Patching Floor with Epoxy

July 18, 2017

Here is an outline of the procedure for patching with Epoxy.com Product #1 and Product #10.  Cold cure is identical but you should make even smaller batches and work even faster.

  1. Mix a small amount of the #10 (mix ratio 2A: 1B).
    1. Measure accurately and mix for 3 minutes with a proper size mixer.
    2. Typically very small batches less than a quart can be mixed with a stir stick.
    3. Larger batches should use a mixing paddle in a low speed drill or similar. Typically  mixing paddles are 5 inches or more in diameter.
  2. Apply a primer coat of #10 at a rate of 250-300 SF per gallon (typically done with a roller) to the substrate the mortar is to be attached to.
    1. Typically you will allow this to harden to the touch to make troweling into it easy.
    2. You can trowel into the wet primer in the case of small patches.
  3. Mortar Patch
    1. Mix another small batch of #10, using the methods in step 1 above.
    2. Add Product #82 Mortar Blend Aggregate to the mixed resin in 3a. You can add as much as 50 to 75 lbs. of mortar blend aggregate to a gallon of mixed #10 resin. If the material appears to wet you can add more, if it is too dry add less.
    3. Quickly trowel the patch into place.  Winter Cure Epoxy can set very fast in the bucket.
  4. Sealer Coat
    1. After the patch in step 3 has hardened, you can grind off any high spots and fill more material again if needed.
    2. Then seal the top of the patch.
  1. Product #10 is thinner than the #1, making it an excellent sealer for sealing up the patch.
  2. Alternately you can go directly to a very thin coat of #1
  1. Top Coat
    1. Mix small batches of #1 using the methods used in #1 above.
    2. Mix optional Antiskid fine into the coating above at a rate of 8-16 volume ounces of Anti-skid per gallon of mixed resin.  12 ounces per gallon is typical.  This is done by mixing the resin first, adding the anti-skid and mixing for another min.
    3. Quickly apply the material with a roller at a rate of 160-200 SF per gallon per coat.  Two coats is recommended.
  2. Please read all the information below before starting your project.
  1. Do with Epoxies
  2. Don’ts with Epoxies
  3. Surface Preparation
  4. www.epoxy.com/10.aspx
  5. http://epoxy.com/1cold.htm
  6. SDS Product #10 Part A – Hardener Lo-Mod Epoxy Adhesive and Mortar Epoxy Resin
  7. SDS Product #10 Part Cold Cure B – Lo-Mod Epoxy Adhesive and Mortar Epoxy Hardener
  8. SDS Product #1A – All Purpose Coating Hardener Component MSDS.
  9. SDS Product #1B -cc – Cold Cure Epoxy Hardener for Product #1

 

BE SURE TO CALL ME WITH ANY QUESTIONS OR CONCERNS!

 

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Posted by Norm Lambert

Epoxy Injection of Structures Part 2

February 14, 2017

Infrastructure Repairs Using Epoxy

Epoxy Concrete Injection Epoxy Wood Injection, epoxy crack repair

Epoxy Structural Concrete and Wood Repair / Waterproofing

The following article is written with enough information about resin injection systems to help protect the Owner from the misuse or improper installation of an injection systems.   For more information contact me: Norm Lambert.

This is the second in a series on Infrastructure Repairs Using Epoxy. Part One was Introduction to Epoxy Injection.  If your have not read that yet you may want to go back and read it before you proceed with reading this.

Part 2: Crack Analysis Before Epoxy Injection

As with all repair and rehabilitation of concrete, the initial job analysis is by far the most important step. Epoxy Injection Resin will weld concrete cracks but, of course, will not repair the cause of the cracking.

Analyze each potential injection application to determine the exact cause or causes of the cracking. Correcting the cracking problem can be fairly simple, or may be difficult involving design changes.

Consult a structural engineer when design changes are necessary. Do this before starting the injection. Repairing cracks by Injection is effective after these design changes. Prevent future cracks by fixing the original cause of the cracking, when ever possible.

Parking garages are an example of cracking problem that require a structural engineering analysis.Epoxy.com Epoxy Inection Often inadequate design for expansion/contraction is the cause for parking garage structural cracking. Avoid weld injecting a crack if there are not enough expansion joints. Sometimes flexible overlays such as Epoxy.com System # 495 can be used to overcome this defect. This does not however encapsulate the rebar in a way that will totally stop the premature deterioration of the steel. Often times additional joints are needed, thus the analysis of cracking problems is critical.

Bridge decks and slab on grades can often be repaired with Epoxy.com Product #684LV crack healer and sealer and save some of the cost of doing epoxy injection.

