Repair Your Concrete Spalls

Restoring the integrity and aesthetics of your concrete floor is vital. We’ll review why concrete spalling repair is important and how to repair it.

What Is Spalling?

Spalling, a frequent issue evidenced by a chipped, cracked, or flaky surface, can undermine your floor’s quality and safety. This prevalent condition warrants urgent attention. Neglect can lead to escalating structural issues, increased repair costs, and potential safety hazards.

Can Spalling Be Fixed? 

Yes, equipped with specialized tools, a meticulous process, and quality materials, transforming a damaged, spalled surface into a durable and visually appealing floor is not just a possibility but a necessity.

Why Concrete Spalling Repair Is Important

Unattended spalling can exacerbate more profound structural damage, reducing the floor’s load-bearing capacity and leading to an unsightly and unsafe surface prone to accidents. 

Tools and Equipment for Concrete Spalling Repair

Having the right tools is about getting the job done and accomplishing it with mastery.

Here’s an enhanced list designed for precision, effectiveness, and safety:

  • Right Angle Grinder with Dustless Shroud: Ensures precision in grinding and containment of dust, offering a cleaner and healthier working environment.
  • Diamond Blades: Known for their durability and cutting accuracy, enabling smooth edges for a seamless repair.
  • Vacuum System: Essential for immediate and effective removal of dust and debris, ensuring a clean surface for optimal adhesion of repair materials.
  • Trowel: Precision-engineered for an even spread of repair materials, ensuring a smooth and level finish.
  • Razor Scraper/Torch: Provides the dual functionality of scraping off loose materials and heating surfaces for effective repair material bonding.

Repair Materials

The selection of repair materials is equally crucial. We’ve enriched the list with additional insights to ensure you’re well-informed:

  • Structural Epoxy Mortar (Metzger/McGuire Armor-Hard): Engineered for superior bonding and structural integrity, this epoxy is designed to endure the demands of industrial traffic. 
  • Rapid Access Repairs (Metzger/McGuire Armor-Hard Extreme): This formula is your ally for speedy repairs, setting quickly to minimize downtime in high-traffic commercial spaces. Armor-Hard Extreme is a two-component, 100% solid epoxy system, specifically designed to endure the constant pounding of industrial-type traffic and is available in both liquid and aggregate forms to suit diverse application needs. It boasts early set properties, permitting foot traffic in just 1 hour and normal traffic in 2 hours.
  • Freezer or Cooler Repairs (Metzger/McGuire Spal-Pro 2000 or Armor-Hard Extreme): Both products perform optimally in low temperatures, ensuring durability and integrity in cold environments. Spal-Pro 2000 stands out as a 100% solid, two-component, semi-rigid polyurea joint filler. It’s expressly designed for application in temperatures as low as -30ºF (-35ºC), perfect for repairing joints and cracks in industrial freezer/cooler concrete floors, allowing a rapid return to service in 30 minutes or less. 

How to Repair Concrete Spalling in 4 Steps

Follow these concrete steps tailored to transform a spalled surface into a masterpiece of strength and aesthetics.

  1. Precision Cuts: Make cuts with a blade or chip out sections at the outer edges of spalling with a chisel to at least ¾-inch deep, ensuring a vertical edge for a seamless repair.
  2. Level the Ground: Grind or chisel any raised spots within the work area. Vacuum, brush, and wipe the area clean, prepping it for the repair material.
  3. Material Application: Generously apply the chosen repair material and trowel it smooth, ensuring it sits slightly higher than the floor surface for an even finish after curing.
  4. Perfecting the Surface: Once you’ve cured the repair material, grind off any excess to create a flush, smooth surface that seamlessly blends with the rest of the floor.

Unleashing the Power of Metzger/McGuire Products

Runyon Surface Prep takes pride in offering the renowned Metzger/McGuire repair materials, a collection crafted with precision. 

Each product in this lineup combats cracks, surface spalls, pop-outs, and other concrete surface imperfections. Explore the effectiveness of these solutions on our website and witness their application and performance firsthand on our YouTube channel.