XYPEX Repair Procedures
For stopping flowing water, patching, resurfacing, and rehabilitating concrete as well as the repairing of cracks.
Sections:
Cracks & Faulty Construction Joints
Download this as a Acrobat PDF with illustration reference.
1. Against High Pressure Water Flow
Step 1
Chip out crack/joint in a “U” shaped slot as per the drawing shown above. The slot it to be 1” (25 mm) wide and 2” - 3” (50 - 75 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage.
Step 2
In area of greatest water flow, drill hole or cavity 0.5” (13 mm) deeper into slot to accommodate a bleeder hose. A bleeder hose is a minimum 1.5 foot (0.5 m) length of smooth surfaced, fairly rigid tubing. Its purpose is to relieve the water pressure while crack/joint is being repaired.
Step 3
Remove all loose material within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak in and then remove all surface water.
Step 4
Place one end of bleeder hose into the hole or cavity and, while holding hose steady, apply Xypex Patch’n Plug to the slot around the hose. Approximately two to four applica- tions of Patch’n Plug may be necessary to secure the hose in place and embed the tubing completely up to surface level.
Step 5
To stop active water flow apply Xypex Patch’n Plug to half the depth of remaining slot area. Patch’n Plug is mixed by adding one part clean water to 3.5 parts Patch’n Plug powder by volume. If slot has dried out before Patch’n Plug application, it should be re-wetted. Remove bleeder hose and pack hole with Xypex Patch’n Plug to stop all active water flow.
Step 6
Apply a slurry coat of Xypex Concentrate at a cover- age of 1.5 lb./sq. yd. (0.8 kg/m2) in the slot over the Patch’n Plug and on the 6” (150 mm) strip of concrete surface on either side of the slot. Application may be performed by gloved hand or by brush.
Step 7
While slurry coat is still tacky, fill slot to surface level with Xypex Concentrate in Dry-Pac consistency. Dry-Pac is mixed by adding one part clean water to six parts Xypex Concentrate powder by volume. Blend by trowel for 10 - 15 seconds only (lumps should be present in mixture). Apply the Dry-Pac by gloved hand, then compress it tightly by using a pneumatic packing tool or a hammer and block.
Step 8
Wet the Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq. yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) strip on either side of slot.
Step 9
Cure by keeping moist using Gamma Cure and/or by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 7 – replace the top 1⁄4” - 1⁄2” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 8 and Step 9 – eliminate.
2. No Water Flow
Step 1
Chip out crack/joint in a “U” shaped slot as per the drawing in PDF (below). The slot it to be 1” (25 mm) wide and at least 1.5” (37 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage.
Step 2
Remove all loose material within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak into concrete and then remove all surface water.
Step 3
Apply one slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq. yd. (0.8 kg/m2) to slot and to 6” (150 mm) strip on either side of slot. Application may be performed by brush or gloved hand.
Step 4
While slurry coat is still tacky, fill slot to surface with Xypex Concentrate Dry-Pac mixed in the following pro- portions: one part clean water to six parts Concentrate by volume. Blend Dry-Pac by trowel for 10 - 15 seconds only (lumps should be present in the mixture). Apply Dry-Pac by gloved hand, then compress it tightly using a pneumatic packing device or a hammer and block.
Step 5
Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./ sq. yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) strip on either side of slot.
Step 6
Cure by keeping moist using Gamma Cure and/or by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 4 – replace the top 1⁄4” - 1⁄2” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 5 and Step 6 – eliminate.
3. Against a Flow of Water
Step 1
Chip out crack/joint in a “U” shaped slot as per the drawing shown above. The slot it to be 1” (25 mm) wide and at least 1.5” (37 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage. Areas with most water flow should be identified and chipped slightly deeper.
Step 2
Remove all loose material within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak in and then remove all surface water.
Step 3
To stop active water flow apply Xypex Patch’n Plug to half the depth of slot immediately after removing surface water. Patch’n Plug is mixed by adding one part clean water to 3.5 parts Patch’n Plug powder by volume. Patch’n Plug should be applied to full length of crack/joint area.
