specialty
Concrete Repair & Restoration
Structural repairs, spall correction, and concrete restoration services
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Serving Johnson County
Concrete repair and restoration services address deterioration, damage, and structural deficiencies in existing commercial concrete throughout Cleburne and Johnson County, TX. From minor cosmetic repairs to major structural rehabilitation, professional concrete repair extends service life, restores functionality, improves safety, and preserves property value without the expense and disruption of complete replacement. Commercial properties including warehouses, retail buildings, parking structures, and manufacturing facilities benefit from proactive repair programs preventing minor issues from escalating into major failures requiring costly emergency interventions.
Concrete deterioration in North Texas results from multiple causes: freeze-thaw damage from winter temperature cycling, chemical attack from deicing salts or industrial processes, reinforcement corrosion from moisture and chloride infiltration, impact damage from forklift traffic or loading dock operations, settlement or heaving from Johnson County's expansive clay soils, and surface wear from abrasion, traffic, and environmental exposure. Professional repair requires accurate diagnosis identifying root causes rather than merely treating symptoms, ensuring repairs address underlying problems for durable, long-lasting restoration.
Common commercial concrete repairs include spall repair using polymer-modified mortars or epoxy compounds restoring deteriorated surfaces, crack repair through epoxy or polyurethane injection stabilizing and waterproofing structural cracks, joint repair replacing damaged sealants or restoring deteriorated joint edges, surface restoration grinding away damaged concrete and applying overlays or coatings, structural rehabilitation using carbon fiber reinforcement or post-installed anchors strengthening deficient elements, and foundation repairs addressing settlement, heaving, or structural movement through underpinning, grouting, or replacement.
Our concrete repair and restoration services encompass comprehensive condition assessment identifying damage extent and root causes, engineering analysis for structural repairs ensuring compliance with building codes, surface preparation using mechanical methods exposing sound concrete for repair bonding, precision repair material selection matching properties to specific applications and exposures, skilled repair execution following manufacturer specifications and industry standards, and long-term monitoring and maintenance planning preventing future deterioration. Whether you're addressing cosmetic damage in retail spaces, repairing structural elements in warehouses, or implementing comprehensive restoration programs for aging facilities, professional concrete repair expertise preserves investments while ensuring safety and functionality for Johnson County commercial properties.
Common Applications
Warehouse Floor Repairs
Distribution and warehouse facilities throughout Johnson County require periodic floor repairs addressing joint deterioration from forklift traffic, surface spalling and scaling from freeze-thaw damage or wear, random cracks from shrinkage or soil movement, and settlement creating trip hazards or flatness issues affecting racking. Repairs use epoxy mortars for durability, polyurethane joint sealants for flexibility, and slab jacking for settlement correction. Extensive damage may warrant floor overlays or complete sections replacement. Proactive repair programs scheduled during slow periods minimize disruption to warehouse operations while preventing minor issues from escalating into major failures affecting material handling equipment and worker safety.
Loading Dock Restoration
Loading docks experience severe concrete deterioration from repeated trailer impacts, forklift traffic, and moisture exposure from weather and trailer refrigeration. Common repairs include spall repair on dock faces and edges using polymer-modified mortars, crack repair addressing settlement or impact damage, joint sealing preventing moisture infiltration, and edge protection using steel angles preventing future damage. Complete dock replacement costs $50,000-100,000+ for typical facilities, while comprehensive repair programs extend dock life 10-15 years at fraction of replacement cost. Repairs coordinate with warehouse operations, often occurring during weekend shutdowns minimizing impacts to shipping and receiving operations critical for distribution facilities.
Parking Structure Rehabilitation
Multi-level parking structures in Cleburne require ongoing maintenance addressing reinforcement corrosion from water infiltration and deicing salts, concrete spalling from freeze-thaw damage, cracking from structural movement or restraint, and joint deterioration allowing moisture penetration. Rehabilitation programs include comprehensive condition assessment using core sampling and corrosion surveys, structural repairs using epoxy injection and concrete replacement, traffic deck overlays providing waterproofing and wearing surfaces, expansion joint replacement, and application of penetrating sealers protecting against chloride ingress. Multi-year rehabilitation programs address deficiencies systematically while maintaining parking availability and controlling costs through phased implementation rather than catastrophic emergency repairs.
Retail Building Repairs
Retail buildings throughout Johnson County require concrete repairs maintaining customer safety and property aesthetics. Common issues include sidewalk trip hazards from settlement or curling requiring grinding or replacement, facade deterioration from weather exposure needing spall repair and protective coatings, parking lot cracking and joint failures addressed through routing and sealing, and foundation settlement creating door and window operation problems requiring underpinning or slabjacking. Repairs prioritize customer safety and visual appearance as deteriorated concrete creates negative impressions affecting retail success. Work is scheduled minimizing customer disruption, often occurring overnight or during slow business hours maintaining continuous operations essential for retail tenants.
