Coating and Repair System

Mastermix Concrete Resurfacing and Repair

Are you looking for a solution for your damaged masonry and cementitious based substrates? At Mastermix, we stock a range of resurfacing and repair products which have been scientifically formulated to future proof your masonry and cementitious based substrates from marine and high acidity environments. In fact, we believe that our product ranges will perform better than the original solution.

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About concrete sealer

The Difference Between Concrete Resurfacing and Repair

Concrete is a tried and tested solution which has stood the test of time. Having said that, concrete can structurally fail due to a variety of factors including:

  • Insufficient reinforcement
  • Marine environments
  • Acid damage
  • Chemical damage
  • Weather exposure
  • Impact damage
  • Excessive loads
  • Structural damage
  • Fire damage
  • Seismic damage

While there are many risk factors which can cause significant damage you probably won’t need to remove the existing cement and start again as most of these problems can be fixed either with specialist resurfacing and repair products. Not only will this save you time and money, with Mastermix the end result could end up having a longer lifespan than the original concrete.

Types of damage

Here are some of the most typical types of damage you may be experiencing.

We would love to help you with your next project so get in touch with Mastermix before deciding on the right concrete coating or concrete repair product. We can help you save time and money by working with you to understand your requirements first. Get the job done right the first time and it will last a long time.

Probably the most common problem with concrete surfaces is cracks forming. This can happen very quickly, especially if insufficient control joints have not been incorporated however larger stress fractures or structural cracks can also form over time. As not all cracks are created equal it is important to be able to understand when you should consider fixing them. Generally speaking we recommend fixing the problem if:
  • The cracks are compromising the structural integrity of the substrate.
  • If water is pentrentating the structure particularly when water is undermining the foundation
  • The cracks are affecting the aesthetics of the structure to a sufficient degree that you are not happy with the overall look
Which is otherwise known as pitting is when little pockmarks begin to pepper the surface of the concrete. This is caused by freeze-thaw cycles causing moisture to expand during the thawing process and putting pressure on the top layers of concrete.
When the soil beneath a concrete slab experiences significant drying and thus shrinkish or wasn’t sufficiently compacted at the time of pouring. The resulting changes to the foundation can cause a general collapse of the affected area into the newly formed recess.
Just as changes to the foundation can cause settlement issues it can also cause a concrete slab to lift. Probably the most common occurrence is when a tree root lifts up a pad.
One of the most common problems our clients call us for help with is the extreme environments their concrete structures call home. Water and wastewater treatment plants, manholes, water tanks in marine environments and other acidic environments take a huge toll on the structural integrity of a structure.

Understanding the type of damage and what caused the damage in the first place is an important step towards finding a solution.

Depending on the extent of the damage and how the damage came about, concrete resurfacing and repair are two processes which could be used to fix the problem. As mentioned most concrete resurfacing and repair products are designed to perform in specific environments so selecting the right solution is parment to future proofing your project. 

At Mastermix

We have a range of concrete resurfacing and repair products which have been specifically designed to solve specific risk factors. To ensure you get the best solution for your concrete resurfacing and repair project please give us a call or send us an enquiry.

prepared, repaired, and overlaid

Concrete Resurfacing

Concrete resurfacing is the process in which concrete is prepared, repaired, and overlaid with a thin cement based surface. It is applied over the existing masonry or concrete based substrate and incorporates a polymer blend which ensures there is good adhesion between the concrete resurfacing product and the original concrete surface.

At Mastermix, we take resurfacing to the next level by offering a number of products in this category which are designed to excel under different conditions:

Our hydrophobic and heavy duty barrier that is waterproof and acid resistant. Click here to see product

Our durable resurfacing solution that leverages the properties of recycled glass to form an acid free and inert top coat. Click here to see product

Our waterproof coating system is designed to be applied internally and externally to almost any stable substrate including concrete, block work and steel. Click here to see product

Concrete Resurfacing Guide

To better understand the concrete resurfacing process, here are the steps involved: 

The existing substrate must be cleaned with a power washer to remove dirt, grease, loose materials and foreign matter.
As the resurfacing product will cover the original surface a colour tint may be added to the mix to match the original look or create something new.
Once the surface has been prepared the resurfacing product is ready to be applied by roller, brush or sprayed. Depending on the solution thickness and finishing requirements may vary.
Depending on temperature, humidity and the dampness of the original surface the newly applied layer will take about 30 minutes to become tacky and cure in 4 hours. Wait at least that time before applying any additional coats.

