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Eversafe were engaged by Betta Built Group to undertake floor repairs to the 11,500m2 facility in Ingleburn. The site has been untenanted for over 12 months and the owners wanted to do some repair works to the site. During the inspection the floor had lots of cracking to the surface and broken edges of the slabs expansion joints. This is mainly caused by movement of the slab and the reinforcement being too close to the surface.

Upon establishing site we started by saw cutting around the broken edges of the concrete slabs which had broken, this is to allow a clean edge and to not feather out the repair material which reduces its strength. Once the edges were saw cut the loose substrate was jack hammered to remove loose substrate to a clean joint was achieved. The joints were then swept clean of all big materials before vacuuming the entire surface till dust and debris free

The expansion joints are now ready for repairing, the best type of material to use for these repairs is an epoxy mortar as it bonds to the surface and has a high strength resistant to impact and movement.

Once the mixing area was established and safety equipment worn by applicants fitted, the joints were “primed” with an epoxy resin mixture to ‘WET” the surface prior to installation of repair materials. This allows penetration into the substrate and a wet surface for the new material to bond to. The materials are then mixed together in a batching mixer where the sand/aggregate fillers are added first before adding the pre mixed epoxy material. This is then allowed to mix thoroughly for approximately 2 minutes then dispatched for installation.

The material is then placed into the repair and trowelled off to remove any air pockets and to create a solid filling material, the tools are primed with a solvent material so as to not stick to the trowel and to “close off” the grainy nature of the repair. Any surrounding areas should be scraped clean as the material will adhere to the surface and requiring scraping or mechanical removal

Once the Epoxy repair material has cured in 72 hours the joints are re saw cut to allow movement between the slabs without cracking the repair. A 3-5mm saw cut is sufficient

Now the main repairs were completed the surface cracking throughout the site was to be repaired. This required vacuuming the cracks to remove any debris and loose materials till clean and ready for repairing. The cracks are occurring due to rocking of the slabs due to substrate underneath moving overtime creating voids which makes the slabs rock. By installing the epoxy repair material we bind the surface back together and stop further cracking and degradation of the surface.

The cracks were then filled to level with an epoxy repair paste which bonds to the surface and removed the trip hazards to ensure OHS compliant surface. Maintaining a safe and trip free surface is paramount for any business and their employees.