Next in the Injection Series:

Part 3: Setting Epoxy Injection Ports

For more information visit our website at http://www.epoxy.com, email us at info@epoxy.com or call our technical service department at +1 (352) 533-2167.

2 Comments | Bridge Concrete Repair, Concrete Bridge Pier Repair, Concrete bridge repair epoxy, concrete dam repair, concrete infrastructure bridge repair, Concrete Infrastructure Repair, Concrete Repair, concrete wall repair epoxy, Epoxy, epoxy concrete repair, epoxy education, epoxy injection, repairing concrete with Epoxy, Structural Repairs, waterproof, Waterproofing | Tagged: , , , , , , , , , | Permalink
Posted by Norm Lambert

Fixing Floor Damage with Epoxy

September 6, 2016

Industrial and commercial floors take heavy abuse. The older the flooring the worse shape it is in. Conventional wisdom says that such a breakdown of the floor is inevitable. There are steps you can take to protect your floor before it gets damaged. Once the damage has happened there are steps you can take to permanently repair most damaged floors.

Floor joints, are the source of many industrial flooring problems. The purpose of these joints (in original construction) is to give the concrete a controlled place for the concrete crack as it shrinks. They sometimes are called expansion joints. In theory they will expand when the concrete gets hot.Indoors, where temperature is somewhat stable, most of their function of these joints has ended after 28 days or so of concrete. Concrete does most of it shrinking in the first 28 days.

wheel across empty joint

A wheel across an empty Joint

The downside of these joints in the concrete is that it gives a place for the concrete to start chipping away. See the highlighted (in blue) corners in the illustration to the right. When wheels pass across the top it hammers the edge in the opposite side of traffic flow. This breaks off tiny pieces of concrete (again drawn in blue as a triangle at the edges of the concrete joint). The bigger the area chipped out earlier, the bigger and faster additional chipping happens. Time goes on and “pot holes”start to form in the concrete joint in direct proportion to the number of times wheels have hit a given spot.This can become a major trip and forklift hazard.

The best way to prevent this concrete damage is to fill the joints with Epoxy.com  – Product #11-100% Solids Flexible Epoxy Joint Filler for Saw Cut Joints. The #11 is semi-flexible so it still allows some joint movement but (unlike caulking) is firm enough to support the hard wheel as it passes over the joint, virtually

wheel across a filled joint

Wheel Supported by #11 as it passes over the joint.

eliminating the pounding and chipping effect on the sides of the joint. See in this diagram how the #11 supports the wheel as it passes over the joint.

For application on flat surfaces Epoxy Joint Filler for Saw-Cut Control Joints Product #11 can be poured or pumped from an Epoxy.com Binary Pumping Systems. In areas where cosmetics are important mask both sides of the substrate before applying the material.

If the areas are bigger you can use Epoxy.com Product #12  blended with silica sand to make a mortar to fill epoxy_joint_repairthe pothole, then re-cut your joint with a concrete saw as shown in the diagram here. The Product #12 can also be mixed with silica sand and used to repair areas in the center of a slab that might have started as a random crack or because of a chemical spill or due to impact damage.

If you need the epoxy mortar to set at a lower temperature and/or faster Epoxy.com Product #10 Epoxy Mortar Resin in fast or cold cure may be the best option.

Here is an outline of getting your flooring ready and some of the types of flooring we can offer you.

I can easily calculate how much material you will need for your floor.  The patching will take a little more effort and some estimation of the geometry of the repairs from you:

