Concrete pavement contractors and public agencies often choose Rapid Set® Mortar Mix Plus because its integral corrosion inhibitor protects reinforced concrete and it’s air-entrained for freeze-thaw durability. Here, Earth Structures used the very-rapid-hardening repair material to quickly eliminate washboarding in a New York City parking garage.
The U.S. military has used Rapid Set® calcium sulfoaluminate (CSA) cement-based products to quickly rebuild runways and other damaged infrastructure for almost two decades. This Concrete Mix project demonstrates the material’s speed and strength benefits in one of many airfield pavement repair applications.
When concrete pavement in a new construction project hasn’t been installed to specifications, there’s not much time to remediate the issue when the owner – in this case, a commercial real estate developer – wants to open the property on schedule. That’s where fast-setting Rapid Set® Mortar Mix Plus came in.
Appleton International Airport's two runways intersect instead of running parallel to each other, so pavement repairs require closing both at the same time -- not ideal for keeping traffic moving. As a result, fines for not reopening a nighttime repair are hefty. An award-winning Wisconsin contractor used Rapid Set® DOT Repair Mix to make sure overnight partial-depth surface and joint repairs were for traffic by 6 am.
When a tall truck took out a Texas bridge, the state DOT wanted new concrete cross beams placed within 24 hours to minimize traffic disruption. The deadline was met because Hunter Industries used Rapid Set® Concrete Mix, Rapid Set® FLOW Control, and Rapid Set® SET Control to make the 10 concrete pedestals required to support the cross beams.
A concrete plinth protects mechanical equipment from floodwater and the floor slab below by evenly distributing the equipment's weight. Here, contractor Gonzalez-De La Garza & Associates used Rapid Set® Concrete Mix, FLOW Control, and SET Control to install 4000-psi concrete pads over an existing slab as part of a boiler installation at Fort Sam Houston in San Antonio, Texas.
Potentially catastrophic structural damage was discovered in the Senate office building parking garage. Excessive loading from landscaping above ground caused water to infiltrate the garage, causing concrete spalling as well as stress on a main girder. Mortar Mix Plus, SET Control and WunderFixx were used for both interior and exterior garage repairs.
The structure’s 9'x7' cells had to be pitched at 25 degrees, from 1.25-inch down to ¼-inch. Aggressive diamond grinding was used to make the surface porous. After grading, Sure-Flex epoxy was used. Mortar Mix Plus, SET Control and FLOW Control were used.
An East Coast city used Rapid Set® DOT Concrete Mix to rehabilitate a structural component rather than replace an entire bridge. SW Construction Enterprises used several techniques to promote concrete workability in temperatures ranging from below freezing to 90 degrees Fahrenheit.
After removing the concrete around the manholes, the collars were reset to the correct elevations using Concrete Mix. SET Control was used when temperatures rose. With no delays, crews met the construction schedule.
Copings at train station were repaired to provide a safe surface for embarking/disembarking passengers. Work was performed during hot weather with temperatures reaching 95 degrees Fahrenheit. Cement All and SET Control were used.
Extensive new flooring was installed in the interior. To accommodate the flooring, Cement All was used to raise the concrete pads. SET Control was used to increase the working time, allowing more time for placement and finishing.
During the store remodel, workers had to perform extensive surface prep prior to the TRU installation. Cement All was used for the repairs and TRU Self-Leveling with integral colors were used as the polished concrete overay. The final surface was polished to an 800 grit and sealed.
Acrylic Primer, Cement All, Concrete Resurfacer, LevelFlor, SET Control and WunderFixx were used in various areas of the completed facility to mitigate standing water and create sanitary, level surfaces.
The shower drains were too flat and not draining properly. Cement All was applied after chipping around the drain to create a slope. It was chosen because of its high bond properties and ability to be applied at a thin application.
To renovate the 19,000 square-foot space with minimal interruptions to operations, the deck was divided into sections so that a portion of the pool area remained open to guests at all times. CR Concrete Resurfacer, Mortar Mix and Concrete Mix were used to make repairs. Thanks to the fast-curing Rapid Set products, delays due to rainfall were able to be made up and the project completed on time and within budget.
Mortar Mix Plus (MMP) was used to level an elevated-deck bus exit ramp. Since this was a fast-track project and MMP achieves 3,500 psi in 3 hours, the contractor was able to meet the deadline.
The Colorado Tower opened as Austin, Texas’ first high rise in 10 years. In the construction of the 2 outdoor patios Rapid Set Cement All and Mortar Mix was used to meet the specifications that called for high-bond and early strength upon the waterproofing membrane.
The runway lights on the airfield needed to be replaced, and spec requirements required a product that would be close to 5,000 psi in a 24-48 hours. After Concrete Mix with Flow Control and Set Control showed 7,900 psi in 24 hours, the material was used in the replacement of 26 lights. By using two bags at a time, the project schedule dropped from two months down to three weeks.
Cement All was used to patch the substrate before performing surface prep. To prevent pinholes and create a strong adhesive grip for the topping, TXP Fast Epoxy Primer was used. TRU Self-Leveling with integral coloring was used as the topping. To make sure the TRU did not set too fast in the heat, SET Control was added to the mix.
Concrete Mix was used to level the seven concrete pads inside this airport's electrical and mechanical rooms. SET Control was used to extend the working time due to the hot temperature setting time and FLOW Control was used to enhance the flow consistency.
Tri-State Underlayments/Franz Floors only had four days to restore 1,200 sq ft of the existing flooring before interior framing began. For this reason, the contractor chose to use Rapid Set cement products to install the flooring, because they set quickly to produce 3,000 psi in one hour and full strength of 8,000 psi in one day. Products used include Concrete Mix, FLOW Control, SET Control, TXP Primer, TRU Self-Leveling.
The January 17, 1994, Northridge 6.6 earthquake did immense damage to many of the region’s vital traffic arteries. One serious disruption was the closing of the I-10 Santa Monica freeway due to the collapse of two bridges. The 1-10 is the busiest freeway in the nation. C.C. Myers completely rebuilt the two bridges 74 days ahead of schedule and received a $14.5 million bonus. Products used include Rapic Set Cement, Rapid Set Flowable Fill, and SET Control.
The historic restoration project includes converting the 1915 concrete-and-brick office building into 300 apartments, 10,000 square feet of retail space, and a 500-space parking garage. Products used include Mortar Mix, V/O Repair Mix, and WunderFixx.
Five international projects show how construction products play a supporting role in industries where new technology rollouts, tight timelines, and sustainable design are the new normal. Products used include Cement All, Concrete Mix, Rapid Set Cement, SET Control, and TRU Self-Leveling.