Step 4
AApply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq. yd. (0.8 kg/m2) in the slot over the Patch’n Plug and on the 6” (150 mm) strip of concrete surface on either side of the slot. Application may be performed by brush or gloved hand.
Step 5
While slurry coat is still tacky, fill slot to surface level with Xypex Concentrate Dry-Pac. Dry-Pac is mixed by adding one part clean water to six parts Xypex Concentrate powder by volume. Blend Dry-Pac by trowel for 10 - 15 seconds only (lumps should be present in mixture). Apply the Dry-Pac by gloved hand, then compress it tightly by using a pneumatic packing tool or a hammer and block.
Step 6
Wet the Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./ sq. yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) strip on either side of slot.
Step 7
Cure by keeping moist using Gamma Cure and/or by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 5 – replace the top 1⁄4” - 1⁄2” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 6 and Step 7 – eliminate.
Slab Interface Joints
Download this as a Acrobat PDF with illustration reference.
1. Against High Pressure Water Flow
Step 1
Chip out a “U” shaped slot as per the drawings shown above and depending on the wall to slab interface configuration such that the bottom corner of the slot is centered over the construction joint. The slot is to be 1” (25 mm) wide by at least 2” - 3” (50 - 75 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage.
Step 2
In the area of greatest water flow, drill a hole or cavity 0.5” (13 mm) deeper into slot and over the joint to accommodate a bleeder hose. A bleeder hose is a minimum 1.5 foot (0.5 m) length of smooth surfaced, fairly rigid tubing. Its purpose is to relieve the water pressure while the crack/ joint is being repaired.
Step 3
Remove all loose materials within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak into concrete and then remove all surface water.
Step 4
Place one end of bleeder hose into the hole or cavity and, while holding hose steady, apply Xypex Patch’n Plug to the slot around the hose. Multiple appli- cations of Patch’n Plug may be necessary to secure the hose in place.
Step 5
To stop active water flow apply Xypex Patch’n Plug to half the depth of the remaining slot area. Patch’n Plug is mixed by adding one part clean water to 3.5 parts Patch’n Plug powder by volume. Remove the bleeder hose and pack the hole with Xypex Patch’n Plug to stop all active water flow.
Step 6
Apply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq.yd. (0.8 kg/m2) in the slot, over the Patch’n Plug, and to 6” (150 mm) up the wall and onto the slab away from the slot. Application may be performed by brush or gloved hand.
Step 7
While slurry coat is still tacky, fill the slot to the surface with Xypex Concentrate Dry-Pac mixed in the following proportions: one part clean water to six parts Concentrate by volume. Blend Dry-Pac by trowel for 10 - 15 seconds only (lumps should be present in the mixture). Apply Dry-Pac by gloved hand, and then compress it tightly using a pneumatic packing device or a hammer and block.
Step 8
Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at coverage of 1.5 lb./sq.yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) up the wall and onto the slab away from the slot.
Step 9
Cure by keeping moist by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 7 – replace the top ¼” - ½” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 8 and Step 9 – eliminate.
2. No Water Flow
Step 1
Chip out a “U” shaped slot as per the drawings shown above and depending on the wall to slab interface configuration such that the bottom corner of the slot is centered over the construction joint. The slot is to be 1” (25 mm) wide by at least 1.5” (37 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage.
Step 2
Remove all loose materials within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak into concrete and then remove all surface water.
Step 3
Apply one slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq.yd. (0.8 kg/m2) in the slot and to 6” (150 mm) up the wall and onto the slab away from the slot. Application may be performed by brush or gloved hand.
Step 4
While slurry coat is still tacky, fill the slot to the surface with Xypex Concentrate Dry-Pac mixed in the following proportions: one part clean water to six parts Concentrate by volume. Blend Dry-Pac by trowel for 10 - 15 seconds only (lumps should be present in the mixture). Apply Dry-Pac by gloved hand, and then compress it tightly using a pneumatic packing device or a hammer and block.
