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Industrial concrete repair

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Today’s harsh industrial environments wreak havoc on concrete floors and other structures that can spell trouble for safety and performance. Loctite® Fixmaster® Magna-Crete flooring products are specialty repair materials for rebuilding, repairing and resurfacing concrete floors.

Cracked surface, rusted steel, crumbling concrete are some of the more commons signs that indicate structural problems in a structure. Consequence of letting these signs go unnoticed could be disastrous. This type of damage may is usually seen on industrial floors, chimney superstructure, slurry pit wall or roads & floorings, since these structures are subjected to heavy wear and tear.

Some of the common causes of concrete failure are:

  • Freezing and thawing
  • Aggressive chemical exposure
  • Mechanical abrasion
  • Corrosion of steel and other embedded metals
  • Chemical reactions of aggregates
  • Non-uniform volume change
  • Unsound cement with excessive amounts of unhydrated CaO or MgO
  • Plastic shrinkage, due to lack of moisture content during concrete setting

Henkel has now introduced Loctite« Fixmaster« Magna-Crete as a superior repair solution for such problems. It is a rapid setting, non cementatious, non-epoxy formulation, which is designed to match the thermal coefficient of expansion. It is a high performance, magnesium polyphosphate based system that helps in building High compressive strength.

This two-component system sets rapidly and has a very high early strength. It is ideal for road and aircraft runway repairs, which can typically be driven over after 45 minutes. It also bonds to new and old concrete, as well as most other construction materials including wood, glass and steel. It is a ready to use product with no water addition required and can be applied at temperatures as low as -15¦F (-26¦C).

Typical applications include the repair of floors, ramps, loading areas, support beams, bridge decking and concrete walls (including those in waste-water treatment plants). Magna-Crete has been proved to be effective for the repair of cold store floors, where heavy use can make surfaces unserviceable. For grouting purposes, Magna-Crete can be employed for precast panels, anchor bolts, crane and track rails, roadway dowel rods, columns, foundations, baseplates and similar applications.

APPLICATION EXAMPLES

Manufacturer of aircraft and turbine parts avoids the multi-day shutdown

Situation

A manufacturer of investment-casted aircraft and turbine parts was operating on a high-volume capacity of three shifts a day, seven days a week. When the concrete ramp leading to a supply warehouse began to break down and re-bar became exposed, maintenance engineers were concerned. Not only was this a hazard to personnel, but fork truck operators who brought in loads of high-quality metal alloy ingots actually lost loads due to the deteriorated condition of the ramp. Because of the high standards in the aircraft industry, if an ingot is damaged, contaminated or looses weight, it has to be scrapped. With each ingot costing hundreds of dollars, this was unacceptable.

Scheduling time for repair would be costly, as well. Typically, this type of floor repair would involve 2-3 days to remove the 5 x 15 foot concrete flooring with a jackhammer, pour the new concrete floor, and wait for it to dry. A shutdown for that length of time would cost the company tens of thousands of dollars, not including the actual cost of the repair.

Solution

The area was prepared using a rotary hammer, a circular saw with a diamond blade, and a vacuum. Loctite Magna-Crete was installed using a screed and a steel trowel.

Result

Instead of a three day shut down Magna-Crete allowed the company to reopen the ramp to traffic in less than three hours.

Rapid repairs of flooring in food processing plant

Situation

A major meat processing company had been experiencing degradation of its concrete floors due to a combination of high production volumes, forklift traffic, process waste and daily chemical wash downs. The eroded floors in every area of the plant were creating major problems for personnel safety, forklift equipment and overall process cleanliness. Cracked flooring in a food processing facility presents opportunities for bacteria growth, and makes it more difficult for effective daily cleanings.

Prior attempts to repair the concrete floors using epoxy and water-based products had repeatedly failed to provide a reliable or lasting repair. In refrigerated areas, water-based systems do not work, because the water in the system would freeze and be ineffective. Also, epoxy-based systems take too long to cure in refrigerators. These failures only added to the erosion that was already occurring. That’s when they called in Henkel and the local industrial distributor of Loctite® brand products to recommend a solution.

Solution

Unlike conventional cement, latex and acrylic-modified quick-set mixes, Magna-Crete« does not use water. Consequently, repairs can be made in temperatures from -15¦ F to 130¦ F (-9¦ C to 54¦ C). The set time of 10 to 90 minutes, depending on air temperature, means you can build on it, walk on it and even drive over it in less than an hour. Within two hours, Magna-Crete« reaches the strength of concrete (3,000 psi) and at full cure Magna-Crete« has strength of more than 13,000 psi.

The local Henkel Adhesives & Sealants Specialist performed a free on-site workshop for the plant’s maintenance personnel on the use of Loctite® Fixmaster« Magna-Crete« and other product solutions.

Results

Henkel was able to provide field expertise in both the selection of the suitable product and correct application. This level of support helped to facilitate successful repairs in all areas of the plant.

The versatility of this product provided several benefits to this facility. Unlike the prior repairs, Loctite® Fixmaster« Magna-Crete« adhered securely to the concrete and did not opop outö when put under forklift traffic.

As a result of the overall improvements in the facility’s floors, the mean time between forklift repairs was extended; thus saving maintenance costs and downtime.

Flooring repairs were made quickly and easily. With no mix ratio requirements, Magna-Crete« was able to be varied for a thinner self-leveling mixture for horizontal Applications, or a thicker mixture for vertical applications.

In addition to providing a high adhesion and high strength repair, Magna-Crete« also exhibits excellent environmental resistance to process waste and cleaning chemicals.

The anti-microbial nature of the cured Magna-Crete« was an added benefit for the facility as well.

HENKEL

Henkel operates worldwide with leading brands and technologies in three business areas: Laundry & Home Care, Beauty Care and Adhesive Technologies. Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with well-known brands such as Persil, Schwarzkopf and Loctite.

Henkel, headquartered in Dnsseldorf / Germany, has some 47,000 employees worldwide and counts among the most internationally aligned German-based companies in the global marketplace.

Henkel is a supplier of complete systems solutions. The services offered range from design and consultancy, product development and dispensing equipment through to process control expertise.

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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