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.
Broken Rule One
Hairline cracks are not worth the trouble fixing.
Broken Rule Two
You have to cut open a hairline crack if you want to actually repair it.
Broken Rule Three
Crack injection requires pumps, ports, slow epoxy, and lots of time.
Let’s 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:
Delivery of materials to the repair area.
The repair material needs to set before if flows away from the repair area .
The repair has to be structurally effective.
Roadware Easy Injection mixers make getting Concrete Mender into 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 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.
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.
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.
Franklin Gutierrez in the Dominican Republic is using Roadware 10 Minute Concrete Mender™ to repair multiple spalls in a warehouse floor that were causing damaged forklifts and damaged backs.
“We did 87 repairs for this client, it is a tin can production plant, they work 24/7 so there was no time to close areas for repairs , also lots of equipment very sensible to dust in the air. The major problem was that those small holes were damaging the wheels of the forklifts, damaging the back of the operators and creating possible dangerous situations for the forklift operators, because they manage very heavy loads and even a small hole could make it unstable.
We did all in two days and the client is very very happy, the problems were solved and there was no interruption for them.
This is a big plant that produces for the local market and export, its called Troquedom.”
Heavy forklift traffic can be restored in about 10 – 20 minutes depending on the temperature.
Roadware 10 Minute Concrete Mender™ with Microdoweling™ performance creates structural concrete repairs that will hold up under the toughest warehouse floor applications. Even if the warehouse is for frozen food and -20F or colder.
At Roadware, we see lots of two-component polymer concrete repair products that claim to be just like Concrete Mender™. One even calls it self, “Quick Mender.” They are all basically polyurea based products that are too thick to effectively penetrate concrete surfaces and are so reactive, they become too sticky and gooey to trowel in just a minute or two after mixing. When you dig a little deeper, you will see a very distinct difference in genuine Roadware 10 Minute Concrete Mender™.
What is Concrete Mender? ProprietaryPolyurethane Blend
Manufacturing: South Saint Paul, Minnesota, USA
Origin: NATO program for rapid bomb damage repair on runways.
Function: To penetrate deep into concrete cracks, joints, and spalls creating a structural repair in 10 minutes.
Military Use: Classified
Civilian Use: Repair cracks, joints and spalls in commercial, industrial and civil applications.
Service Life: Indefinite
Cure Time: 10 Minutes at 70°F (21°C)
Distribution: Worldwide Distributor Network
Surface Tension is a measurement of the ability of a liquid to overcome its own internal friction and penetrate into a material like concrete. Roadware 10 Minute Concrete Mender™ has a surface tension One third of water. It will penetrate concrete cracks and fissures quicker and deeper than water. This low surface tension lets Concrete Mender™ penetrate normal bond lines and allows structural bonding with the aggregate in the concrete. See the electron microscope slide below.
Low surface tension has another little hidden benefit. It allows Roadware 10 Minute Concrete Mender™ to be combined with more than two parts sand and still be workable and trowel-able. Try that with a polyurea and you will have a gooey mess on your hands.
Roadware Microdoweling™ Technology:
Slab to slab micro-doweling action, provided by Roadware 10 Minute Concrete Mender, links concrete slabs together, locks them in place and allows for full-traffic, dynamic-load transfer, in 10 minutes. This micro-doweling action is more compatible with concrete and less re-active in harsh environments than even Poly-coated re-bar. Millions of micro-dowels penetrate, then bridge and bond, side by side, broken and jointed slabs. Hairline cracks, trench wide cracks, irregular cracks, cured control joints and variable depth spalls are candidates for this amazing technology.
In 10 minutes, at 70°F (21°C) , this micro-doweled bond has the same compressive and shear strength as poured and fully cured concrete. This makes bond-line failures a thing of the past. Parallel re-cracking, often experienced when epoxies cure out, are eliminated with Roadware’s micro-doweling technology.
Roadware 10 Minute Concrete Mender™ is 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.
