minute Concrete Mender. Clear repair tape temporarily seals the crack while being repaired.

Concrete Mender crack injection with speed inject mixer.
Roadware 10 Minute Concrete Mender is slowly injected into the crack using a Soft-tip sealing mixer.

Inject Roadware 10 Minute Concrete Mender into the crack until the product appears under the tape. This fills the crack from the bottom up.
Inject Roadware 10 Minute Concrete Mender into the crack until the product appears under the tape. This repairs the crack from the bottom up. Work several holes at a time allowing the product to gel and seal the bottom as you go.

Concrete Mender crack injection into 24 inches of concrete.
Slowly injecting Roadware 10 Minute Concrete Mender into 24″ of concrete using 600ml cartridge and soft-tip injection mixers.

Core drilling of Concrete Mender repair shows full depth repair down 24 inches using this method.
Core drilling of the repair shows full depth repair down 24 inches using this method.

The core sample shows full depth repair down 24 inches.
The core sample shows full depth repair down 24 inches.

Concrete Mender repair shown under UV light. See how the Concrete Mender flows into the smallest cracks and brings the concrete back to a pre-cracked condition.
Concrete Mender repair shown under UV light. See how the Concrete Mender flows into the smallest cracks and brings the concrete back to a pre-cracked condition.

Using Roadware 10 Minute Concrete Mender and Soft-tip injection mixers, you can structurally repair concrete cracks and delaminations with simple tools and methods. This unique system saves time and money and allow for a high production rate for installers. The drill hole/inject method is much less invasive than traditional cut and fill methods and creates a lot less silica dust on the jobsite. The Microdoweling properties of Concrete Mender and Soft-tip Injection promises to be a winning combination for tough concrete repair challenges.

80300 Roadware 10 Minute Concrete Mender 600ml Cartridge
80300 Roadware 10 Minute Concrete Mender 600ml Cartridge

80300 Roadware 10 Minute Concrete Mender 600ml Cartridge

1006-STR 24-element static mixer with Easy Injection Tip
1006-STR 24-element static mixer with Easy Injection Tip

1006-STR 24-element static mixer with Easy Injection Tip

*“Workers may be exposed to dangerous levels of silica dust when cutting, drilling, grinding, or otherwise disturbing materials that contain silica. These materials and tasks are common on construction jobs. Breathing that dust can lead to serious, often fatal illnesses.” The Center for Construction Research and Training. Click here to learn how to work safely with silica.

** Structural Polyurethane: 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 than 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.

Swimming Pool Repair with Concrete Mender

Pool spalls are cleaned and prepared for repair with Roadware 10 Minute Concrete Mender.
Pool spalls are cleaned and prepared for repair with Roadware 10 Minute Concrete Mender.

What do you do when your pool has cracks and spalls and it has to be open is three days? Back in 2001, the City of South Saint Paul, Minnesota had a problem with their new splash pool. Just before opening the pool for its second season, cracks and spalls were discovered in the concrete pool bottom and along corner where the floor meets the wall. The damaged was probably caused by the first Minnesota winter for this neighborhood splash pool facility. The repairs needed to be done fast. The pool was scheduled to be open in just three days. Any delay would be a disappointment for local families and political problem for the City who spent a lot of money to build this water recreation facility.

The call went out to see if anyone could come up with a solution. Roadware Incorporated, also located in the City of South Saint Paul, received a call from the Parks and Recreation Maintenance Department to see if we had any ideas. It turns out, Roadware 10 Minute Concrete Mender™ is a great product for repairing concrete pools. The cross-linked polyurethanes in Concrete Mender and very resistant to water, chlorine and other pool chemicals.

Roadware personnel were at the pool within a few hours and repairs were made using a mixture of Roadware 10 Minute Concrete Mender and manufactured sand.

Mixing 10 Minute Concrete Mender with sand in a bucket prior to repairing a spall in the concrete pool floor.
Mixing 10 Minute Concrete Mender with sand in a bucket prior to repairing a spall in the concrete pool floor.

 

Roadware 10 Minute Concrete Mender is flooded into the spalled ares and seeded with manufactured sand.

Roadware 10 Minute Concrete Mender and sand are applied to spalls in the pool floor.
Roadware 10 Minute Concrete Mender and sand are applied to spalls in the pool floor.

 

The Concrete Mender and sand bland can be troweled in place and will cure in about 10 minutes.

Roadware 10 Minute Concrete Mender mixed with sand is troweled into place.
Roadware 10 Minute Concrete Mender mixed with sand is troweled into place.

 

Vertical surfaces can be repaired by mixing Concrete Mender with fine manufactured sand and troweled in place.

Pool repairs at the pool edge are made with Concrete Mender mixed with sand and troweled in place.
Pool repairs at the pool edge are made with Concrete Mender mixed with sand and troweled in place.

 

Repairs can be painted using standard methods in 10 minutes after application at 70 degrees F (23C).

Finished Concrete Mender spall repairs in pool were ready for paint in minutes.
Finished repairs were ready for paint in minutes.

 

All the repairs took just a few hours to complete and the pool was ready for a fresh coat of paint in minutes. The pool was painted and filled with water the next day. The Concrete Mender repairs have largely been forgotten, but continue to perform to this day.

The South Saint Paul Splash Pool in 2017. Concrete Mender repairs in the pool still look good 16 years later.
The South Saint Paul Splash Pool in 2017. Concrete Mender repairs in the pool still look good 16 years later.

 

 

Products:

Roadware 10 Minute Concrete Mender™

Roadware 10 Minute Concrete Mender™ 600ml cartridge item 80300.

 

 

Hoover Dam Demonstration Project Update

Project Update: Almost 7 years after application, this Roadware 10 Minute Concrete Mender™ and MatchCrete™ Clear repair still looks good.

Concrete repair with Roadware MatchCrete Cleat and Concrete Mender at Hoover Dam almost 7 years after application.

Roadware Hoover Dam Demonstration Project
Use Roadware 10 Minute Concrete Mender and MatchCrete™ Clear to make decorative and color matching repairs.

 

1) Top of dam shows various cracks.

 

2) Damage is built up with Roadware 10 Minute Concrete Mender.

 

3) A top layer of MatchCrete™ and matching brown silica sand is applied.

 

4) Structurally bonded and blended well with surrounding concrete.

Special thanks to Randy Sisson and Minitman Supply Colorado for sending this in.

Roadware YouTube Channel Hits 2 Million Views

The Roadware YouTube Channel hits TWO MILLION VIEWS. Roadware maintains a YouTube video channel that shows Roadware products in action. This month our channel surpassed two million views. The YouTube channel currently has over 50 in-house produced videos showing simple concrete crack repair to advanced decorative and exposed aggregate concrete repairs. Check it out here. Two million views accounts for about 3.8 million watched minutes. That’s about 63,000 hours of watch time.

Here is a gallery of Roadware videos from the Roadware YouTube Channel.