flexKRETE – Repair, Don’t Replace

Nothing lasts forever – unfortunate, but so true. As durable as concrete, asphalt, steel, and wood are, they need care, maintenance, and replacement at some point. For decades, certain repairs to these surfaces were not possible for several reasons. Perhaps the repair material simply wouldn’t hold up, as it would not be able to adhere well enough to the original surface. In other instances, the strength of the repair might not allow the surface or structure to maintain its original load capacity.

Then, flexKRETE was invented, an innovative repair product for all of these surfaces. It truly has been a game-changer for anyone charged with repairing and maintaining surfaces without the need to fully replace them.

Why replace when you can repair?

  • Cost savings. Repairing a concrete, asphalt, steel, or wood surface is considerably less expensive than replacing it.
  • Less downtime. Especially in high-traffic areas, having the ability to perform a repair versus demolition and new construction creates significantly less downtime for the public. Access and use of the surfaces can resume in hours, not days or weeks.
  • Convenience and ease of use. The flexKRETE repair product can be used on horizontal, vertical, and overhead surfaces. It is available in convenient FLEXKITs in multiple sizes and in larger quantities for bigger jobs.

What you once considered an irreparable surface may well be a candidate for flexKRETE. It is proven to successfully make cosmetic and structural repairs with unparalleled strength and service life. Consider its specifications:

  • When the flexKRETE vinyl polymer is cured, it reaches a strength between 10,000 and 12,000 psi. Curing occurs in minutes or hours, depending on the ambient temperature.
  • The product has been installed in temperatures from -36 to 220 degrees F. It can be used during any season.

Learn more about flexKRETE and FLEXKITs, and trust the team at JES Supply Company to talk through projects with you to determine if flexKRETE is a right fit for your particular project. 

flexKRETE – Repair Trip Hazards

Trip hazards are an eyesore, and more importantly, they are a liability issue that needs to be addressed as soon as they appear. There are a variety of ways to remedy the danger. A few of the most common are to remove and replace (the most expensive), grind the higher side down to the level of the lower side (damages the concrete, likely causing future failure), or fill the lower side to the elevation of the high side (most economical). flexKRETE is the perfect material for this type of repair. With flexKRETE’s ability to be placed at any depth and then troweled out to a feathered edge is unmatched. Any cement-based product will eventually fail. It will start to develop cracks, and the thinner areas will begin to “flake up” and pop out. This will not happen with flexKRETE.

FLEXKITs are designed to make the repair of damaged concrete structures an easy, simple procedure. FLEXKITs contain all materials, which are self-contained, and premeasured.

               

 

THE REPAIR

The entire slab, within the curb, had sunk as much as one inch, but the curb had not moved. A handheld grinder with a masonry disc was used to widen the cracks, and the entire area was swept clean of all dirt and debris. The cracks were primed with flexPRIME. A thin layer was brushed on with a 2” chip brush. Once the primer had become tacky like duct tape, the flexKRETE was prepared. A mixture of 3:1 (3 parts sand to 1 part flexKRETE) was troweled into the cracks and allowed to cure. Duct tape was then placed one foot in from the curb as a guide, then primer was applied between the tape and the curb and allowed to “tack up.” The next step was to mix more flexKRETE (at a 3:1 ratio) and trowel it in between the tape and the back of the curb. The tape was immediately removed. This process eliminated the trip hazard by forming a gradual slope from the back of the curb to the sunken slab. The remainder of the slab was treated to a broadcast to blend and cover the cracks and other blemishes in the slab. flexKRETE was mixed without sand and a ⅜” nap paint roller was used to spread the catalyzed flexKRETE over the entire slab, then sand was broadcasted, to refusal, over the wetted area. Once cured, the excess sand was vacuumed up. The entire process took two men 3½ hours to complete.

Remember, “Fix It with FlexKrete and Forget About It.”

Best of Success,
Ed

flexKRETE Columns

These are before and after pictures of one of four columns that support a slide structure at a local North Las Vegas swimming pool. The before picture clearly shows the extent of the damages caused by the chemicals in the pool water. These chemicals attacked the concrete, as well as the rebar, causing extensive damage and compromising the integrity of the column.