Advantages– Due to the very low surface tension of the material and low viscosity, complete saturation bonding of cracks can be easily achieved. Minimal prep to remove loose debris is all that is normally required. This can be considered a structural repair if the material is allowed to gravity flow to the full depth of the crack. Manufactured sand or quartz may be introduced into the repair as necessary to prevent under slab ponding and martial waste. For repair greater than 0.125 inches, specified sand may be added at a ratio of two parts sand to one part mixed polyurethane as the crack is filled to extend the material and add strength. The sand also brings the thermal coefficient of expansion of the repair material closer in-line with surrounding concrete. Polyurethanes of this nature may be applied in a wide range to substreight temperatures making them useful in frozen and cold storage warehouse applications or cold weather application below -20F (-23C). Repairs are typically ready to accept traffic in approximately 10 minutes at 72F (22C).
Roadware 10 Minute Concrete Mender™ mixed with sand gets about as hard as concrete, yet it’s modulus of elasticity is slightly less than concrete so it will move with the slab, not work against it.
Common uses for 10 Minute Concrete Mender™
Spalled control joints and cracks.
Spalls and holes.
Uneven slabs and thresholds.
Crack Injection using gravity:
Typical crack injection repair techniques involve epoxy, ports, pumps, and pressure to force thick epoxies into a crack. Roadware 10 Minute Concrete Mender™ with its low surface tension can do same job in less time, less mess, and better performance.
Easy Floor Crack Injection using cartridges:
Roadware 10 Minute Concrete Mender can be injected into a wide range cracks and delaminations using a simple cartridge and special Soft-tip injection mixers. Successful full-depth repairs have been made in 24″ of concrete.
Vertical Crack injection
For fast and easy vertical crack injection on walls and structures, we recommend the Gebbie Tech System
THE GEBBIE TECH SYSTEM TRANSFORMS VERTICAL CONCRETE WALL REPAIR
Comprehensive testing by Opus International Consultants – repairs have consistently achieved results higher than the manufactured panel.
Full training in the system – a step by step training video and instructional booklet is included within each kit.
Save time and money! Conventional repair methods with epoxy have longer repair times, additional downtime and are more expensive.
Use a hand gun – no need for expensive pumps! The Gebbie Tech System uses the cost effective Roadware 10-Minute Concrete Mender™ hand gun to repair walls.
Complete penetration. Due to the composition of the Roadware 10-Minute Concrete Mender™ the resin travels easily from the injection point.
The approved vertical wall repair system. The Gebbie Tech System is listed in Roadware’s 10 Minute Mender Concrete Data Sheet as the approved method of vertical concrete wall repair.
Repairs cracks from a hairline through to quarter inch. Walls are repaired within 2 – 12 hours depending on the temperature, and the length of the cracks.
Polishing your floor to a mirror like finish? Repairs made with Roadware 10 Minute Concrete Mender™ will not smear into the surrounding surface or gum-up diamond polishing pads. You can even add natural sand to match the grain and color of the surrounding concrete.
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.
By adding two parts silica or quartz sand to a gallon of Concrete Mender™ you will yield about 2.2 gallons of repair material.
A gallon of polyurea or epoxy will yield a gallon of repair material. That makes polyurea more expensive to use even at half the material cost! This does not even factor in the hidden costs of short repair life, damage to the surrounding concrete caused by pre-mature failure, or the cost of redoing the repairs when they fail.
Roadware 10 Minute Concrete Mender™ hand packed with state-of-the-art packaging materials. They have to be good. The very low viscosity and surface tension require it.
Due to the the extended working time formula, bulk mixing of Concrete Mender™ is easy. Unlike polyureas that start to gel up instantly, Concrete Mender will remain workable and flowable for several minutes before curing begins. Much less wasted product setting up in buckets.
With a Roadware needle tip mixer, you can apply Concrete Mender™ within-point accuracy delivering product to where it is needed most. Our needles come as small as 1.2mm in diameter. If you can get a finger nail in the crack, we can get some Concrete Mender in there as well.
