Concrete Repair

Utilized throughout the construction industry, from highways to skyscrapers, steel reinforced concrete, allows Architects and Engineers to construct ever more complicated and exciting projects. Unfortunately, if left unprotected, the effects of the environment can take their toll.  Damage to concrete by freeze thaw action, mechanical damage, acid rain and even chemical reactions between the concrete and atmospheric CO₂ can have a detrimental effect on our buildings and infrastructure. 

We believe the best way to complete concrete repairs, is with thermally compatible and dimensionally stable, cementitious materials. This is why in side by side testing of major suppliers, our concrete repair products consistently come out on top. 

When used in conjunction with our comprehensive range of compatible waterproofing and corrosion protection products, Stonhard Construction Solutions offers a complete repair and protection solution in every environment, no matter how challenging or difficult. 

• Structural Concrete V/O

  Vertical / Overhead Permanent Repair

  Description

  Structural Concrete V/O is a high strength, rapid setting, one component, permanent concrete repair material for vertical and overhead structural repairs.  Structural Concrete V/O produces a repair which is dimensionally stable, develops an integral bond to existing concrete, and restores structural integrity within hours of placement.  Structural Concrete V/O provides increased corrosion protection to steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability.  Moisture sensitive coatings can be applied in 8 to 24 hours.

  Advantages

  • Can be troweled vertically or overhead
  • High three hour strength gains
  • Can be coated in 8 to 24 hours
  • Excellent freeze/thaw resistance
  • Very low chloride ion permeability
  • One product for thin and thick placement
  • Outstanding corrosion resistance for protection and rehabilitation

  Uses

  • Rapid repair of load bearing walls, ceilings and other structural members
  • Rapid repairs during shutdown
  • Marine and hydraulic structure repairs
  • Available for Nuclear Safety Zone Applications

  Documents

  • Structural Concrete V/O PDS
  • Structural Concrete SDS

  
  

• Structural Concrete

  Fast, High Early Strength Permanent Repair

  Description

  Structural Concrete is a high early strength, single component, permanent concrete repair material. Structural Concrete produces a repair which is dimensionally stable, develops an integral bond to existing concrete, and restores structural integrity within hours of placement. Application thickness can range from 1/4 inch to 12 inches (6 mm to 300 mm) in a single pour. Structural Concrete provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability. Moisture sensitive coatings can be applied in 8 to 24 hours.

  Advantages

  • Single component for reliability and ease of use
  • High three hour strengths
  • Very low chloride ion permeability
  • Fast turnaround times with high 3 hour strengths
  • High bond strength
  • Coarse aggregate extension
  • Very low shrinkage
  • Excellent freeze/thaw resistance
  • One product for thin and thick placements
  • Outstanding corrosion resistance for protection and rehabilitation

  Uses

  • Repair of concrete structures
  • Rapid machinery foundation rebuilds
  • Concrete floor repairs and overlays
  • Construction joint repair
  • Marine and hydraulic structure repairs
  • Repair of tanks, sumps and curbs
  • Available for Nuclear Safety Zone Applications

  Documents

  • Structural Concrete PDS
  • Structural Concrete SDS
  • Viva Bus Depot Case History

  
  

• Highway Patch

  Fast Traffic Area Repair

  Description

  Highway Patch is a one component, fast setting hydrailic cement material ideal for horizontal repairs of concrete in traffic areas.

  Advantages

  • High early strength
  • One component/ease of use
  • Open to traffic in two hours
  • Freeze/thaw resistance
  • Resistant to salts
  • Cold weather installation
  • Coarse aggregate extension

  Uses

  • Highways and bridges
  • Parking decks and ramps
  • Airports runways and taxiways
  • Expansion joint rebuild
  • Dowel bar retrofit
  • Cold weather repairs

  Documents

  • Highway Patch PDS
  • Highway Patch SDS

  
  

• Structural Concrete ES

  Fast, High Early Strength, Extended Working Time, Permanent Repair

  Description

  Structural Concrete® ES (Extended Set) is a high early strength, single component, permanent concrete repair material which provides a 45-minute working time. The extended set facilitates deep/large volume pours up to six cubic yards in a single lift. Structural Concrete® ES produces a repair which is dimensionally stable, develops an integral bond to existing concrete, and restores structural integrity within hours of placement. Structural Concrete® ES provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability.

