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Cracks in concrete floor.

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Dick in NH

09-24-2001 18:57:24




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Last year I had a concrete floor poured in my new 24'X 26'workshop that I built. I thought that I did everything right but I still ended up with numerous cracks in the floor. The soil is of good quality and has excellent drainage. I used 4000 psi concrete placed 5" thick over a 16" X 16" grid of 1/2" re-bar. I made sure the soil was well compacted but I still ended up with a lot of cracks.

My question is what would be the best method to fill and hide these cracks. I thought about using a cement filler then painting the entire floor with a epoxy paint but don't know how durable and long lasting this would be.

Thanks for any and all advise.

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Matt Smith

09-28-2001 19:47:15




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
If the contractor didn't put at least two layers of plastic on top of the base, then the base will draw moisture out of the wet concrete. One layer will allow condensation to form. Remember, it's limestone. We all know that lime absorbs water. Also, time (no, not lime...) is the best ground compactor, no matter what any concrete expert tells you.



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ROD

09-26-2001 07:05:17




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
THERE'S NO SUBSTITUTE FOR A GOOD BASE! THE CONCRETE IS ONLY AS GOOD AS THE COMPACTED DIRT BENEATH. THERE ARE PLACES AROUND HERE WHERE THE BUILDING SITE HAS TO BE UNDERCUT THREE FEET AND CLAY SHALE HAULED IN AND COMPACTED JUST TO GET A BASE FOR A SLAB. THERE'S NO SUBSTITUTE FOR A GOOD BASE!



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BB

09-26-2001 04:37:04




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
I am just curious. Did they pour beams in the slab? Or was it just poured on flat ground? I had one poured for a 30'x40' shop 2 years ago. They dug trenches about a foot and a half wide by about 3 feet deep around the perimeter and crossing the middle front to back and side to side. This also had 1/2" rebar on 16" grid and the beams had even more than that. They used 40 yards of concrete. This contractor was a little higher than others, but I knew he had a good reputation. I could see a few hairline cracks before I painted it, but nothing that you would even consider having to fill. In fact, the paint completely covered the cracks.

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Dick in NH

09-27-2001 18:50:06




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 Re: Re: Cracks in concrete floor. in reply to BB, 09-26-2001 04:37:04  
To BB and Rod:

They didn't pour any type of grade beams before pouring the slab but it certainly sounds like good insurance.

The soil below the slab is excellent with a very good perk rate. I know because I have a full 8' foundation on the back wall that steps up to 4' below grade on the front wall because of the slope on which the garage was built.

The contractor that poured the slab has done others for me and I was always satisfied with his work. He did tell me these spider web cracks have been occuring on other jobs and he was suspect to the quality of the portland cement the plant was using.

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Steve

10-02-2001 02:30:49




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 Re: Re: Re: Cracks in concrete floor. in reply to Dick in NH, 09-27-2001 18:50:06  
Dick, sure can be frustrating huh? You think you done everything right and..... . Samething happened to me. I built a 24 x 40 garage. You can drive right through each end. I used a 5 sak mix with 3/4 rock with 18" x 16" footing w/ 4 cont. #4 rebar. Heavy mill visquine and rienf. wire that I made sure the boys helping me pour lifted into the crete. MAN, the pour was going sweet not a prob. I even cut joints full length & width to absorb any cracks. I even keep the slab from drying to quick by misting it occasionally, not over doing the water thing. Dude when it was misted it looked like GLASS. But guess what???? My glass broke. I had spider cracks emerging in various areas. Then they grew alittle larger. MAN I was pissed! We busted our butts. Anyway if your soil is like mine out here in CA. then its a tuff one to call especiaaly when you know you went by the book and some. Sometimes if crete dires to fast it w/tend to crack, or a bad batch,hard to prove w/out taking a core sample and testing. (not worth the trouble though). Sorry I couldint be more help. Thats one thing I tell people up front "I'll guarante that it w/be setup & poured right but I wont guarante against cracking. Oh buy the way, the 2 driveways (approaches) NOT A BLOODY CRACK!!!!! you figure. take care & enjoy...

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Dick in NH

09-25-2001 19:10:23




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
Thanks for your input guys.

I really don't know what caused this much cracking but I did notice that when they were placing the concrete some of it didn't appear to be thoughly mixed. I live pretty close to the concrete plant and perhaps the concrete wasn't in the truck long enough to mix.

At any rate, it is to late to cry about it now and the cracks are mostly cosmetic with the largest one being about 1/8" in width. The concrete filler in the caulking gun sounds like a good way to go with a couple coats of epoxy paint on top.

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Ray,IN

09-25-2001 17:56:00




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
Go to a contractors supply store and ask for the self-leveling concrete crack filler, it is available in the large caulking gun tubes. This is concrete color, gives 600pct.before tearing, runs down into the bottom of cracks and chips and does not deteriorate in sun or exposure to chemicals. Concrete cracks eventually nothing can stop it, the rebar, wire mesh and expansion joints only control the movement of the pieces. I was sold the story of the fiber reinforced air-entrained concrete not cracking, in leu of using rebar to hold things together. Guess what- it cracked and the contractor said "I didn't guarantee it though". Now in addition to cracks, they're widening. Sure the labor was less minus the rebar and wire, but I got what I paid for darn it.

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Dean

09-25-2001 03:26:43




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 Re: Cracks in concrete floor. in reply to Dick in NH, 09-24-2001 18:57:24  
Until the soil settles, the floor will continue to crack. Sometimes the water drainage pattern changes after construction (water running off the roof, etc.) and causes water to move through the soil settling the soil in some places and not others. Another possibility is that the concrete was not cured properly. A 5" pour should be kept wet and covered for at least 2 weeks, depending on the weather.

They make a patching compound for exactly this purpose; see your dealer. I've used both epoxy and polyurethane paints over concrete with excellent results. Both are pricey, require perfect surface preparation, and take some time to apply. Neither will prevent future cracks. They tend to make the floor slippery unless you mix in some special sharp sand with the paint.

I know it's too late but next time, use air-entrained, fiber reinforced concrete. Pricey but won't crack, even without rebar.

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VaTom

09-25-2001 15:22:57




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 Re: Re: Cracks in concrete floor. in reply to Dean, 09-25-2001 03:26:43  
Hate to break it to you Dean, but my air-entrained, fiber reinforced concrete floor, that was properly cured, cracked. Concrete cracks unless it's a small area. Rebar doesn't prevent cracking, only controls it. As far as Dick's floor goes, if you can't live with the cracks, I'd wait until it quit moving and then resurface with a thin top layer. Lots of choices for what to surface with. Check with your concrete material supplier.

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Dean

09-25-2001 16:13:44




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 Re: Re: Re: Cracks in concrete floor. in reply to VaTom, 09-25-2001 15:22:57  
I don't doubt you for a minute but I have driven my 10,000 lb. tractor over my 4" thick air-entrained and fiber reinforced 8' x 28' apron for years. It sits directly on top of the soil, red clay, which absorbs and releases a lot of water yet it doesn't even have a hairline crack in it. Maybe the difference is in the crew that did the work.



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Jim in N M

09-25-2001 19:19:37




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 Re: Re: Re: Re: Cracks in concrete floor. in reply to Dean, 09-25-2001 16:13:44  
I've been told that "Sakreet" has a new product out that can be trowled over cracked concrete and will solve the problem,It comes in Red bags,where their other product comes in a yellow bag.I've not used it but heard it talked about on a national radio show on Sunday mornings It's called "Ask the handy man"----- -Jim



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