PRODUCTS
Optimus 4010
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Description: Rapid Concrete Repair – Rapid Restore Cracks & Spalls 4010 is a very rapid set, high strength ultra-low viscosity concrete repair polymer. This two part polymer system is designed for rapidly rebuilding deeply spalled or damaged concrete surfaces, broken control joint walls and repairing cracks and spalls in concrete rapidly even in cold conditions. 4010 is an aromatic polymer but can also be supplied in an aliphatic version (4010ALP).
Heavy Loads In 10 to 15 Minutes: 4010 repairs are put back in service in minutes after the installation is made. The 4010 is intended for use in damaged concrete, from parking decks to warehouse/cold storage floor spalls. This product is especially useful in these areas where "Down- time" is limited and a facility must operate around the clock.
Unique Characteristics: 4010 is very low in viscosity allowing the product to deeply penetrate and “nano-lock” into the concrete better than epoxy. 4010 does not become brittle as epoxies do over time and 4010 sets very quickly allowing use in just minutes. Below Zero: Cold Temperatures The product is unique in that it can repair cracks and spalls of most any size at temperatures below zero, (-10°Fto -15°F) . Man Hours: The 4010 is intended to be extremely fast setting, reducing working time, man hours and down-time. The product can be ground smooth and become almost invisible when properly prepared and coated.
Advantages RAPID FLOOR REPAIRS COLD CONDITON USE -10°F SATISFIES OSHA FLOOR FACILITY SAFETY AND SURFACE CONDITIONS SAVES BEARINGS AND WHEELS REDUCES FACILITY “DOWN-TIME” & MAINTENANCE MAN HOURS MEETS USDA REQUIREMENTS FUEL RESISTANT BACK-IN-SERVICE TIME 10-15 MINUTES NANO-LOCKS INTO CONCRETE, VERY LOW VISCOSITY HIGH STRENGTH & FAST SET
Use Areas •ALL CONCRETE SPALL/DAMAGE RAPID RESTORE & REPAIR •REBUILDING CONTROL JOINT WALLS, FLOOR REPAIR •KNITTING CRACKED CONCRETE WITH REBAR •SHALLOW SPALLS ON WAREHOUSE FLOORS BRIDGE DECKS •GRADE MATCHING •COLD STROAGE THRESHOLDS •DECKS & LOADING DOCKS
General Physical Characteristics
Preparation: Concrete must have a minimum 28 day cure prior to application. The area must be dry. Clean the surface and remove all unsound concrete, dust and debris. Prepare surface using a dry diamond blade or a twisted wire wheel for spalls. Cut perimeter of damage with dry diamond blade to form a key-way. Application: Mix 4010 at a 1:1 ratio. Use a speed mixer, jiffy mixer or other multi blade mechanical mixer only. No paddle mixers. Mix part A and B mechanically at high speed for approximately 30 seconds. Blend mixed product into sand quickly. Mix product and sand for another 30 seconds and immediately pour into the prepared applications area. Work into the repair area quickly. Screed to finished grade and allow to set, top surface with product as needed, broadcast additional stand as needed. For better finished repair surface, pour grout mix slightly high above the finished grade. Allow to set and grind using a grinder fitted with a fine grit Zec wheel. Work in circular motion to grind/smooth to finished grade. Seal the surface using mixed product neat with no sand. Application with pre-placement of sand: Limitations: Do not use on wet surfaces or expose part A to moisture. This product is moisture sensitive and should not be applied to wet surfaces. * Product will bond damaged slabs together and may stop movement. Not intended for use where substrate movement is required. Hot Conditions: the product will be considerably faster in warm or hot conditions and slower in cold conditions. Do not use product that is hot. Pre-condition the product temperature for use at cold temperatures or to slow product set time keep product cold. Call Madison for additional information. Packaging: two gallon kits, 10 gallon kits and 110 gallon drum kits. Pot Life: Two minutes Set Time: Three to four minutes, hard for traffic in about fifteen minutes, final cure 24 hours.