  Advantages

  • 45 minute working time
  • Can be coated in under 24 hours
  • Deep, large volume pours up to six cubic yards
  • High six hour strengths
  • Coarse aggregate extension up to  100%
  • Provides permanent concrete and equipment/machinery foundation repair
  • One component
  • Facilitates equipment rebuilds in under 24 hours
  • Pumpable
  • High bond strength
  • Excellent freeze/thaw resistance

  Uses

  • Hot weather concrete repair
  • Heavy industrial repairs and retrofits
  • Concrete floor toppings and overlays
  • Deep, large volume repair of concrete structures and machinery foundations

  Documents

  • Structural Concrete ES PDS
  • Structural Concrete ES SDS

  
  

• Structural Concrete Gunite

  Fast Turnaround, Dry Process Shotcrete Repair

  Description

  Structural Concrete® Gunite is a dry process shotcrete applied, high early strength permanent concrete repair material. Containing migrating corrosion inhibitor technology, Structural Concrete® Gunite produces a repair which is dimensionally stable, develops an integral bond to the existing concrete, and restores structural integrity within hours of placement. Moisture sensitive coatings can be applied in 8 to 24 hours.

  Advantages

  • Single component
  • High three hour strengths
  • Vertical and overhead repairs
  • Excellent resistance to sulfates
  • Cold weather installation
  • Excellent freeze/thaw resistance
  • High bond strength
  • Very low chloride ion permeability
  • Application thickness down to 1/4" (6 mm)
  • Can be coated in 8 to 24 hours

  Uses

  • Rapid repair of load bearing walls, ceilings and other structural members
  • Rapid repairs during shutdown
  • Rapid structural repair for industrial plants
  • Marine and hydraulic structure repairs
  • Cold weather repair

  Documents

  • Structural Concrete Gunite PDS
  • Structural Concrete Gunite SDS

  
  

• Structural Concrete Gunite S300

  High Strength Dry Process Shotcrete Repair

  Description

  Structural Concrete® Gunite S300 is a dry process shotcrete applied, high strength, permanent concrete repair material. Structural Concrete® Gunite S300 may be used from 1/4 inch (6 mm) to deep/full depth applications and provides a long finishing time. Structural Concrete® Gunite S300 provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability.

  Advantages

  • Available in 3000 lb bulk bag packaging for large volume applications
  • Long finishing time
  • High bond strength
  • Low rebound
  • Versatile - 1/4" (6 mm) to full depth applications
  • High one and 28 day strengths
  • Very low chloride ion permeability
  • Excellent freeze/thaw resistance

  Uses

  • Vertical and overhead repairs
  • Repair of load bearing walls, ceilings and other structural members
  • Structural repair for industrial plants
  • Marine and hydraulic structure repair

  Documents

  • Structural Concrete Gunite S300 PDS
  • Structural Concrete Gunite S300 SDS

  
  

• Structural Concrete Gunite WP

  High Strength Wet Process Shotcrete Repair

  Description

  Structural Concrete® Gunite WP is a wet process shotcrete applied, permanent concrete repair material. Structural Concrete® Gunite WP may be used from 1/4 inch (6 mm) to full depth applications and provides a long finishing time. Structural Concrete® Gunite WP provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability.

  Advantages

  • Large volume applications
  • Long finishing time
  • Pneumatically applied
  • Low rebound
  • Versatile 1/4" (6 mm) to full depth applications
  • Very low chloride ion permeability
  • Excellent freeze/thaw resistance
  • Available in 3000 lb bulk bag packaging for large volume applications

  Uses

  • Vertical and overhead repairs
  • Repair of load bearing walls, ceilings and other structural members
  • Structural repair for industrial plants
  • Marine and hydraulic structure repair

  Documents

  • Structural Concrete Gunite WP PDS
  • Structural Concrete Gunite WP SDS

  
  

• Structural Concrete HTR

  High Early Strength Repair for High Temperature Exposure

  Description

  Structural Concrete HTR is a unique high temperature resistant concrete repair material which can be pumped or poured into place.  Structural Concrete HTR gains strength rapidly and can be exposed to 1000°F (538°C) in six hours and up to 2400°F (1316°C) after a 7-day curing procedure.

