Guide to Basic Floor Repairs with Metzger/McGuire Products

Metzger/McGuire makes industrial concrete floor repair and maintenance products that have set the standard in the industry for over 40 years.

Timely concrete floor repairs are essential to maintaining the seamless production schedules required in industrial and commercial businesses. Even a small crack or surface defect can create a hazardous situation, especially in locations where forklifts or other transport vehicles frequently operate. Metzger/McGuire is dedicated to protecting your clients’ concrete floors, and in turn their most valued assets, with products that will repair cracks, spalls, gouges, missed saw cuts, joint deterioration and pop-outs.

Guide to Basic Floor Repairs

We carry a full line of Metzger/McGuire Rapid Refloor and Spal-Pro floor joint materials, as well as Armor-Hard and MM 80. These polymer fillers are designed for use on industrial or retail concrete floors to repair cracks, surface spalls and pop-outs, as well as other defects that happen over time on concrete surfaces. This basic guide to floor repairs is a comprehensive checklist of general floor defects coupled with the proper Metzger/McGuire solutions and the tools required to get the job done right. Take a look:

Metzger McGuire Guide to Basic Floor Repair Poster

4 Critical Steps for Permanent, Durable Floor Repairs

In addition, Metzger/McGuire offers this advice for floor contractors:

  1. Determine the Causes of Floor Deterioration – Identify the underlying causes of floor defects before you begin repairing them, to determine the best long-term repair strategy. For example, if joint spalling is the result of an improper joint filler installation such as low filler profile or poor joint cleaning prior to filling, the wrong joint filler (urethane that is too soft to support traffic, or no joint filler at all), it’s an issue with the material. Joint spalling could also result from differing slab elevations, called slab curl or rocking slab conditions, which are structural problems that need to be corrected prior to performing standard joint repair.
  1. Select Appropriate Floor Repair Materials – Choose the repair materials best suited to meet the requirements of your facility’s operations. Considerations may include frequency of traffic, vehicle loading and types, building temperature, time allowed to perform repairs, defect width, etc. For example, the repair material best suited for a spalled joint may be heavy-duty, semi-rigid epoxy or polyurea, or a structural epoxy mortar. This depends upon:

a) the width of the spalled joint with wider exposures, requiring more rigid products

b) the cure time required

c) the current structural condition of the floor

d) the location of the defect, such as a freezer/cooler (polyurea is likely best, in this scenario)

  1. Prepare Defect for Repair Material – Failure to properly clean and prepare a floor defect is the number one cause of unsuccessful floor repair projects. The key to achieving long-lasting repairs is making sure the edges of the defect are defined and the defect is cleaned properly prior to filling with repair material. Even the best possible repair material will not function properly if it’s placed into a poorly cleaned joint or crack, or if the repair material is “feather-edged” along the outside of the defect. The edges of joints, cracks, and surface spalls all should be at least 1/2” deep vertically, and clean and dry prior to filling, to ensure the long-term durability and structural stability of any repair.

Finished Repair Should Be Flush with Floor – Simply filling a defect “even” with material generally results in a finished profile that is concave or dished, as repair materials typically settle a bit during cure. The goal in any floor defect repair is to restore a smooth, continuous transition across the floor surface. To achieve a flush profile, repair materials should be placed slightly higher than the floor and be allowed to cure, then shaved or ground flush with the surface. The finished profile of any repair should be “flush” with the floor’s surface.

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How to Properly Prep Your Concrete Floor with a Shaver

Shaving concrete is a precise preparation method for the quick removal of a thin layer of concrete or concrete coating from the surface of contaminated floors, ceilings and walls. A reliable process for commercial, industrial and decommissioning contractors, shaving removes material at a uniform depth with one pass of the equipment, leaving a polished surface.

Concrete shaving is most valuable for a variety of floor applications:

  • Leveling floors that have curled at the joints
  • Removing existing or concrete floor toppings without causing surface damage
  • Removing accumulated layers of existing concrete floor coatings

Shaving versus Scabbling

When applied under the correct conditions, shaving is typically a more efficient preparation method than scabbling, which uses a chipping and hammering machine that can remove more material than necessary. This in turn can produce much more dust and secondary waste that needs to be controlled and contained at the job site.

The CONTEC CT320 Shaver

If you need to shave concrete, asphalt or steel floors, the CONTEC CT320 concrete floor shaver is the largest and most aggressive floor shaver on the market today. It’s made for the absolute toughest applications and floors and used to shave, mill, scarify or plane horizontal, dry floors with or without a coating. Precision aligned, heavy-duty bearings ensure low maintenance and trouble-free operation. The CONTEC CT320 is used in conjunction with:

  • a diamond cutting drum
  • carbide tipped cutters capable of scabbling, planing and grooving for a textured look to concrete
  • a milling drum with carbide-tipped cutters to strip away thermoplastic road or runway markings

See How the CT320 Operates

In this instructional video, Runyon Surface Prep’s tech support rep Dan Knuth shows you:

  • how to wire the phase-sensitive power controls correctly
  • how to use the manual soft-start procedure for turning on the machine
  • how to hook up and use the vacuum hose ports
  • how to engage the transport mode and cutting mode
  • how to set and stabilize the cut depth
  • how to drop the drum blades for cutting
  • how to turn the machine back and forth in a left-right direction
  • how to cut a straight line
  • how to set the self-propelled machine in the forward and reverse direction
  • how to use the potentiometer to remove concrete
  • how and when the diamond drum is set to level

Easy Operation Tips

  • After mounting the appropriate tools, the operation of the shaver can begin.
  • Never switch the motor of the shaver on while the tools still touch the floor.
  • The lever of the height adjustment has to be in the upper position and the hand wheel of the height adjustment must be turned anti-clockwise as far as possible before the shaver is switched on.
  • Always lift the shaver and the tools clear from the floor and then switch the motor on.
  • Switch the motor on before lowering the shaver with the lever to the operating position.
  • Turn the hand wheel of the height adjustment until the tools are lowered to the
  • floor and until you achieve the required finish.
  • Lowering the tools too much decreases the performance of the shaver, destroying the shafts in the drum and the bearings of the machine.
  • Heavy dust can be avoided by connecting a dust collector to the dust port.
  • The vibration damped handle bar ensures an easier operation.