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Some commonly used tools except heating stove though in the picture
 A newly repaired freezer threshold floor |
 Before: Spallings observed in passage aisle in a typical freezer |
 During: Mixed fluid before set looks blackish in colour |
 After: Repaired spallings that have set and harden look dark gray in colour |
4 Steps to Restoring Freezer Thresholds
All in a Day's work without costly freezer shutdown even @ -30 deg. C
This is a typical problem face by many cold storages. The concrete in a threshold between a freezer and a warmer warehouse section (usually an Ante area) often shows signs of damage. The damage is caused by the constant thermal cycling of warm to cool slab temperatures on one side of the threshold, exerting different co-efficients of expansion and contraction pressures on the cold side of the threshold slab. Both the cold side and the warm side develop cracks and deterioration resulting in spalling. Fork lifts traffic and frequency increases the damage through weight and impact.
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Fig 1: A Typical Freezer Threshold (6m2) damage/spall with icing surrounding it |
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Fig 2: Step 1 (Time-9am begin) Saw cut corners with an angle grinder attached to a vacuum cleaner to a depth of at least 1 inch deep for maximum adhesion. |
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Fig 3: Step 2 (Time-9.45am) Using a demolition hammer, hack to remove loose concrete and laitance to a depth of at least 1 inch. Remove and vacuum free debris. |
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Fig 4: (Time-1pm) Hacking Completed! Floor is ready for repair works. |
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Fig 5: (Time 2 pm) Step 4 - immediately mix repair product (1 part A to 1 part B and pour into spall followed by select sand or gravel and trowel, repeat this process until grade level (ie. same level as existing floor). Wipe off spillover with cloth or using pen knife to cut excess when product has set but not hardened. As product is rapid setting, repair was carried out in sections whilst sand was used to contain product fluids. |
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Fig 6: (Time 4.30pm) Freezer threshold repair is completed. Inner section is somewhat blackish as the product is setting. Typically, it takes about 2 to 3 hours o set and 6 hours for product to harden. Traffic may resume after product hardens. Usually, restoration work is carried out on a Sunday and traffic may resume the next day. |
Optimus 4010 Rapid Concrete Repair
Spalled and degraded joints on a cold storage loading dock continually caused damage to forklift wheels and bearings. Requirement: Make a repair that will last and not shut down the facility for hours.
Solution: Optimus 4010, short down-time and a lasting repair.
The concrete is prepared using a dry diamond saw. The area is provided with a perimeter cut along one side of the damaged area.
The unsound concrete is removed using a chipping hammer.
A select sand is pre-placed into the prepared area
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The 4010 is a 1:1 ratio mix. |
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After the product has been properly mixed it is poured into the prepared repair area and into the pre-placed sand. The product is very low in viscosity and will saturate the sand and be self priming. In some of the larger repairs the additional sand is broadcast over the wet 4010 to produce a surface repair that is slightly above the finished grade. |
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The 4010 will be set in about 10 minutes and can be surface ground to produce a smooth repair surface allowing for an even and bump free transition over the repair for forklifts. |
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With the product setting fast the finishing can be completed quickly and the area open to forklift traffic in as little as 25 minutes. |
Optimus 4010 Rapid Repair - Iraq 2007
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| Damage to landing surfaces the Marine Corps uses have to be repaired quickly. 4010 allows quick repairs and traffic access in about 10 minutes. |  |
| One part of mixed 4010 is mixed with 2 parts of dry sand. |  |
| It is immediately poured into the prepared spall. |  |
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The surface is troweled (somehow).
Optimus 4010 can support traffic weight |
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Optimus 4010 - Sump/tank Leveling – Sensors
Gas station sumps with a rounded tank below the chimney access did not have a level enough surface for the environmental sensors to operate properly.
Optimus 4010 was used to create a hard surface and level the surface of the tank below so the sensors would activate properly and detect leakage. The 4010 was applied via a LS pump unit with some aggregate over the rounded tank to form a floor. When the product cured in about 10 to 15 minutes the 820 60/120 was used around the perimeter of the 4010 where the product meets the fiberglass wall.