  Advantages

  • Thermal shock resistant
  • Resistant to sulfates
  • High temperature resistance
  • High early strengths
  • Coarse aggregate extension up to 100%
  • Excellent freeze/thaw resistance

  Uses

  • Areas of high temperature exposure
  • Rapid repairs during shutdown
  • Thermal cycling up to 2400°F (1316°C)
  • Coker, kiln and foundry repairs

  Documents

  • Structural Concrete HTR PDS
  • Structural Concrete HTR SDS

  
  

• Structural Concrete HTR Shotcrete

  Rapid Strength, Dry Process for High Temperature Exposure

  Description

  Structural Concrete HTR Shotcrete is a unique high temperature resistant concrete repair material which is applied by dry process shotcrete. Structural Concrete HTR Shotcrete gains strength rapidly and can be exposed to 1000°F (538°C) in three hours and up to 2400°F (1316°C) after a 7-day curing procedure.

  Advantages

  • Thermal shock resistant
  • Resistant to sulfates
  • High temperature resistance
  • Dry process shotcrete application
  • Rapid strength gain
  • Excellent freeze/thaw resistance

  Uses

  • Areas of high temperature exposure
  • Rapid repairs during shutdowns
  • Thermal cycling up to 2400°F (1316°C)
  • Coker, kiln and foundry repairs

  Documents

  • Structural Concrete HTR Shotcrete PDS (1)
  • Structural Concrete HTR Shotcrete SDS

  
  

• Structural Concrete S300

  Long Working Time Permanent Repair

  Description

  Structural Concrete® S300 is a normal setting, one component, enhanced hydraulic cement mortar used for pourable and pumpable repairs of concrete structures. Structural Concrete® S300 may be extended with coarse aggregate for large volume repairs and foundation upgrades. Structural Concrete® S300 provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor technology and very low chloride ion permeability.

  Advantages

  • Large volume repairs
  • Very low chloride ion permeability
  • Available in 3000 lb bulk bag packaging
  • One day turnaround
  • 60 minute working time
  • Pumpable
  • Coarse aggregate extension
  • Excellent freeze/thaw resistance

  Uses

  • Repair of concrete structures
  • Equipment foundations
  • Ready-mix concrete truck batching
  • Industrial floors, slabs and overlays
  • Repair of tanks, sumps and curbs
  • Structural fortifications

  Documents

  • Structural Concrete S300 PDS
  • Structural Concrete S300 SDS

  
  

• Structural Concrete Underwater HP

  Hand Applied, Rapid Strength Underwater Repair

  Description

  Five Star Marine Structural Concrete Underwater HP is a rapid strength gain, permanent concrete repair material intended for underwater application by hand or trowel. This concrete repair material allows small volume underwater hand placements with minimal washout.  It is designed for placement in tidal zones and underwater where application thickness may range from one-half inch (13 mm) to several inches in a single installation.

  Advantages

  • Rapid set underwater placement
  • Minimal washout
  • Saltwater resistant
  • Chloride and sulfate resistant
  • High three hour strength
  • Variable application thickness

  Uses

  • Underwater repair of concrete tanks, dams and hydraulic structures
  • Underwater repair of concrete piles, piers, seawalls and marine structures
  • Filling underwater concrete cavities and voids

  Documents

  • Structural Concrete Underwater HP PDS
  • Structural Concrete Underwater HP SDS

  
  

• Structural Concrete Underwater PG

  High Early Strength Pump Grade Underwater Repair

  Description

  Structural Concrete Underwater PG is a high early strength, single component, permanent concrete repair material designed for pumping underwater. This concrete repair material features excellent pumping properties and minimal washout during large volume placements underwater and is designed for placement in tidal zones and underwater. Structural Concrete® Underwater PG provides increased corrosion protection of steel reinforced structures with migrating corrosion inhibitor.

  Advantages

  • Pumpable
  • Large volume placements
  • Saltwater resistant
  • High six hour strength
  • Adjustable working time
  • Course aggregate extension
  • Variable application thickness
  • Chloride and sulfate resistant

  Uses

  • Large volume underwater concrete repairs
  • Tanks, dams, marine and hydraulic structure repairs
  • Filling underwater concrete cavities and voids

  Documents

  • Structural Concrete Underwater PG PDS
  • Structural Concrete Underwater PG SDS

  
  

• Rapid Surface Repair Easy Mix

  Five Star Rapid Surface Repair Easy Mix is a self-leveling, low viscosity, two-part liquid polyurethane-hybrid polymer.