Technical Specifications
Epoxy Crack Injection
Epoxy injection repairs structural cracks by bonding crack faces restoring monolithic concrete integrity. Low-viscosity epoxies (under 200 cps) penetrate narrow cracks (down to 0.002 inches) under 20-100 PSI injection pressure. Surface ports are installed along crack length at 6-12 inch spacing, crack faces are sealed preventing epoxy escape, and injection proceeds from lowest port working upward until epoxy appears at next port. Properly injected cracks achieve tensile strength exceeding virgin concrete. Epoxy injection is permanent but requires dry conditions: wet cracks use polyurethane injection. Materials must meet ASTM C881 specifications for epoxy concrete repair.
Concrete Spall Repair
Spall repair involves removing deteriorated concrete, preparing surfaces, and installing repair materials bonding to substrate while matching existing concrete properties. Spalls are saw-cut to square edges (minimum 1-inch depth) preventing feathered edges that fail quickly. Surfaces are sandblasted or pressure-washed achieving concrete surface profile (CSP) of 3-5 per ICRI standards. Bonding agents (epoxy or latex-modified) are applied just before repair material placement. Repair materials include polymer-modified concrete, epoxy mortars, or rapid-set cements selected based on exposure and traffic conditions. Proper repairs achieve bond strengths exceeding 200 PSI per ASTM C882.
Slabjacking / Mudjacking
Slabjacking lifts settled concrete slabs by pumping grout beneath slabs through 1.5-2 inch diameter holes drilled at strategic locations. Traditional mudjacking uses cement-based grout (soil-cement mixtures) pumped under 100+ PSI pressure filling voids and hydraulically lifting slabs. Polyurethane foam injection uses expanding foam providing similar lifting with lighter weight (important for Johnson County soils), faster curing (15-30 minutes versus 24 hours), and higher strength-to-weight ratios. Lifting is controlled monitoring slab elevation, with typical lifts of 1-4 inches achievable. Post-injection, holes are patched with concrete or epoxy mortars matching slab surface.
Carbon Fiber Reinforcement
Carbon fiber-reinforced polymer (CFRP) systems strengthen concrete beams, columns, and slabs through external bonding of high-strength carbon fibers in epoxy matrices. Applications include flexural strengthening of under-reinforced beams, shear strengthening, column confinement, and slab reinforcement. Carbon fiber fabrics or pre-cured laminates are bonded to prepared concrete surfaces using structural epoxies, developing bond strengths exceeding concrete tensile strength. CFRP provides tensile strength 5-10 times steel at fraction of weight, won't corrode, and installs with minimal disruption to operations. Design requires engineering analysis per ACI 440 guidelines ensuring strengthened elements achieve code compliance.
Rapid-Set Repair Materials
Fast-track repairs use rapid-setting materials achieving service loads in 1-4 hours versus 7-28 days for conventional concrete repairs. Materials include magnesium phosphate cements, calcium aluminate cements, and proprietary polymer-modified rapid-set products. These materials achieve 3,000-4,000 PSI in 3-4 hours, allowing repairs in occupied facilities with minimal downtime. Applications include loading dock repairs, floor spall repair, and emergency structural repairs. Trade-offs include higher material costs, shorter working times requiring skilled crews, and potential shrinkage requiring proper mix design and placement techniques. All rapid-set repairs must meet ASTM C928 for rapid-hardening cementitious materials.
Surface Preparation Standards
Proper surface preparation is critical for durable repairs. ICRI (International Concrete Repair Institute) defines Concrete Surface Profiles (CSP) from 1 (nearly smooth) to 10 (very rough) achieved through different preparation methods. Most repairs require CSP 3-5 providing adequate mechanical interlock for bonding. Preparation methods include sandblasting, scarifying, shotblasting, and water jetting, selected based on required profile and site constraints. Surfaces must be clean (free of laitance, dirt, oil, and loose material), sound (deteriorated concrete fully removed), dry (unless using wet-compatible materials), and properly profiled. Pull-off testing per ASTM C1583 verifies adequate bond strength before full-scale repair material application.
Quality Control Testing
Repair projects incorporate comprehensive quality control ensuring materials and workmanship meet specifications. Testing includes compressive strength cylinders from repair materials documenting adequate strength gain, bond testing using pull-off tests verifying adequate adhesion (typically 200+ PSI minimum), chloride testing for reinforcement corrosion assessment, and half-cell potential surveys mapping corrosion activity. For epoxy injection, cores are drilled through repaired cracks verifying complete epoxy penetration and crack bonding. Visual inspection documents proper surface preparation, material placement, and curing procedures. All testing results are documented and submitted to building officials for permitted structural repairs.
