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Shaking concrete foundations are
common in many heavy industrial settings, including paper warehouses,
steel manufacturing, and other heavy-weight or high-traffic
applications.
The vibration is most often
caused by moving equipment crossing expansion joints that are cut into
the concrete when it is poured. Cement contractors cut these expansion
joints in the floor to allow for the shrinkage that occurs during curing
of the concrete slabs. The joints also help prevent cracks when the
concrete expands and contracts due to changes in temperature. However,
expansion joints can sometimes be more of a problem than a solution.
Sidewalks, bridges, and highways may also expand and contract to a
considerable degree. Most climate-controlled modern buildings, however,
have only minor temperature variations within a 10 to 15 degree range.
Flexible caulks used in expansion joints help make a transition between
the slabs yet allow for movement. Unfortunately, if movement is frequent
or extensive, it can become a costly problem.
A better solution is to use epoxy with 100 percent solids and color
quartz to fill in the joints. The epoxy-quartz filler makes the rut
between slabs level and eliminates the vibration, wear, and structural
damage that can be caused by moving equipment. The quartz-epoxy
combination has been proven to withstand test strengths of 22,000 psi.
The first step is to set a masonry blade on a Skilsaw at 1/4 to 1/2
inches and run it down the expansion joint on both sides to clean them.
Flexible chalk will ooze out of the joint during this operation. Once
the joint has been cleaned, color quartz is poured into the joint until
it is slightly lower than the surface of the floor. Clear or colored 100
percent solids epoxy is then poured over the joint until it saturates
the quartz and rises level with the floor. About twelve hours later the
joint should be inspected and topped off.
These joints often have openings at the bottom and some epoxy may leak
through them. The color quartz will remain and prevent leakage on the
second application. It is important to return to the floor about ten to
twelve hours later to scrape off any excess epoxy. Too long a wait and
the epoxy will be too hard to shave; too little setup time and the epoxy
will be tacky. A 4-inch razor scraper with a long handle is used. Each
side of the joint guides the scraper. The result is an even, smooth
filling over the joint. If this process is done well, floor life will be
extended, the need for repairs will decrease, and the rolling equipment
may never notice the joints again.
Filling deep holes and repairing badly eroded floors can be done less
expensively by using color quartz, a filler, and a wear inhibitor.
Mixing 100 percent solids epoxy with color quartz to 28 pounds per
gallon gives a trowel mix with the consistency of peanut butter. This
mix can be put into holes using a trowel or putty knife. Small vertical
holes are best filled by hand, using a heavy rubber glove and rubbing
the mixture in.
Durall Industrial Flooring of Minneapolis, a coating company, has taken
the lead in joint repair. Durall is the only industrial flooring
manufacturer that also makes over 500 specialty cleaners. This allows
them to make special preparations, cleaners, and application systems to
ensure optimum wear results and flooring adhesion.
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