With the fast approaching swim season, repairs needed to be made quickly. The City had heard of flexKRETE’s superior compression strength and fast cure rate and felt flexKRETE was the way to go. The City contacted Terra Contracting, one of flexKRETE’s certified installers, to make repairs on the columns.

 

column-before                                            column-after


THE REPAIR

Screw jacks were fabricated and installed to support the weight of the structure during the repair. The 4 columns were then covered with a coat of flexPRIME to ready the concrete for the flexKRETE application. The primer also sealed the rebar. which cuts off the oxygen, thereby keeping it from further deterioration caused by the rust. An 18-inch tall section of sauna tube was used as a form. A cut up the length of the tube was needed to allow the tube to be opened up and placed around the column. Once in place a ratchet strap was used to secure the tube. The flexKRETE was mixed at a 3:1 ratio (3 sand to 1 flexKRETE) and flexTEMP was added to speed up the curing process. The mixture was packed into the form, vibrated and allowed to harden. It took no more than 10 minutes for the mixture to harden, and the form was removed and slipped up 12 inches and the process continued. It took two men less than a day and a half to complete 4 columns and resurface 22 stairs. The flexKRETE will not succumb to the same forces that caused the concrete to deteriorate, as it forms a waterproof barrier that is impervious to water, chlorine, muriatic acid or any other chemicals found in pool water. The repair is structural, the cost was minimal, the repair was quick and the customer is pleased.

Remember, “Fix It with FlexKrete and Forget About It.”

 

Best of Success,
Ed

flexKRETE – Tack on Curb

Tack on curb is widely used due to its low cost and its quick installation time. This type of curb is used in a variety of locations, but the two most common are parking lots and landscape features. Both take abuse from vehicles and equipment such as cars and trucks to push and riding mowers. Oh yeah, don’t forget the skateboarders. 

The above pictured curb sits in the parking lot directly in front of the entryway to the sales office of an apartment complex. It is important to have this damage repaired as soon as possible not only for aesthetics, but for liability reasons as well. 

The before picture shows the trailing end of the curb has been broken off and separated from the main run of curb. Also the very tip or end of the curb is altogether missing as you can see. The after picture shows the curb back in place and the tip replaced. The total repair took less than ½ hour and this after picture was taken 4 months after the repair was made. You can see that the curb has been hit after the repair was made.

To make the repair, a grinder was utilized to cut several groves ( like biscuits in woodworking) into the asphalt where the tail end piece would be placed. This was done to give the curb additional strength to fight off the pressures of being hit by a vehicle. flexKRETE was mixed with sand and fumed aggregate to a doughy consistency and used just like mortar. The flexKRETE was packed down into the groves in the asphalt and spread evenly over the entire underside of the broken section of curb, as well as its joining end. The “chunk” of curb was then pushed back into place and the flexKRETE was allowed to cure. 

 

Remember, “Fix It with flexKRETE and Forget About It.

 

Best of Success,
Ed

flexKRETE – Stair Repair

Stairs are a costly item to replace, so repairing them is definitely the way to go. The problem is that up to this point, you could only patch them. flexKRETE has changed this; you can now actually repair stairs. In the past, the materials used to patch large chips like these would expand and contract at different rates than the concrete they were patching, caused by temperature changes. This constant movement between the two different materials would eventually cause the bond between the two to fail and the patch material would “pop out.” No more. flexKRETE, with its ability to expand and compress, will absorb this movement, and with its unique bonding capabilities, will not “pop out.” In addition, the fact that it cures to 12,000 psi makes the patch stronger than the structure itself. This is a true repair, not a temporary patch.

Using a chip brush, the damaged areas were primed using flexPRIME. Once the prime coat became tacky (like duct tape), a batch of flexKRETE was prepared using 1 part flexKRETE, 1 part sand and 2 parts fumed silica. This mixture was applied using two trowels, placing one on the face of the rise and one on the top of the run. Once the mixture hardened (less than an hour), a grinder was used to smooth out any imperfections, tape was applied and the stairs were painted and placed back into service in less than two hours. 