Project Timeline
Condition Assessment
Comprehensive inspection documents damage extent, identifies root causes, and establishes repair priorities. Assessment includes visual examination, measurement of crack widths and spall dimensions, concrete coring for strength testing, reinforcement corrosion surveys (if applicable), and photography documenting existing conditions. For structural repairs, licensed professional engineers evaluate damage and determine repair methods ensuring code compliance. Assessment culminates in detailed repair specifications and cost estimates.
1-3 days for typical commercial building
Engineering & Permitting (if required)
Structural repairs require engineering analysis and stamped repair designs. Engineers evaluate damage, perform structural calculations, specify repair methods and materials, and prepare drawings for permit submittals. Building permits are obtained from Cleburne Building Inspections, with plan review occurring before construction approval. Third-party special inspection may be required for structural repairs. Non-structural cosmetic repairs typically proceed without permits or engineering.
2-4 weeks for structural repair engineering and permitting
Site Preparation & Protection
Establish work zones using barricades and signage protecting workers and public. Cover or protect adjacent finishes, equipment, and materials from dust and debris. Install dust control measures for interior work. For occupied buildings, coordinate work schedules minimizing disruption to operations. Temporary shoring may be required for structural repairs removing load-bearing concrete. Establish quality control procedures and material testing protocols.
1-2 days
Demolition & Surface Preparation
Remove deteriorated concrete using pneumatic chipping hammers, scarifiers, or sawcutting exposing sound substrate for repair bonding. For spall repairs, saw-cut square edges around damaged areas preventing feathered edges that fail quickly. Expose reinforcing steel (if corroded) and clean using wire brushing or sandblasting. Clean prepared surfaces using pressure washing, sandblasting, or vacuum removing laitance, dirt, and loose material. Surfaces must be clean, sound, and properly profiled for repair material adhesion.
2-5 days depending on damage extent
Repair Material Application
Apply bonding agents promoting adhesion between existing concrete and repair materials. For crack repairs, inject epoxy or polyurethane under pressure filling voids and bonding crack faces. For spall repairs, place polymer-modified mortars, epoxy mortars, or concrete repair materials matching existing properties. For structural repairs, install carbon fiber reinforcement, steel plates, or post-installed anchors per engineering specifications. All materials are placed per manufacturer procedures ensuring proper consolidation, thickness, and curing.
3-7 days depending on repair scope
Finishing & Curing
Finish repair surfaces matching existing texture and appearance. Smooth surfaces receive trowel finishing, exposed surfaces may receive broom finish or other texture, and decorative areas are matched to surrounding appearance. Apply curing compounds or wet-curing methods ensuring repair materials achieve design properties. Protect repairs from traffic, weather, and damage during curing. For fast-track repairs, rapid-setting materials achieve service loads in hours rather than days.
Concurrent with placement plus 3-7 day cure
Inspection & Approval
Final inspection by Cleburne Building Inspections (for permitted work) verifies repairs comply with approved plans and building codes. Third-party special inspectors document structural repair quality. Material testing confirms strength and adhesion meet specifications. Owner walk-through identifies any punch-list items requiring attention. For occupied buildings, areas are cleaned and returned to service minimizing downtime.
1-2 days for inspection and final cleanup
Cleburne & Johnson County Considerations
Expansive Soil Related Damage: Many concrete repair needs in Johnson County stem from expansive clay soil movements causing foundation settlement, floor slab cracking, and structural distress in buildings and parking lots. Effective repair requires addressing underlying soil problems, improving drainage directing water away from structures, installing root barriers preventing tree roots from drying soils beneath foundations, or implementing soil stabilization using lime treatment or moisture barriers. Repairing visible damage without addressing soil causes provides only temporary relief as movements continue stressing repairs. For severe cases, foundation underpinning using helical piers or push piers transfers loads to competent soils below active zone, preventing future movement. Geotechnical consultation helps determine appropriate soil remediation before concrete repair proceeds.
Freeze-Thaw Damage Prevention: Cleburne's winter freeze-thaw cycles cause progressive concrete deterioration particularly in parking lots, sidewalks, and other exposed horizontal surfaces where water ponds and saturates concrete. Repairs incorporate air-entrained concrete (4-7% entrained air) providing microscopic voids allowing frozen water to expand without damaging concrete. Surface sealers (silanes or siloxanes) reduce water absorption while allowing water vapor escape. Proper drainage eliminating ponding prevents saturation triggering freeze-thaw damage. For existing deteriorated concrete, repairs use polymer-modified materials with enhanced freeze-thaw resistance superior to standard concrete. Annual resealing of horizontal surfaces extends life and reduces repair frequency in North Texas climate.
Frequently Asked Questions
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Service Areas
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