  1. Joints
    1. Fill joints with Epoxy.com Product #11 – epoxy.com/11.aspx.If there is spalling at the joint see “pot hole” repair below.
  2. Pot holes
    1. Fill shallow areas with a blend of Epoxy.com Product #12 – epoxy.com/12.aspx -And Epoxy.com Product #71 – www.epoxy.com/71.aspx fumed silica
    2. Fill Deep areas with a blend of Epoxy.com Product #12 and product #82 Mortar Blend Aggregates
  3. Priming
    1. Oil Saturated areas (if any) – Epoxy.com Product #201 – epoxy.com/201.aspx
    2. Areas with moisture vapor transfer issues (if any – see epoxy.com/surfaceprep.aspx ) with Epoxy.com Product #830 – www.epoxy.com/830.aspx
    3. All areas not subject to the items above primed with
      1. Epoxy.com Product #12 – www.epoxy.com/12.aspx or
    4. Epoxy.com Product #899 – www.epoxy.com/899.aspx.
  4. Floor Coating – High Build
    1. High build all purpose epoxy floor coating:  Epoxy.com Product #1 – epoxy.com/1.aspx or
    2. High build mid range chemical resistant epoxy floor coating: Epoxy.com Product #2 – epoxy.com/2.aspx or
    3. High build highly chemically resistant epoxy floor coating: Epoxy.com Product #633 – epoxy.com/633.aspx
  5. Seamless Flooring
    1. Chip Flooring – epoxy.com/chips.aspx or
    2. Solid Colored Standard chemical resistance Flooring
    3. Product #24 Pigmented mortar – www.epoxy.com/24.aspx and silica sand
      1. Top coated with Product #1 – www.epoxy.com/2.aspx  or
    4. For high chemical resistance Epoxy.com Product #2 – epoxy.com/2.aspx
    5. Epoxy Quartz Flooring – www.epoxy.com/15.aspx.
  6. Chemical Resistant Epoxy Flooring
    1. Product #630 and silica sand – www.epoxy.com/630.aspx
    2. Product #633 and silica sand – www.epoxy.com/633.aspx 

Still not sure? Email epoxy.com Technical Support info@epoxy.com  call us at 352-533-2167. We will help you select the right product for your job. We can also help you estimate how much of it you need, and quote you on those quantities.

You can also visit us at www.epoxy.com 24 hours a day 7 days a week.

 

Leave a Comment » | Care and Maintenance of Epoxy, Concrete Repair, Epoxy, epoxy concrete floor patch, epoxy concrete repair, epoxy education, General Interest, Installation, Structural Repairs | Permalink
Posted by Norm Lambert

Tombstone Repairs with Epoxy

August 22, 2012

A technician who uses a non-Epoxy.com product to repair tombstones wrote me recently looking for help with problems that he was having.  He goes on to say that the epoxy that he uses never fails, but rather the stone fails. When a secondary break occurs, the stone always re-breaks about 2 mm (about ¾ inch) above or below the epoxy joint.  The epoxy attached to about 2 mm of the stone and holds well.

He asked me if the epoxy shrinks so much that it will ‘ pull away ‘ from the stone it’s attached to, and in his case, it pulls about 2mm of stone with it.

No I doubt it is epoxy shrinkage causing the problem. High quality epoxy has little or no shrinkage.  It would have to be a very poor quality epoxy to be shrinking enough to do that.

The reason his epoxy is not working is that it is too rigid.  His existing rigid material has a “high modulus of elasticity”.  A material with “high modulus of elasticity” is a material that is stiff and/or rigid.  A “low modulus of elasticity” material is semi-flexible, and is not rigid or brittle.

Smaller pieces of the stone structure (in this case a tombstone) and pieces not in touch with the ground tend to get hotter and cooler faster than the larger pieces and pieces with ground contact. This is called “differential timing of the event”. For example the top of a tombstone can be heated and cooled on 5 sides, the top and the 4 sides. The base of the tombstone which is buried in the ground has earth or stone on all of its surfaces.  This earth and stone tends to keep the temperature of the base more stable by insulating it and slowing the change in temperature. This works much like the insulation in your house slows temperature changes inside your house.

When an object like a piece of stone is heated it expands (gets bigger).  When an object cools it contracts (gets smaller).  For example 100 feet of concrete will be 1 inch longer once it is heated 100 degrees F.  That is why expansion joints are cut into concrete.

In the case of tombstones all the pieces of the same type of stone have very similar if not identical “coefficient of expansion”. Since the pieces are positioned with potentially different timing of heating and cooling there is a “differential timing of the event” (see above). The result is stress areas you are seeing in the closest weakened plane in the stone near the bond line.

Product #2005  was specifically designed for tombstone (monuments) and/or stone bonding, or repair. Epoxy.com Product #2005 is very strong yet it is has a “low modulus of elasticity” (semi-flexible).  The low-modulus of elasticity helps to absorb differential movement (two sections of stone heating and cooling at different times), making it much less likely to cause a stress area in adjacent weakened planes.

Camouflage the bond line rubbing stone dust(ground off the original stone or a similar colored stone) into any exposed epoxy material while the epoxy is still “wet”. That way the dust will stick in the wet epoxy making the epoxy difficult to impossible to see.

Please send your additional question and blog ideas to norm@epoxy.com

 

Leave a Comment » | adhesive, bonding, crack isolation epoxy, Epoxy, flexible Epoxy Membrane, glue, Structural Repairs, Surface Preparation, tombstone repair | Tagged: , , , , , , , , , , | Permalink
Posted by Norm Lambert

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