Concrete Truck Hopper Pad

Project Description – Rebuild and resurface of Antelope Coal Mine Concrete Truck Hopper Pad.

Application - Repair exterior concrete truck hopper pad, which had become deteriorated due to truck load activity, extreme weather exposure and salt/plow treatment for ice/snow melt.

Industry - Mining

ContractorCreative Maintenance Solutions, Inc. 

Problem - The concrete truck hopper pad was deteriorated.  Customer wanted area preserved and resurfaced, but down time was an issue to their Operation.  Customer contracted to have repair made within a 24 hour window (during month of October, 2014).  Additionally, temperature ranges during repair timeframe would fluctuate between 15-60 Degrees F. 

Solution - Clean substrate, using high pressure fire hoses. Mechanically prepare the substrate using needle scaling and chisel point needles.  Warm the prepared concrete substrate, as needed, using weed burners, to get substrate temperatures above 45 Degrees F.  Using air knives, blow away dust, dirt and debris.  Condition the concrete by brushing on Belzona 4911 Magma TX Conditioner.  Rebuild and resurface pad area using Belzona 4131 Magma Screed, applying via pin rakes and steel trowels.  Entire area was covered with concrete blankets and sealed, to create a heated containment area.  Indirect hot air heat was piped under tarps, to assist with curing the application area.  Substrate and air temperatures were 38 Degrees  at 9PM, when heat was applied.  Heat was applied until 8 AM the following morning – air and substrate temperatures in the heat confined areas were in the 137 to 146 Degree F range.  At 11AM, Belzona 4131 repair materials were deemed to be cured.  Heat confinement area was removed and customer returned to full load truck operation at 5:30PM.

Product Applied - Belzona 4911, 4131

Product Detail –  Belzona 4911 (Magma TX Conditioner) - A two-component thixotropic resin system with excellent adhesion to masonry and metallic surfaces. It is used for conditioning metallic and masonry surfaces prior to application of Belzona 4000 series products.

Belzona 4131 (Magma-Screed) - A non-porous, 2-part epoxy repair composite designed for resurfacing and protecting large areas of concrete, stone and many other surfaces. This solvent free material provides excellent chemical and abrasion resistance and protection from impact and environmental attack.

Far stronger than concrete, Belzona 4131 (Magma-Screed) can be used as a repair material or to provide an extra strong top layer to existing concrete areas.  In addition, it meets the USDA requirements for incidental food contact as it offers a safe and hygienic surface.

This simple to apply material is easy to mix and can be applied by trowel without the need for specialist tools.