We bring this series home with Part 3 which provides some DIY help & tips on using Carbon Fiber to repair concrete.
Initial DIY Repair (Cracked Concrete)
One easier project one may consider in their own home as a test would be a slightly cracked floor repair, maybe outside on the porch or in a shop type of environment. Failure isn’t going to mean catastrophic consequences of an entire building. As one becomes more comfortable with the idea, structural repairs may be within reach.
For repairing a cracked floor, use the above concepts and follow below as a guide to complete a staple repair for cracked concrete.
Clean the immediate area and drape a cloth around the areas needed that will mitigate later clean up.
Using an angle grinder with a bit made for cutting or grinding concrete will suffice. Grind away rigid hard edges of the cracks, smoothing all surfaces on the concrete substrate.
Acquire carbon staple assembly and place it as close to the beginning of the crack as possible. Center the staple perpendicular to the crack. Draw the outline of the staple(s) with a sharpie or other marking material. Follow the crack another 8-12” and repeat the outline perpendicular to the crack. Do this for the entire length of the crack.
Using a grinder or other means of cutting away concrete in a straight manner, cut the traced marking to the depth of the carbon fiber staple. Ensure this is done to its full extent for the staples to go in completely and there is not a raise in the floor afterwards. Once the lines are cut, drill a hole to the size of each staple end, (2) per staple. It is highly encouraged to use masonry bits as if you do not, this will be an endless job. The staple will need to fit completely inside the cut away concrete.
Once complete vacuum the entire area, ensuring there is no dust or FOD present within the immediate area. Remember, cleanliness in the next steps is critical to achieving a good bond between the epoxy, the staples, and the concrete.
After ensuring the staples will fit into the holes adequately, fill each cut and drilled hole(s) with an epoxy paste. As they are filled, apply the carbon staples. Once all holes are filled with staples, apply another layer of paste over each staple until it is even with the existing concrete surface. Using a scraper removes any excess epoxy, any excess could be used for the next hole.
Once the epoxy has fully cured, any excess may be removed by grinding. As an option, one may choose to paint over this repaired area. We are unsure why one would hide such a masterful piece of repair art, but it is not our repair either, we’re just here to help.