Prime Practices

Repairing Spalls and Chips with Epoxy

Call: 1-800-321-7212

Problem:
Damaged and unrepaired floors can cause damage to equipment, products and add to worker fatigue. They also reduce the value of the building and can lead to more costly repairs later. An economical, high-strength mortar will get floors back into service with minimal interruption.

Steps:

• Mark out area to be repaired.
• Remove damaged concrete, dirt and debris from repair area. Clean, sound concrete is critical for a successful repair.
• Saw cut all perimeter edges to vertical, do not use “v” blades. Minimum edge (perimeter) patch thickness is 1/4” – do not feather edge repair material.
• Use chipping hammer to somewhat level floor or bottom of patch.
• Use vacuum to remove all dust from demolition.
• If rebar or wire mesh is encountered, clean steel and remove concrete by minimum of 1/4” to allow repair mortar to get underneath.
• Once clean, sound and dry, prime repair area with neat mixed resin: mix small amount of component “A” and “B” and coat all surfaces within repair with paintbrush.
• Once primer has been applied, mix up additional resin and hardener based on area to be repaired. Mix with low speed drill and jiffy mixer for 1 minute in a clean dry pail.
• Add up to 4 – 5 parts by volume oven-dried sand and mix for 2 minutes leaving no dry sand pockets. Place material into spalled area and trowel smooth with surrounding floor.
• Do not overwork: Place it, level it, leave it alone. Once cured, any high spots can be ground off.

Safety Considerations:
• Carefully read SDS prior to handling any chemical.
• Always wear OSHA-approved saftey equipment, including safety goggles when drilling, grinding, flushing, injecting or handling resins.
• Always wear protective clothing, chemical resistant gloves and safety goggles at all times when handling resins.
• Make sure no loose clothing can come into contact with moving mechanical equipment.
• Keep first aid kit (eye wash, bandages, etc.) present on site with easy access.

Materials List:
• Prime Bond 3000, Prime Bond 3000 Fast (both are gray 1:1 ratio) or Prime Bond 3100 (clear to amber 2:1 ratio)
• Oven-dried silica sand
• Cleaning solvent for tools
• Disposable paintbrushes for primer coat
• Plastic sheeting (to protect floors in mixing area)
• Several clean, dry pails for mixing
• Trowels
• Rags
• Gloves and safety glasses
• Wooden paint sticks (for mixing primer)
• Small plastic mixing container/cup (for mixing primer in)

Equipment List:
• Concrete saw (preferably dustless)
• Grinder with diamond blade (preferably dustless) or chipping hammer with chisel bit
• Electric cords
• Shop vac
• 1⁄2 – 3⁄4 hp drill
• Jiffy type mixing paddle