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Roadware 10 Minute Concrete Mender™ and Easy-injection mixers make full depth crack repairs in hairline cracks without cutting. This less evasive crack repair technique breaks the rules for concrete repair.
Lets look at these, “rules” one by one.
Broken Rule One: Hairline cracks are not worth the trouble fixing. Did you know that just about every crack in concrete started out as a hairline crack? Some so fine, you can not even see them with the naked eye. Cracking naturally occurs in concrete slabs as the concrete cures and shrinks. We use saw cut control joins to encourage the concrete to crack inside the saw cut or tooled joints. The problem is, the concrete doesn’t always listen and can crack where it wants to crack. We don’t like it, but that’s just the way it is. The truth is, we would fix hairline cracks if there was a good and efficient way to do it. Most of the time, we ignore hairline cracks and blame them on the nature of concrete and say things like, “It will be fine, you still have aggregate interlock and the crack is just on the surface.” Or, “All concrete cracks, and its just the nature of the product… Check out our new floor covering selection.” The customer, who just invested in a new concrete floor, is never happy with these explanations.
The truth is, we would fix hairline cracks if there was a good and efficient way to do it.
Broken Rule Two: You have to cut open crack if you really want to repair it. A repair material has to actually get into a crack so it will actually do some good. Anything short of that is no better than caulk. For the most part, this is true. We can’t repair what we can’t reach. Traditional cut and cover techniques us a diamond blade saw to open up a crack, forming a shallow well for Concrete Mender to accumulate and flow down into the crack. It works really well and Roadware has been doing this for over twenty years.
What is needed is a way to actively push repair products into hairline cracks. With a few simple techniques and Easy Injection Mixers, Roadware 10 Minute Concrete Mender can do the job. That brings us to:
Broken Rule Three: Crack injection requires pumps, ports, slow epoxy, and lots of time.
For a successful crack injection repair you need to accomplish three things:
Roadware Easy Injection mixers make getting Concrete Mender cracks as small as 20 mil (0.02 inches) simple. Just drill a 3/8 inch hole into the crack and push the nearly water thin Concrete Mender into the cracks. You can actually watch the Concrete Mender flow along the length of the hairline crack. Leave the expensive injection pumps in the shop. A cartridge of Concrete Mender and a manual application gun is all you will need.
Roadware 10 Minute Concrete Mender starts to thicken and cure in about 5 minutes after application, so the material will stay where you put it. Traditional injection epoxies take hours to cure. In many cases, at the end of the day, the epoxy all ends up under the slab and no longer in the crack.
Roadware 10 Minute Concrete Mender™ with Microdoweling™ penetrates traditional bond lines and repairs concrete from the inside out. This structural polyurethane will not become brittle over time. Epoxy injection resins become very hard and brittle. As the the concrete deflects under traffic, the brittle epoxy will start grinding away at the bond-line and the deterioration will start all over again. Roadware 10 Minute Concrete Mender is designed to restore aggregate interlock and deflect with the concrete under heavy traffic and loading. This structural polyurethane will not become brittle over time and is designed to bring the cracked concrete back to original pre-cracked condition.
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.
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.
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.
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.
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.
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.
*“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.
Bill Neal of Neals Design recently repaired spalled and cracked concrete on the fly at a service station in Washington. A customer had broken an ankle stepping out of a truck into the badly spalled concrete. Bill was able to make the repair in minutes, eliminating the safety hazard without major disruption to the service station.
Roadware 10 Minute Concrete Mender is your go to product for making long-lasting repairs with minimal downtime. At 70 degrees F or 21C, A Concrete Mender repair can be ready for heavy truck traffic in about 10 minutes.
The ultra low viscosity Concrete Mender mixes very easily with manufactured sand or quartz. A tough and durable polymer concrete mortar can be mixed in a bucket by hand with simple tools. No expensive pumps or power mixers needed. See how it is done here. Concrete Mender™ Bulk Application Instructions
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.
Roadware 10 Minute Concrete Mender is flooded into the spalled ares and seeded with manufactured sand.
The Concrete Mender and sand bland can be troweled in place and will cure in about 10 minutes.
Vertical surfaces can be repaired by mixing Concrete Mender with fine manufactured sand and troweled in place.
Repairs can be painted using standard methods in 10 minutes after application at 70 degrees F (23C).
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.
Roadware 10 Minute Concrete Mender™
The Milan-Malpensa MXP International Airport in Ferno, Italy handles nearly 20 million passengers per year and over 500,000 tons of international freight annually. Crews are using Roadware 10 Minute Concrete Mender™ to repair cracks in taxiways. The deep penetration of Concrete Mender and the 10 minute cure helps keep the historic airport running at top efficiency.
Roadware 10 Minute Concrete Mender™ is a tough high penetration polyurethane quickly soaks into small cracks and repairs them before they become big problems.
The MXP Airport saves time and money by repairing cracks early when they are small. The Concrete Mender cures in just 10 minutes. This is perfect for repairing taxiways that have to remain open 24 hours per day.
Crews use Concrete Mender supplied in self-mixing 600ml cartridges to quickly apply material exactly where it is needed. No material is wasted. Manufactured sand is added to extend the product volume and control how much Concrete Mender flows into the crack.
Repairs are ready for airport service in about 10 minutes at 70 degrees F (23C).
JUNE 13-15, 2017 | MCCORMICK PLACE | CHICAGO, IL
Roadware will exhibit in the Global Cold Chain Expo 2017. Look for us in Booth 5128.
The GCCE covers all aspects of cold storage warehousing and logistics. Roadware 10 Minute Concrete Mender™ is the go-to product for repairing cracks, joints and spalls in all kinds of refrigerated and freezer warehouse applications.
The cold environment and heavy weight traffic in a freezer warehouse represents the ultimate challenge for a concrete repair material. Roadware 10 Minute Concrete Mender™ has been used for over 20 years in tough cold storage environments.
For reduced or free admission to the GCCE, contact Kelton Glewwe – firstname.lastname@example.org, by June 1st, 2017. For qualified attendees only. Limited time offer.
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.
The Microdoweling™ action of Roadware 10 Minute Concrete Mender™ can structurally, “glue” concrete back together. Pictured here is a concrete break-out caused by a forklift hitting an anchored steel bollard.
Concrete Mender™ was used to re-attach the broken concrete piece and repair the crack.
After about 10 minutes, the repair was buffed smooth and open for traffic.
About a week later, the bollard was again hit with a forklift and at the same angle. The repaired concrete held in place. The concrete broke on the other side of the bollard this time. Concrete Mender can’t stop forklifts from hitting bollards. It can help minimize the damage and make lasting repairs.