  Description

  Five Star Rapid Surface Repair Easy Mix is a self-leveling, low viscosity, two-part liquid polyurethane-hybrid polymer. When supplemented with its proprietary blended aggregate, this product is used to repair and rehabilitate concrete and asphaltic concrete pavements. The enhanced polymer is high performance, rapid setting, and can be used to make an impact and traffic resistant polymer concrete. Within minutes of placement, durable, long-lasting repairs are able to handle vibration, heavy traffic, and thermal movement.

  Advantages

  • No priming required to bond to concrete, asphalt, steel or wood
  • Stops further corrosion of reinforcing steel
  • Traffic ready in as little as 30 minutes
  • Waterproof, chemically resistant membrane protects substrates from freeze-thaw spalling
  • Very low odour
  • Make repairs year round
  • Use neat or with aggregate

  Uses

  • Expansion joint and bridge header reconstruction 
  • Repair cracks, potholes, spalls
  • Control joint filler 
  • Resurface runways, walkways, floors, and parking lots

  Documents

  • Rapid Surface Repair Easy Mix PDS

  
  

• Centri-Cast Pipe Repair Mortar

  Five Star Centri-Cast Pipe Repair Mortar and Five Star Centri-Cast Pipe Repair Mortar w/Microban.

  Description

  Five Star Centri-Cast Pipe Repair Mortar and Five Star Centri-Cast Pipe Repair Mortar with Microban Technology are high-performance cementitious mortars designed for the trenchless renewal of underground pipes without disturbing the pipe. Both are a single component, fibre-reinforced hydraulic repair material. Five Star Centri-Cast Pipe Repair Mortars provide sealing, rehabilitation and corrosion protection of existing underground metal and concrete pipes and is a quick and economical pipe repair solution that creates a dense and highly impermeable repair coating. For added protection, Five Star Centri-Cast Pipe Repair Mortar with Microban Technology is infused with an antimicrobial agent to guard against the growth of mold and mildew.

  Advantages

  • Large volume applications 
  • Versatile 1/4 inch (6 mm) to 1 inch (25 mm) single pass applications
  • Centrifugally cast in place 
  • Fibre reinforced for crack resistance and strength
  • Infused with Microban Technology extends the useful life of repaired structures
  • Low chloride ion permeability mortar by inhibiting deterioration caused by mildew

  Uses

  • Trenchless repair of underground pipes
  • New pipe corrosion protection
  • Pipe rehabilitation, repair and protection

  Documents

  • Centri-Cast Pipe Repair Mortar PDS

  
  

• Centri-Cast Pipe Repair Mortar HS

  Five Star Centri-Cast Pipe Repair Mortar HS and Five Star Centri-Cast Pipe Repair Mortar HS w/Microban.

  Description

  Five Star Centri-Cast Pipe Repair Mortar HS and Five Star Centri-Cast Pipe Repair Mortar HS with Microban Technology are high-performance cementitious mortars designed for the trenchless renewal of underground pipes without disturbing the pipe. Both are high strength, single component, fibre-reinforced hydraulic repair materials. Five Star Centri-Cast Pipe Repair Mortar HS products provide sealing, rehabilitation and corrosion protection of existing underground metal and concrete pipes and is a quick and economical pipe repair solution that creates a dense and highly impermeable repair coating. For added protection, Five Star Centri-Cast Pipe Repair Mortar HS with Microban Technology is infused with an antimicrobial agent to guard against the growth of mold and mildew.

  Advantages

  • Large volume applications 
  • Versatile 1/4 inch (6 mm) to 1 inch (25 mm) single pass applications
  • Centrifugally cast in place 
  • Fibre reinforced for crack resistance and strength
  • Infused with Microban Technology extends the useful life of repaired structures
  • Low chloride ion permeability mortar by inhibiting deterioration caused by mildew

  Uses

  • Trenchless repair of underground pipes 
  • New pipe corrosion protection
  • Pipe rehabilitation, repair and protection

  Documents

  • Centri-Cast Pipe Repair Mortar HS PDS