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Concrete Repair, Concrete Repair

Amazon Warehouse – Full depth crack repair without sawing.

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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

 

concrete mender, Concrete Repair

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.

concrete mender

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.
 control-joint-filler-original

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.

control-joint-filler-curled
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.
control-joint-filler-curled-dynamic-load
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.
control-joint-filler-curled-spalled-repaired
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.
Diagram of a spalled contraction joint repair using 10 Minute Concrete Mender headers.