Working in the cold? We’re from Minnesota. We know first hand what it takes to work in freezing temperatures. Roadware 10 Minute Concrete Mender™ can be applied at temperatures below -30 F ( -34C). That is really cold. Exposed flesh will freeze in seconds. That is almost too cold to go ice fishing. Most repair products would freeze solid before curing and quickly fail. Roadware 10 Minute Concrete Mender™ generates its own heat. Curing will take several hours, but you will still get the same great performance.
Roadware Concrete Mender™ comes in two standard colors. Concrete Grey and natural off-white. Since a typical repair is made up of two parts sand to one part liquid, the color of the sand will determine the color of the finished repair. By adding colored quartz sand to off-white Concrete Mender, you can make custom colors as needed.
We also custom make Concrete Mender in Safety Yellow, Red, Blue, and Black. Use Concrete Mender Yellow to create permanent safety lines and marks in difficult areas like cooler and freezer floors.
Roadware 10 Minute Concrete Mender™ is completely self-reacting and does not out-gas solvents or VOC’s when curing. This material meets FSIS guidelines for work is federally inspected meat and poultry plants.
For over twenty years, Roadware 10 Minute Concrete Mender™ has performed without fail in thousands of applications. Many times outliving the facility itself.
Concrete Mender repair in a cold storage warehouse after 15 years of heavy forklift traffic.
Utilizing technology developed to repair bomb damaged runways for NATO, Roadware 10 Minute Concrete Mender™ was reformulated and brought to commercial markets in the early 1990’s. You can find us in nearly every industry that has concrete floors, decks, slabs or surfaces.
From the Roadware Crackrepair Fax Newsletter August 17, 2004
Tricks of the Trade
Hereʼs one you can warm up to. While installing 14 cases of Roadware Flexible Cement II (thatʼs 168 tubes), Roadware contractor Dave Wilson got tired of shaking and turning tubes, waiting for the ball bearings to start clicking. Dave headed over to a Super Wal-Mart looking for an electric blanket. It was the wrong time of the year, but they did have heating pads.
Dave had this crazy idea if they warmed up the cartridges, the material would mix immediately, speeding up the installation and keeping the installation virtually striation clear. To make a long story short, he got that and a whole lot more.
The heating pads exactly fit the boxes of Flexible Cement II™..
Open the bottom of the box, remove the bubble packing and insert a heating pad.
Open the top and place an additional heating pad on top of the cartridges.
Turn the pads on to medium/medium high.
Wait 15 minutes.
Take out a layer of cartridges (3) and place the pad on the next layer.
Shake the three cartridges until the white side has a consistent color. You will hear the steel ball rattle inside. Set up the three cartridges and run out 10-15 feet of expansion joint or construction joint with FLEX II.
Have second crew member follow behind with a second application and a third crew member follow with a third application.
At the end of the third application leave the nozzle stuck in the joint to dam the warmed FLEX II.
Set up three more cartridges and continue the run until complete.
The warmed FLEX II will self level, require no additional trowel work and if done carefully, no clean-up needed. Pull the nozzle-dam and replace it with FLEX II as you start the next run. This will eliminate cold joints.
When breaking for lunch, reduce pad heat to medium.
Dave’s Comments: “Iʼve never heard the ball bearings rattle before, but I hear them now. This puts cartridge applications on a par with bulk-mixed FLEX II. Itʼs quick, easy and very effective. The material thins to Mender-like viscosity and penetrates joint walls securing the FLEX II and the joint. The pads may be reused, of course, and the set-up cost is minimal.”
“I highly recommend you try it. It sure worked well on this job and we will continue to use a little heat to keep things flowing.”
Roadwareʼs Comments: “Why didnʼt we think of that?”
Electric heating pads are a good way to warm up Flexible Cement II prior to application. Use caution not to “cook” your cartridges for more than 12 hours. Leaking at the seals may be the result.