Step 5
Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at coverage of 1.5 lb./sq.yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) up the wall and onto the slab away from the slot.
Step 6
Cure by keeping moist by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 4 – replace the top ¼” - ½” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 5 and Step 6 – eliminate.
3. Against a Flow of Water
Step 1
Chip out a “U” shaped slot as per the drawings shown above and depending on the wall to slab interface configuration such that the bottom corner of the slot is centered over the construction joint. The slot is to be 1” (25 mm) wide by at least 1.5” (37 mm) deep. A “V” shaped slot is not acceptable. The slot may be saw cut instead of chipped but ensure that the slot is dovetailed or otherwise shaped such that there will be mechanical interlock of materials placed into the slot at a later stage. Areas with most water flow should be identified and chipped deeper.
Step 2
Remove all loose materials within the slot and to 6” (150 mm) on either side of slot. Clean, profile (ICRI CSP-3) and saturate this area with water. Allow water to soak into concrete and then remove all surface water.
Step 3
To stop active water flow apply Xypex Patch’n Plug to half the depth of the slot. Patch’n Plug is mixed by adding one part clean water to 3.5 parts Patch’n Plug powder by volume. Patch’n Plug should be applied to the full length of crack/joint area.
Step 4
Apply a slurry coat of Xypex Concentrate at a coverage of 1.5 lb./sq.yd. (0.8 kg/m2) in the slot, over the Patch’n Plug, and to 6” (150 mm) up the wall and onto the slab away from the slot. Application may be performed by brush or gloved hand.
Step 5
While slurry coat is still tacky, fill the slot with Xypex Concentrate Dry-Pac mixed in the following proportions: one part clean water to six parts Concentrate by volume. Blend Dry-Pac by trowel for 10 - 15 seconds only (lumps should be present in the mixture). Apply Dry- Pac by gloved hand, and then compress it tightly using a pneumatic packing device or a hammer and block.
Step 6
Wet Dry-Pac surface lightly with water, then apply a slurry coat of Xypex Concentrate at coverage of 1.5 lb./sq.yd. (0.8 kg/m2) over the repaired area and to 6” (150 mm) up the wall and onto the slab away from the slot.
Step 7
Cure by keeping moist by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.
Note:
When early exposure to water is required:
1. In Step 5 – replace the top ¼” - ½” (6 - 12 mm) of Xypex Concentrate Dry-Pac with Xypex Patch’n Plug.
2. Step 6 and Step 7 – eliminate.
Defective Concrete & Honeycomb
Honeycombs, rock pockets, spalls and other concrete defects occur in a variety of sizes, shapes and situations which makes it difficult to create work procedures that cover all variables. The following information gives general directions and procedures for repair of standard, small or medium-large sized deficiencies. These procedures should not supersede ACI, ICRI or other recognized authorities’ recommendations. The steps outlined here can be modified and adapted to fit most scenarios and provide long term, well bonded concrete repairs.
Download this as a Acrobat PDF with illustration reference.
1. Repair Areas Larger than 6" (150 mm) Diameter
Step 1
Chip out defective, poorly consolidated or delaminated concrete until sound concrete is encountered.
Step 2
If corroded reinforcing steel (rebar) is encountered the defective rebar should be fully exposed by chipping and removing any concrete cover until corrosion free rebar is reached. Remove all corrosion from the exposed rebar and chip around the rebar such that mortar can be placed on all sides of it. If due to corrosion the cross section of the rebar is noticeably reduced advice from a structural engineer on rebar replacement is recommended.
Step 3
If there are active water leaks in the excavated area create a void of approximately 1” (25 mm) diameter by about 1” (25 mm) deep at each leak point.
Step 4
Delineate the chipped area to as close to a simple square shape as is practical by saw cutting to minimum 3/8” (10 mm) deep or as specified; 3/4” (19 mm) is preferred. If cutting to this depth will damage the rebar then reduce the depth of the cut until rebar is not impacted. Remove the concrete within the designated repair area to the saw cut to create a straight sided excavated area.
