Repairing Concrete Spalls Permanently

The Step-by-Step FlexKRETE Repair Method.

CASE STUDY: Repairing Spalls Permanently 

Customer: Lowes Home Improvement 

Problem: Concrete spalls and damage from forklifts 

Solution: Longterm repair using FlexKRETE Superior Concrete Material


1. Remove loose and hollow sounding concrete with concrete scarifier, milling machine, grinder or by blasting. Void-test by dragging chain or "pinging" with hammer.  A clean, white, rough and solid substrate is desired

2. Use a diamond blade saw to establish perimeter by cutting 1/2" vertical 'key' with 45º slope from inside.

3. Route cracks with crack chaser, a minimum 1/2" deep to prepare for filling.

4. Blow or vacuum all dust and debris from cracks and prepped areas.

5. Using pressurized spary-gun, apply thin coat of FlexPrime, leaving no puddles or ridges. Apply just enough FlexPrime to darken concrete, then allow to tack.

6. Mix 2 parts sand with 1 part catalyzed FlexKrete and force flush into cracks with a trowel.

7. Mix 3 parts sand with 1 part catalyzed FlexKrete, fill spall areas and smooth with trowel, fresno or screed, extending to, and forcing material into perimeter 'key'.

Material Costs and Completion Time (Approximate)

FlexKRETE              $675.00

Sand                         51.00

FlexSealer                50.00

FlexPrime                 40.00

TOTAL                  $817.00

Completion Time: 2.0 hours

For information about the FlexKRETE Advantage call 972-964-8707. 

Click on the below image for hi-res version.

Questions? Call 972-964-8707 or email us at

Subscribe to FlexKrete's Newsletter 

Comments are closed.