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
Roadware distributor Bill Bacha of Precision Devices in Connecticut has developed an innovative way to create yellow safety markings in warehouse and cold storage floors. By simply using a 4′ core drill and Roadware Concrete Mender in Safety Yellow, Bill can mark safety areas that are permanent and can be applied at temperatures well below freezing.
Use a core drill to make 3″ circle impressions about 1/4″ inch deep.
Fill the circles with Roadware Concrete Mender in Safety Yellow color.
The safety circles will cure yellow in about 15 minutes at 70 degrees F or in an hour at 0 degrees F.
Roadware Concrete Mender in Safety Yellow permanently bonds with the concrete using Roadware’s Microdoweling™ technology.
• 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.
If your business is refrigerated warehousing or grocery distribution, Roadware 10 Minute Concrete Mender™ is the premier concrete repair product for keeping your floors in top condition. The unique Microdoweling™ polyurethanes in Concrete Mender™ will cure at temperatures well below -20 degrees F. ( -28 C) in just a few hours. You can repair cracks, spalls, slabs, joints, and surfaces while the warehouse is in service.
Easy to mix one-to-one ratio polyurethane.
Add manufactured sand to extend the material over to two times. Two gallons of Concrete Mender™ will make 4.4 gallons of repair material.
Ultra low viscosity for easy application and workability.
Microdoweling™ penetration into the concrete for load transfer bonding.
Cures only has hard as the concrete. Will not become brittle like epoxy.
Tough repairs that can take industrial levels of punishment.
Smooth and safe floors.
Less damage to forklifts and equipment.
Clean floors. Meets FSIS and USDA guidelines.
Less tipped loads and damaged product.
Reduced cleaning and floor maintenance costs.
Reduced workers comp claims attributed to accidents.
Cold environments such as walk-in freezers and refrigerated warehousing pose difficult challenges for repairing concrete. In temperatures less than 0° F, most repair materials become unworkable and may take many hours to set and cure. Most epoxies are not usable below 32° F. Roadware Polyurethanes have been used in temperatures as low as -20°F below freezing. Listed below are some problems and solutions for working in cold environments.
Cold Environment Challenges
Frost: Frozen moisture in the concrete will act as a barrier between the repair material and the pours of the concrete. Most repair materials will try to bond to the frost coated concrete. When the temperature increases, the frost melts and so does the bond.
Working Conditions: Working with materials in the cold is challenging to both man and materials. Mixing epoxies or mortars in the cold is especially challenging. As the temperature decreases, the viscosity and flow rate of these materials increase making them harder to mix and much more difficult to work with.
Curing: With most materials, cure times in cold environments are extended significantly. A product that normally cures in an hour at room temperature may take as much as 12 hours in a cold environment. Some materials may not cure at all before actually freezing solid.
The extremely low viscosity and rapid cure times of Roadware 10 Minute Concrete Repair products make them excellent for cold environment application. Successful repairs are routinely made at temperatures below -20°F in freezer floors.
Preparation: Prepare cracks, joints, and spalls according to standard recommended methods. Make every effort to remove any moisture from the repair area. A propane torch or heat gun is very helpful in removing frost and moisture. In extreme cold, it is necessary to heat up the concrete prior to application.
Application: Keep material and sand or aggregate warm. Place materials in a warm area (between 70°F and 90°F) prior to application. Warm cartridges mix better, flow easier, and cure faster. Apply material as directed. It is a good practice to pre-wet all concrete surfaces with material before the introduction of sand. This insures full penetration and a strong bond.
Curing: Roadware materials are designed to cure in approximately 10 minutes when all components involved are at 70° F. In cold environment, the cure time depends on the temperature of the material, the temperature of the sand or aggregate if used, the volume of the repair, and the temperature of the concrete. Below is a chart of approximate cure times at various temperatures and conditions.
Storage: Roadware material should be stored between 60°F and 80°F. Material stored in extremely cold environments should be slowly brought up to room temperature before use. It may be necessary to agitate material subject to extreme cold prior to mixing. Call Roadware Technical Services for further instructions (800-522-7623).