Rapid Concrete Repairs that keep you running

Who It’s For

This session is useful for:

• Plant Manager

• Facilities Manager

• Maintenance Manager

• Maintenance Supervisor

• Reliability Manager

• Engineering Manager

• Plant Engineer

• Project Manager

• Capital Projects Manager

• Construction Manager

• Operations Manager

• Operations Director

• Director of Facilities

• Director of Maintenance

• Industrial Facilities Manager

• Manufacturing Manager

• Production Manager

• EHS Manager

• Safety Manager

• Warehouse Manager

Today, we’ll discuss rapid concrete repairs that help keep your operations running. Our guest speaker is Doug Klingensmith, Vice President of Sales and Marketing at Unconventional Solutions. In his day-to-day role, Doug works directly with clients to solve complex issues involving corrosion, erosion, abrasion, chemical attack, and metal repairs. He is passionate about helping customers repair equipment instead of replacing it, avoid unplanned downtime, and return to service as quickly as possible.

Thank you for the kind introduction, Chris.

Having worked in this industry since 1995, I was once told by a wise contractor that there are only two types of concrete: concrete that has cracked and concrete that’s going to crack. Concrete simply doesn’t hold up well against rock salt and de-icing chemicals.

Today, we’ll discuss concrete repairs and the cost of downtime. Traditional concrete typically becomes firm within 4–12 hours, can withstand rain after 24 hours, and is ready for foot traffic within 3–7 days. However, standing water can wash out the surface, so puddling must be avoided.

Concrete requires approximately 28 days to reach its full design strength and stop releasing moisture. Protective coatings should not be applied until the concrete has cured for roughly 28–30 days. Applying a coating too early can trap moisture and cause it to peel.

At Unconventional Solutions, we use non-cementitious repair materials for damaged concrete, particularly in chemical containment areas and heavy industrial flooring applications. For example, our 570 XF patch repair is ready for foot traffic in just two hours and can handle heavy loads within four to five hours. It can also receive a chemical-resistant lining immediately after installation.

Some of you have asked about DuraMar MagCrete. Traditional concrete typically reaches compressive strengths of 2,800–4,000 PSI, while DuraMar MagCrete can reach 5,000 PSI in just one hour under normal temperatures.

Here’s a great example of when a non-cementitious epoxy repair compound makes more sense than traditional concrete. These steps at one of our military academies were in very poor condition, and graduation was only 28–30 days away. Removing the existing concrete with a jackhammer and repouring it would have been nearly impossible.

The contractor used Resimac 576XF and Resimac 71LW, but then lost 15 days of work due to rain. That left only 15 days or less to complete the project. As you can see, the finished repair turned out beautifully. A UV-stable epoxy coating was then applied to blend the repair into the surrounding surface, and the steps were ready in time for graduation.

We typically recommend four or five products for concrete patching that can restore service in hours instead of days. The 570XF comes in convenient small kits and reaches a compressive strength of 12,000 PSI—three to four times stronger than most traditional concrete.

During a dolly pull adhesion test, the surrounding concrete fails before the epoxy bond does. Unlike some products available at hardware stores that may last only one or two seasons, these epoxy systems are designed for long-term performance, including freeze-thaw conditions.

The 576 Quartz Screed and 577 Chem Screed are especially durable because we first apply a penetrating tack primer that creates a tenacious bond with the concrete. Within 48 hours, the 576 Quartz Screed, 577 Chem Screed, and DuraMar MagCrete can reach approximately 12,500 PSI in compressive strength.

DuraMar MagCrete is also ideal for cold-weather applications, including temperatures below freezing—down to -15°F. For steel mill environments, where molten steel may reach concrete temperatures of 1,000–1,500°F, DuraMar MagCrete can withstand temperatures up to 2,000°F.

Here’s another example from a Marathon loading facility near Catlettsburg Refinery. Because shutting down the loading and unloading docks for weeks wasn’t an option, repairs were completed over the weekend—starting around 3 p.m. Friday and finishing by 4 p.m. Sunday—so the facility could be back in service Monday morning. A chemical-resistant coating was then applied over the repair.

For comparison, standard concrete typically has a compressive strength of 3,000–4,000 PSI, while some high-strength products may reach 5,000–6,000 PSI. Our materials offer significantly higher performance:

• 571 Lightweight: Can be troweled vertically up to 2–3 inches thick without forms.
• DuraMar MagCrete: Up to 11,500 PSI.
• 570XF: Up to 12,000 PSI.
• 576 Quartz Screed: Up to 12,500 PSI.
• 577 Chem Screed: Similar strength to the 576, with the added benefit of being a novolac epoxy repair mortar.