As extensive as this may sound, it is still quicker and more economical than pouring concrete for a whole new surface.

Concrete Repair Guide

While concrete resurfacing deals with the top 3mm, concrete repair is about ensuring the structural soundness of your substrate. It is fairly common to first repair a structure before applying a concrete resurfacing product for a professional finish that is consistent with the look required. Planning is essential as understanding what caused the damage in the first place is the first step towards putting a long term solution in place.

Depending on factors such as the weather all year round, environmental conditions such as acidity, load management, moisture and proximity to the ocean combined with strategic decisions like site access and will the site be closed down during the repair process. 

Finding a product which can satisfy these conditions can be a real challenge. At Mastermix, we are used to working in difficult environments and working on projects which are still operational while we make the repairs. We worked with the Timaru District Council to fix an operational treatment plant where the work had to be split into two stages to ensure the plant could remain functional.

Our repair range covers a wide variety of conditions which we can help you understand how to apply to your project.

Our high stress point solution which offers fast curing times and high compression strength characteristics. Click here to see product

Our hydrophobic repair system which offers fast curing times and critical early high compression strength for load bearing repair work. Click here to see product

The Range

At Mastermix, we have a range of concrete resurfacing and repair products which have been specifically designed to solve specific risk factors. To ensure you get the best solution for your concrete resurfacing and repair project please give us a call or send us an enquiry.

Mastermix Armor is a high grade product which is hydrophobic with high adhesion characteristics which forms an extremely effective waterproof and acid resistant barrier. It is ideal as a repair solution for masonry and cementitious based substrates which have been damaged in marine or high acidity environments.
In fact, a single 10mm coat of Armor will provide a highly effective acid resistant and waterproof barrier which can withstand compressive loads of up to 14.7MPa making for a durable and hard service which will extend the life of your project.

Trade quality product

Resistant to acidic solutions like sulphuric, phosphoric and hydrochloric acids

High adhesive strength

Fast setting

High tensile strength & flexibility

Reduces deposit build up in sewer applications

Fully Complies with AS/NZS 4020:2005, Products for use in contact with Drinking Water

Mastermix Armor is suitable for general use in the building and refurbishment of:

Manholes

Reservoirs

Storage tanks

Pump stations

Wet wells & Swimming pools

Water & Wastewater Treatment Plants

Other applications: Floor and wall coatings for hygienic areas, Coating for critical bunding area, Tunnel repairs and sealing

Independent laboratory tests have shown that Armor has been independently tested by AMS Labs under the following test condition EN 1348, AUS Standards 134 and NZ Standards 3112.

Adhesion >1 Mpa

Compressive Strength 14.7MPa

Flexural Strength 6MPa

Residual Strength 11.26MPa

Shrinkage 0.005%

Acid Resistance Very high when immersed at pH0

Laboratory partners such as AMS have commited to redeveloping the testing standards for refurbishment products to better understand the performance limits of Armor and the expected Industry Standard for competing products in this category.
MORE ABOUT ARMOR
Mastermix Shield is a product category redefining coating system which utilises recycled glass to form a hard wearing durable top coat over most substrates, which require a waterproof coating that is inert and acid free.

Independent tests from respected international laboratories are in the process of being revamped to better understand the performance limits of this product. Shield is redefining the Industry Standard for its product category. Tests have shown a design life of better than 50 years!

Trade quality product

Environmentally friendly

Adheres in damp conditions

3mm coating will provide a durable waterproof coating that is Acid & Alkali resistant

Spray applied for easy application

Waterproof repair medium

Drinking water safe

3 to 4 hours curing

Sulphuric, Hydrochloric, Lactic acid and Hydrogen Sulphide resistant

High strength and flexibility

Mastermix Shield is suitable for the building and refurbishment of:

Wastewater Treatment and Dairy Plants

Concrete & Steel Structures

Manholes and Pump Stations

Wet Wells and Reservoirs

Swimming Pools and Storage Tanks

Other applications: Wall & Floor Coating, Acid Protection, Critical Bund Coating

Independent laboratory tests have shown that Shield has a compressive strength of better than 20Mpa. These tests were carried out in Sulphuric, Hydrochloric, Lactic acids, and Caustic soda. Compressive strength tested to ISO: 13007.
Laboratory partners such as AMS have commited to redeveloping the testing standards for coating systems to better understand the performance limits of Shield and the expected Industry Standard for competing products in this category.
MORE ABOUT SHIELD
Mastermix Rapid Repair is a high performance product offering fast curing times with early high compressive strength characteristics, excellent adhesion qualities, is hydrophobic and can be trowelled to a smooth finish.
Designed to repair most concrete products including Water Treatment Plants, Water Storage Facilities and Manholes Rapid Repair will give your project a second life often longer than the first!

Trade quality product

Adheres in damp conditions

Fast setting

High Adhesive Strengths

High Flexibility

Waterproof repair medium

Suitable for potable water applications

Non-toxic

Repairs to damp, wet or under water surfaces

Rapid Repair is a safe and cost effective alternative to epoxy solutions which are dangerous to use and can cause long term health effects to the applicator:

Infiltration barrier for manholes and tunnels

Commonly used in conjunction with Armor (as a cavity filler)

Reservoir and bridge repairs

Sealing of pipe penetrations in manholes, tanks and reservoirs

Swimming Pools

Canal Refurbishment

Independent laboratory tests carried out in accordance with NZ3112 and is designed to conform to NZ Standards 4210:2001 show that compressive strengths will be achieved as follows:

2 hours – 20.0MPa

24 hours –36.0MPa

28 days – 45.0MPa

Further set time is 17 minutes from mixing.

Laboratory partners such as AMS have commited to redeveloping the testing standards for refurbishment products to better understand the performance limits of Armor and the expected Industry Standard for competing products in this category.
MORE ABOUT RAPID REPAIR
Mastermix Multi-Cote has been developed to form a high performance coating system that enables it to be applied internally and externally as a render to almost any stable substrate including concrete, brick, block work and steel.

It forms a waterproof top coat that is inert and does not adversely affect the quality of stored water which can be applied to walls, ceilings and floors. As you might expect it has proven to be particularly useful in the ‘leaky homes’ era of house renovation!

Trade quality product

Adheres in damp conditions

Colour tint can be added to the mix or finished product can be painted

Acid and alkali resistant

High Flexibility

Waterproof repair medium

Non-toxic & Stored water safe

Waterproof Coating for:

Water TanksPlants

Swimming Pools

Concrete & Steel Structures

Leaky Homes

Water & Wastewater Treatment Plants

Commonly used in conjunction with Rapid Repair (link to product page) to fix larger cracks

Independent laboratory tests show that the adhesion tensile strength of Multi-Cote was greater than 3.2 N/mm2 for both concrete and steel substrates. Tests have shown a design life of better than 50 years!
Laboratory partners such as AMS have commited to redeveloping the testing standards for cementitious protectant products to better understand the performance limits of Multi-Cote and the expected Industry Standard for competing products in this category.
MORE ABOUT MULTI-COAT
Managing high stress points can determine the long term success of your project. HSR is a high performance product offering fast curing times combined with very fast high compressive strength characteristics.

It is resistant to acid attack and is an ideal product for resetting hinges, pins and bolts that are set in concrete and, with discussion with our technical department, may be used to repair and protect concrete members in both prestressed and reinforced concrete structures.

Trade quality product

Ideal for geothermal and marine environments

Fast curing times, combined with very fast high compressive strength characteristics

Set time approx 7 minutes

Shrinkage compensated

Resistant to acid and alkali attack & Non-toxic

Has a wide range of uses where fast curing times are crucial

High Strength Repair Medium for:

Geothermal Areas

Water & Wastewater Treatment Plants

Repairs to concrete roads, kerbs and paths

Reset hinge pins and bolts

Repair concrete members both pre-stressed and reinforced

Pipe repairs

Independent laboratory tests produced the following outstanding results:

+20MPa in 3hours

+30MPa in 24hrs

+40MPa in 7 days

+50MPA in 28days

+Flexural strength 5MPa Acid resistance – no change when immersed for 56 days at ph 3.5 @ 45ºC with minimal shrinkage >0.05%
MORE ABOUT RAPID REPAIR

Contact Us

We can help choosing the best product for your project.