Hardline Concrete and Masonry in Minnesota sent us a video showing how to repair a concrete spall using Roadware 10 Minuet Concrete Mender in bulk. 2-Gallon kits.
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Heavy Duty Contraction Joint Rebuild Application For High Traffic Areas
Using Roadware 10 Minute Concrete Mender.
Remove loose material and create a shelf on both sides of the joint with a minimum profile of 1.5” deep and 2” wide on each side. Vacuum and thoroughly remove dust and contaminates.
Create a repair base by filling repair area halfway to grade with bulk mixed 10 Minute Concrete Mender™ combined with 10-20 grit silica sand.
Use a ratio of 1 Part mixed Concrete Mender to 2 parts silica sand. Up to 1/2 part additional sand may be added during application to assist with troweling and placement. Be sure to leave the lower half surface rough and sand covered to accept the next layer.
EXAMPLE
1 Qt side A,
1 Qt Side B,
4 Qts 10-20 silica sand,
Up to 1 quart additional sand as needed.
Once the first layer sets and turns grey, continue with an additional layer up to flush with the surface.
The mixed material should always be resin rich and the sand should be fully saturated when applying to the repair area.
For extra surface strength, 30 grit aluminum oxide may be broadcast and troweled in place on top as the materials start to gel in about 5 minutes after placement. Allow to fully cure and grind flush within 24 hours. OPTIONAL: Re-saw the contraction join
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.
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.
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.
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
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.
After buffing and clearing excess material, floors can be returned to service immediately.
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™ TDSProduct used in the project:
New Full-depth Hairline Crack Injection Breaks the Rules
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 often dismissed as not worth fixing. However, it’s important to note that almost every concrete crack starts as a hairline crack. Some of these cracks are so tiny that they are not visible to the naked eye.
Cracking naturally occurs in concrete slabs as the concrete cures and shrinks. We use saw-cut control joints to guide the concrete to crack inside the designated joints, but sometimes the concrete cracks in unexpected places. We wish there were an efficient way to fix hairline cracks, but for now, we generally ignore them and attribute them to the nature of concrete. We might reassure customers by saying, “It will be fine; you still have aggregate interlock, and the crack is just on the surface,” or “All concrete cracks, and it’s just the nature of the product.” Unfortunately, customers who have invested in a new concrete floor are usually dissatisfied with these explanations.
The truth is, we would fix hairline cracks if there were 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 it for over twenty years.
What is needed is a way to actively push repair products into hairline cracks. Roadware 10 Minute Concrete Mender can do the job with simple techniques and Easy Injection Mixers. 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.
The Roadware Easy Injection mixers make it easy to fill cracks as small as 20 mil (0.02 inches) with Concrete Mender. Simply drill a 3/8-inch hole into the crack and then push the almost-water-thin Concrete Mender into the cracks. You can see the Concrete Mender flow along the entire length of the hairline crack. You won’t need expensive injection pumps for this – just a cartridge of Concrete Mender and a manual application gun.
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.
Getting Started
Full Depth Crack Injection with 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.
- 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).
- 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.
- 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.
- 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.
- Once the crack is filled to refusal, move on to the next few drilled holes until the whole crack is filled.
- 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.
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.
Spall Repair with MatchCrete™ Clear
Using Roadware matchCrete Clear, cement powder, and rock to make exposed aggregate concrete spall repairs.
This driveway was seriously damaged from deicing snowmelt treatments. I simply routed out the perimeter of each of the damaged areas. I then thoroughly power washed to remove all dirt and loose debris and allowed the area to dry. I mixed up four separate batches of Matchcrete mender with 1/4”pea gravel seeded on top. I then applied a small amount of fine sand before the surface had hardened. The homeowner was extremely pleased with the finished results!! Thanks so much to the folks at Roadware Inc for their insight and positive support on this project!! Please note,
I will diamond cut, and route open the original joints after full cure time.Bill Neal, Redmond, WA
Exposed Aggregate Surface Repair with MatchCrete™ Clear.
Use MatchCrete Clear and matching rock to repair exposed aggregate surfaces.
New Freezer Floor Coating Stops Concrete Dusting
A new freezer floor coating developed by Roadware, Inc. can stop concrete dusting and restore freezer warehouse floors. Concrete dusting in your warehouse floor is a difficult challenge. Dusting is when the concrete surface deteriorates to powder due to heavy traffic, improper placement of the original concrete, mix design failure or a number of other reasons. Surface dusting can lead to hazardous conditions for personnel, unsanitary conditions and product contamination. If the concrete is solid beneath the surface, these slabs can be made serviceable with specialized coatings. Coating slabs like this is even more challenging in a working freezer where temperatures are typically -20 degrees F (-29C).
Concrete dusting can lead to the complete breakdown of the concrete wearing surface. Pallet jacks and forklifts can grind down the concrete allowing silica dust to become airborne and causing a health hazard.
Disbonded topping slabs and epoxy coatings can also create a hazardous dusting situation.
Here concrete polishing equipment with metal grinding pads are used to remove the dusting surface of the concrete back to a solid surface.
Hand grinders can also be used to remove the dusting surface. Dust collection systems are used to collect hazardous silica dust.
Roadware Freezer Floor Coating is mixed at a ratio of 1:1:1:
One quart A
One quart B
One quart 4030 grit silica or manufactured quartz sand.
Combined on a pail and mix with a paint stick or 10 seconds. Apply immediately.
Coverage rate shown here is approximately 2.5 Meters Sq per mixed liter.
Keep materials at outside the freezer at about 60-70 degrees before mixing. Floor and air temperatures in the freezer for this project were -4 degrees F (-20C).
A single trowel down application is all it takes to provide a new surface to the concrete and good working floor. Product is applied at freezer operating temperatures. Product cures in several hours depending on the temperature and odor is very slight. Stand-up trowels may be used as well.
Full warehouse traffic can resume in 10 hours after application.
Floors treated with Roadweare Freezer Floor Coating are resilient and serviceable once again.
Product: Roadware Freezer Floor Coating
Features:
- Low Viscosity
- Easy Mixing
- Fast Curing in sub zero applications
- Very low odor
- Very low VOC’s that polymerize into the material.
Benefits:
- Freezer floors can be repaired or coated while operating.
- Can be applied in odor sensitive areas.
- Easy trowel down application.
- Warehouse traffic can resume in 12-24 hours depending on temperature.
Uses:
- Coating freezer floors to reduce dusting and improve riding surface.
- Repairing cracks, joints, and spalls in freezers.
Limitations:
- Products cures a translucent natural amber. Dry colored pigments may be added to the final mixing process if needed.
- Surface must be, clean, dry and free of frost.
- Frost and moisture must be removed with a propane torch or electric heated air just before application.
- Excess moisture can cause the product to whiten in high moisture areas and will cause an inconsistent look.
Roadware Freezer Floor Coating is available on a special order basis at this time. Call 800-52-7623 for more information.
Roadware to Present at the ICRI 2020 Virtual Fall Convention
Join me, Kelton at Roadware at @ICRIorg’s Virtual Fall Convention #ICRIFall20. I’ve been selected to present in a product demonstration, Less Invasive Crack Repair for Concrete Floors and Structures on October 13, 2020. 2:40 – 3:10PM CST. See a preview of the presentation on YouTube. Learn more about the virtual convention here.
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:
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:
Thank you and be safe,
Roadware, Inc.