Remember, “Fix It with FlexKrete and Forget About It.”

 

Best of Success,
Ed

flexKRETE – Repairing Overpasses

This past week flexKRETE was called into service by the Nevada Department of Transportation to make repairs on the underside of the Tropicana overpass on I-15.

The underside of the overpass was damaged when a northbound truck, in the number 1 lane, struck the leading edge of the structure, removing a wedge of concrete approximately four feet long and two feet deep. A quick setting, permanent, structural repair was needed. The answer? flexKRETE!

Once the traffic control devices were in place, NDOT crews went to work on the repair. A boom truck was positioned directly under the damaged area and an inspection took place. At the same time, crew members were mixing straight flexKRETE (with a touch of FlexTemp to speed up the curing process) to use as a primer. The damaged area was “wetted out” to assure thorough absorption of the flexKRETE. Once the primed area became tacky, the crew started hand packing a mixture of flexKRETE, sand and fumed silica onto the void. The flexKRETE mixture was placed in three-inch-thick layers to control sagging and fallout. Keep in mind that the overpass is in constant vibration caused by the continuous flow of traffic traveling over the structure. This vibration makes it difficult for conventional patch materials to adhere to the concrete while it’s curing. This is not an issue for flexKRETE. The mixture used on this repair was 1 part flexKRETE, 1 part sand and 2 parts fumed silica with a small amount of FlexTemp to aid in the acceleration of the setup time. Total repair time, including set-up and take-down of the traffic control devices, was 5 hours.

Fumed silica is a thickening agent made from quartz sand that is vaporized by a 3000° C flame. It is used to add volume and reduce weight. This allows the flexKRETE to adhere to vertical or overhead surfaces without falling out due to excessive weight.

 

Remember, “Fix It with flexKRETE and Forget About It.”

flexKRETE – How to Apply (Decorative Overlay)

flexKRETE – HOW TO APPLY A DECORATIVE OVERLAY

Overlays. What is a decorative overlay and how can it save money? A decorative overlay is generally a thin layer of material used to cover concrete, asphalt, steel or wood and give it a decorative look. flexKRETE is the perfect product to use as an overlay on any of these surfaces. Resurfacing will almost always save money. Removing and replacing unsightly or slightly damaged concrete is expensive and time consuming. Burdensome equipment, short load add-ons, material disposal and additional labor are some of the costs associated with concrete R&R, not to mention possible down time for a business if repairs are made to a storefront. 

 

To perform a flexKRETE overlay:

