It is possible to reduce panel thickness by 20%, eliminate 70% or more of traditional rebar, and erect panels the same day they are poured. Products used include Cement All, WunderFixx, Rapid Set Cement and FastRock TU.
180,000 square feet of wall panels were completed with Mortar Mix used on the major repair work and WunderFixx used to patch the minor blemishes.
Cement All and Mortar Mix were used for structural repairs on the 850,000-square-foot beverage manufacturing and distribution hub. WunderFixx was then used to smooth the surfacers before paint was applied.
Mortar Mix was used to repair spalling and bug holes. Cement All was used to fill spalls larger than ½ inch and fastener holes left behind by drilled-in formwork. WunderFixx was used for cosmetic pinhole repairs and to coat larger areas for a smooth appearance.
Construction of the Walmart Distribution Centers was broken into two large tilt-up concrete projects. The first building is 1.2 million square feet while the second is just shy of 1 million square feet. After the concrete panels were errected for each structure, Samuel Express Tilt Patch, patched the imperfections and pinholes on the outer sides of the wall. Products used include Mortar Mix and WunderFixx.
Unlike portland cement-based patching compounds that can take weeks to cure, these products are based on rapid-setting hydraulic cement that cures very quickly and has a low pH, so it can be painted the same day. While initially developed for tilt-up, the patching compound can also be used on precast and for cast-in-place concrete. Product used was WunderFixx.
Owners were demanding a smooth appearance comparable with drywall finishing. Sackers tried conventional drywall mud, but it is not formulated for exterior applications, and would swell and pop off when it got damp. Portland cement alone would not adhere to the concrete reliably. In the early 2000s, CTS began developing a material to address this problem. Product developed was WunderFixx.