Step 5
Remove all loose materials in the excavated area using a 3,500 - 5,000 psi (250 - 350 bar) pressure wash and saturate the area with water. Allow the concrete to absorb the water until it is in a “saturated, surface dry” condition.
Step 6
Stop any active leaking by filling the 1” (25 mm) diameter by 1” (25 mm) deep voids at the leak points with Xypex Patch’n Plug.
Step 7
Apply a scrub coat of Megamix II mortar to the inside surface of the patch area and, while it is still wet or “green”, fill the entire area to the surface with Megamix II.
Step 8
If the void is deeper than 2” (50 mm) on a vertical or horizontal surface or 1½” (37 mm) on an overhead surface the void should be filled in layers (lifts) of not more that the stated thicknesses. For mechanical bond of the next layer, provide profile by scoring the surface of the installed mortar with the tip of the trowel. In situations where the repair area requires multiple lifts reinforcing such as wire mesh mechanically attached to the substrate should be considered.
Step 9
Apply a coat of Xypex Concentrate slurry at 1.5 lb./sq. yd. (0.8 kg/m2) over the repair area and to 6” (150 mm) beyond the edge of the patch.
Step 10
Cure by misting with water to keep moist or by covering with a wet curing blanket for two to three days. Open to water contact per Xypex Coatings guidelines.Note: When early exposure to water is required eliminate Step 9 and Step 10.
2. Repair Areas 6" (150 mm) Diameter or Less
Step 1
Chip out defective, poorly consolidated or delaminated concrete until sound concrete is encountered.
Step 2
If corroded reinforcing steel (rebar) is encountered the defective rebar should be fully exposed by chipping and removing any concrete cover until corrosion free rebar is reached. Remove all corrosion from the exposed rebar and chip all the way around it such that mortar can be placed on all sides of the rebar. If due to corrosion the cross section of the rebar is noticeably reduced advice from a structural engineer on rebar replacement is recommended.
Step 3
If there are active water leaks in the excavated area create a void of approximately 1” diameter (25 mm) by about 1” (25 mm) deep at each leak point.
Step 4
Delineate the chipped area to as close to a simple square shape as is practical by saw cutting to minimum 3/8” (10 mm) deep or as specified; 3/4” (19 mm) is preferred. If cutting to this depth will damage the rebar then reduce the depth of the cut such that the reinforcing steel is not impacted. Remove the concrete within the designated repair area to create a straight sided, excavated area.
Step 5
Remove all loose materials in the excavated area using a 3,500 - 5,000 psi (250 - 350 bar) pressure wash and saturate the area with water. Allow the concrete to absorb the water until it is in a “saturated, surface dry” condition.
Step 6
Stop any active leaking by filling the 1” (25 mm)diameter by 1” (25 mm) deep voids at the leak points with Xypex Patch’n Plug.
Step 7
Apply a scrub coat of the selected repair mortar to the inside surface of the patch area and, while it is still wet or “green”, fill the entire area to the surface with the same mortar. Note that Patch’n Plug is a very rapid setting material so it must be applied immediately after the scrub coat.
Step 8
If the void is deeper than 2” (50 mm) it should be filled in layers (lifts) of not more than 2” (50 mm). For mechanical bond of the next layer, provide profile by scoring the surface of the installed mortar with the tip of the trowel. In situations where the repair area requires multiple lifts reinforcing such as wire mesh mechanically attached to the substrate should be considered.
Step 9
Apply a coat of Xypex Concentrate slurry at 1.5 lb./sq. yd. (0.8 kg/m2) over the repair area extending to 6” (150 mm) beyond the edge of the patch.
Step 10
Cure the repair area by keeping moist by fog spraying periodically with water for two to three days. Open to water contact per Xypex Coatings guidelines.Note: When early exposure to water is required eliminate Step 9 and Step 10.