  1. ) The first procedure is to thoroughly clean the surface. Many concrete surfaces may have had a sealer applied to them; you can verify this by pouring a small amount of water on top of the concrete. If the water beads on top of the concrete, it most likely has been treated with a sealer of some kind. If the water soaks in rather quickly, it most likely does not have a sealer on it. If it has been sealed, the sealer must be removed. This can be accomplished with a liquid sealer remover or by grinding/sanding it off. A mild mixture of muriatic acid and water can be used, as well. Make sure you abide by all laws and regulations when using any types of solvents. Once the entire surface is scrubbed down and rinsed, it needs to be dried. A leaf blower works well; pay close attention to the nooks and crannies, as moisture will hinder the curing of the flexKRETE. If you must, let it dry overnight.
  2. ) The next step is to fill all holes and depressions in the surface. Any damages to the concrete should be repaired with the following procedure. The damaged area must be clean and dry. Use a wire brush or a grinder to thoroughly clean the damage area. Apply the primer. Mix equal amounts of flexPRIME Part A and Part B into a clean mixing cup. (A little goes a long way.) Mix until the primer turns a dull yellow (30 seconds). Apply a thin coat to the damaged area using a small chip brush, being careful not to leave any puddles or pools. Wait for the primer to become tacky, like duct tape. The time it takes to become tacky will depend on temperature and humidity.
  3. ) Once the primer is tacky, you can apply the flexKRETE using a 3 to 1 mixture of sand and flexKRETE. Use flexTEMP to speed up the curing process; this will allow you to quickly move to the next step. Once the repairs on holes, chips and depressions have cured, a quick once-over with a grinder to ensure a flat surface is recommended.
  4. ) Now that the surface is clean and flat, it can be primed. Mix equal amounts of Part A and Part B flexPRIME together. For large overlay areas, a 9” or 18” wide roller with  ⅜” or 1/4” nap works well for applying the primer. Apply a thin layer onto the concrete, making sure to avoid any puddling or pooling of the primer. A small paint brush can be used for tight spots or edges.
  5. ) Once the primer has become tacky, you are ready to apply the flexKRETE. When applying the flexKRETE, we believe a 3/8” nap paint roller works extremely well for most horizontal applications. The idea is to distribute the flexKRETE evenly over the entire area. We have discovered that the best coverage is about 80 to 100 sqft. per gallon. Pour the flexKRETE onto the surface and spread with a grooved squeegee with 1/8” grooves. As soon as possible, saturate the roller with flexKRETE and begin rolling to even out any line or puddles left by the squeegee. Always roll in the same direction. Use a grid pattern for better consistency. As soon as the flexKRETE is rolled on, the broadcast material can be applied. We have found broadcasting by hand is the most effective way of applying the aggregate materials. Simply take a handful of broadcast material, throw it in the air and allow it to settle onto the flexKRETE. The material will sink to the bottom, continue to broadcast until the area is completely covered, watch for “wet spots.” If you see a “wet spot,” broadcast additional material over the spots. The rejected material can be swept up and saved for the next project, blown off or vacuumed up. It is important to have the entire process continue without interruption to keep from having any cold joints. If you must stop, try to stop on an expansion joint. Allow the flexKRETE to cure; once cured, you can scrape the overlaid surface to remove any additional material. This will help provide a much smoother surface.
  6. ) The next step is to cut in all the existing expansion joints, this is a necessary step to avoid any unsightly cracks. Even though flexKRETE will cure to 10,000 psi, a thin 1/16” to 1/8” layer will eventually crack where there is an existing joint. Once all the joints are cut in, a through blowing off of all the dust and broadcast material should be performed.
  7. ) A thin layer of sealer can be applied to protect the finish from staining.

Remember “Fix It with flexKRETE and Forget About It.

 

Best of success,
Ed

Welcome to the World of flexKRETE

JES Supply Company would like to welcome you to the exciting world of flexKRETE, an innovative concrete, asphalt, steel and wood repair system. In the coming weeks, I will be posting news about flexKRETE, as well as “How To’s” and “Where To’s” along with pictures and descriptions of repairs made on concrete, asphalt, steel and wood, performed by certified installers from around the world using the flexKRETE system. It is our intent to give you a thorough understanding of when, where and how flexKRETE can be used to save you and your customers time and money, while providing you with a quick and permanent repair of damages to your concrete, asphalt, steel and wood surfaces and structures.

flexKRETE is not just for horizontal repairs; it works, as well, on vertical and overhead applications. Having a single product that is capable of making cosmetic and structural repairs on a multitude of materials is a cost savings in itself. flexKRETE is shipped in 5-gallon steel buckets as well as 3 separate FLEXKIT sizes for smaller repairs. These kits and our 5-gallon buckets are steel to protect them from the mishaps of handling that can result in damages to ordinary plastic buckets and paper sacks. The easy-open lid does not require any special tools to open, yet remains airtight due to the rubber seals within the steel lid, all adding to the cost-saving benefits of the flexKRETE System.

flexKRETE is a vinyl polymer, which is mixed with clean, dry blast sand and when cured reaches strengths between 10,000 and 12,000 psi. Repairs made to traffic areas can be returned to service in as little as 15 minutes depending on outside temperatures. It has been installed in temperatures ranging from as high as 220 degrees F to as low as -36 degree F, making it perfect for year-round applications.

Remember “Fix It with flexKRETE and Forget About It.

 

Best of success,
Ed