The 577 Chem Screed provides excellent chemical resistance, withstanding hydrochloric acid concentrations of approximately 34–36% and sulfuric acid spills ranging from 93% to as high as 98%. It’s an ideal choice for repairs exposed to aggressive chemicals.

The 571 Lightweight is especially useful for applications like transformer stations, where concrete supports may have extensive damage and large sections of concrete are missing.

Remove all loose and deteriorated concrete before beginning the repair. The 571’s adhesive strength is greater than that of the surrounding concrete, so the weak concrete must be eliminated first.

In this example, the finished repair looks excellent. The team used our white 550 roofing membrane for waterproofing, though the white 555 can also be used for waterproofing repaired areas.

It’s important to remember that we offer multiple concrete repair solutions—not just one product. Chris has highlighted our five primary materials:

• 570XF: Best for smaller repairs, such as trip hazards, slips, and falls. These incidents are among OSHA’s most commonly reported workplace injuries and can cost companies approximately $22,000–$23,000 per incident.
• 571LW: Designed for lightweight repairs on vertical, overhead, and suspended surfaces.
• 576 Quartz Screed: Our workhorse for large areas of damaged concrete. It can be screeded over existing concrete and is used with our 503 tack primer. The 503 can also help dustproof newer concrete.
• 505 Damp: A damp-bonding concrete dustproofing material and primer for wet concrete surfaces.
• 577 Chem Screed: Designed for areas exposed to aggressive acids and caustic chemicals. The 576 can also be used in these environments, but it requires an additional chemical-resistant coating. The 577 provides chemical resistance in a single application, helping facilities return to service faster.
• DuraMar MagCrete: Developed to meet specific performance requirements, including application in temperatures as low as -15°F and resistance to temperatures up to 2,000°F.

Here’s another example from a wastewater treatment plant in Kalamazoo, completed around 2001 or 2002. According to the maintenance manager, the finished repair has performed extremely well.

We also repaired steps at one of our first warehouses in 2005, and as of 2026, they still have no cracks. These materials are designed for long-term repairs—not temporary fixes.

The 576 can also be used for grouting and aisle repairs, with overnight forklift traffic typically allowed after about 24 hours. The 577 is the ideal choice for acid-resistant applications, while DuraMar MagCrete offers additional versatility for demanding environments.

Expansion joints should be properly chipped and prepared before the next shift. However, 570XF should not be used to fill expansion joints; it is designed for quickly repairing damaged concrete.

One of our early projects was completed at Fermi Nuclear Power Plant, where the cooling tower walls were in extremely poor condition. The facility purchased approximately $40,000 worth of 571 Lightweight material for the repairs and was extremely satisfied with the results.

These products provide a faster way to restore damaged concrete and return areas to service. Traditional concrete reaches only about 40% of its strength after three days and approximately 70% after seven to eight days. By comparison, these repair materials can often be ready for full use in hours or days—not weeks.

QUESTIONS:

Q: What is the biggest mistake an applicator can make when a plant needs an area back in service the same day—one that could prevent them from achieving the promised rapid return-to-service time?

A: The biggest mistake is failing to properly remove the damaged concrete. Applicators should use a hammer to identify hollow areas and chip out anything that sounds loose or compromised. Even if the surface looks sound, hollow concrete often indicates deterioration underneath.A second common mistake is underestimating the amount of material needed or using the wrong application tools. Proper surface preparation, accurate material calculations, and the right equipment are essential for achieving fast return-to-service times.

Q: When evaluating a concrete repair, what key factors help determine whether to repair the existing concrete or remove and replace it entirely?

A: In most cases, I recommend repairing the existing concrete rather than removing and replacing it. Full replacement only makes sense when speed isn’t a priority and the facility can afford to lose a loading dock or manufacturing area for several weeks.

For exterior concrete, replacement may also face the same long-term damage from de-icing chemicals used during winter. When minimizing downtime matters, a properly prepared repair is usually the better solution.

Q. Are these products UV-stable on their own, or do they require a protective topcoat?

A. I wouldn’t describe these products as fully UV-stable, but they do offer good UV resistance. For example, the repair we completed at our former warehouse in Milford, Michigan, showed no discoloration. The primer may yellow over time when used alone, but that doesn’t necessarily mean it’s breaking down.

According to AMP, epoxies may lose approximately 0.5 to 1 mil per year from UV exposure. However, because these products are applied at a much greater thickness, UV exposure typically has little practical impact.

If you have any more questions, we’ll be sending out a survey to everyone who attended to ensure we’re providing maximum value with these discussions. You can also reach out to us at 248-735-7000 or via email at office@usigroups.com.