How to repair and renew concrete driveway?

[SK]

Hello, 

Hoping to get some expert advice & steps on how best to proceed further on our DRIVEWAYS Mini Project, using something that's much more sustainable & durable. That is non slippery, can withstand hot summer sun, vehicle pressure & winter rain. (than what we had explored, but not so suitable for uncovered driveways, that also serve as carport sometimes.) 

A (Surface) & C (Edge connected to Brick Tiles) had cracks.

Gripset Betta Concrete Crack Filler and  Selleys Spark Filla Heavy Duty were attempted. But the results (especially on A) hasn't been too satisfactory.

Here's a closed up on A after only 3 weeks under the hot Sun, with only some light rains in between. Weather were dried the few days before & after double application. perhaps due to incorrect application/movement of vehicle before they were fully cured, cracks formed not long after.

On C (Edge of joint to Brick wall/Tiles where kids can walk/jumping on top), new cracks appear too in less than 4 weeks. Could be resulted from combination of high UV/ vehicle movement, is our guess, or wrong choice/method of application.

B (Expansion joints)were crowded with weeds & soils. After they were removed, the expansion/contraction joints (B) gaps were wide, ranging between 5mm to 20mm wide, and up to 5mm to 20mm deep. Parfix Triple expanding foam filler were applied once to try fill up the joints. The results looked smooth & joints completely filled, before the overflow foam were cut.

Here's a closed up of the expansion joints (B) foam filling after the excess/overflow foams were cut, to level up with the concrete surface.

As is, the joints (just like the entire driveway, before garage entrance) look ugly, and there're tiny holes along the joint lines, allowing water & sands to going under. And along those sections where not enough depth of soils were removed,some of the foams pieces had dried up & got pushed off by soils underneath, with pressure from vehicle. 

Clearly, we haven't yet met a good adviser on the right choice of materials &/ correct application steps, to accomplish what we hope achieve, and have the entire driveway & joints line properly sealed & renewed.

Really hope we can find soon some real experts, and/or people with previous experience handling the same. 

Someone has suggested looking at using either :-

1) Earls MultFill (Walnut Color) to fill up all remaining cracks & holes, and let the color tone up with existing color (to make the carport looks less multi-colors), and watch if cracks/hole appear again, before attempting to clean up/paint over. Is this product suitable to prevent crack ? What paint may go best with this ?

2)  Combination of Crommelin Enhanced Satin & Tint to seal up remaining surface cracks & holes (2-3mm) on expansion lines. (After  pressure washing). Is this suitable as we can't see any warranty period stated on product ?

3) Crommelin Maximum Slip Resistant  Safety Floor Coating, with waterproofing & UV protect properties, to seal up remaining surface cracks & holes on expansion lines. Is this viable ? 

4) Crommelin Exterior Grade waterproof with UV stable properties (Grey) on all Expansion Joints surface with holes/gaps unfilled. Is this viable ? Much more cost effective & easier to apply & clean up than using caulking gun ? 

5) Explore application of a All In One (Non-Slip, UV Protect, High Pressure tolerance, AntiCracks, waterproofing) coating, made specific for Driveways (that Bunnings already sell/can help source). Does something like this exist yet ? 

Looking forward hearing your expert advice and experience you may previously had previously on your driveway renewal. 

Thank You. 

[Akanksha]

Hi again @SK,

Thanks for your question on repairing and renewing your driveway. As per my other message, @EricL will be back on the site later today and happy to assist you. Thank you for your patience.

In the meantime, sharing a related discussion posted by another member in case this helps: 
How to repair cracks and resurface the driveway?

Akanksha

[EricL]

Hello @SK

My apologies for the late reply. It looks like you've been testing quite a few products trying to repair the cracks in your driveway. In these situations, I often recommend using Gripset Betta 1L Concrete Crack Filler. However, if you're not satisfied with its performance there are other products you can use. 

I suggest looking at Dunlop 5kg Ardit Rapidset Repair Mortar. It can be used on concrete surfaces and is ideal for filling cracks in your driveway. Next is the Sika 1L High Strength Epoxy Repair Adhesive Concrete Fix Kit. This is a high-strength epoxy repair kit that can take a heavy load. Then there is Earl's 1kg Concremate Expanding Cement, it's easy to use and is quick setting.

Because you've used a variety of fillers, it will be necessary to remove them if you decide to use the products I've mentioned above. This is so that the new fillers will anchor properly to the surface of your driveway. It's important to give the fillers the proper amount of time to cure. If they are run over or moved too early they will move and crack producing an unsatisfactory seal.

Once you've repaired the damage on your driveway, I suggest having a look at the White Knight 1L White Heavy Duty Ultra Pave Concrete And Paving Paint. It resists hot tyre pick-up and can be applied over oil and water-based topcoats. It can be tinted to many colours so please choose carefully.

Here is a handy step-by-step guide: How to paint a concrete driveway

If you need further assistance, please let us know.

Eric

[SK]

Hello Eric & Akansha

Appreciate both your times taken on the above, and every suggestions/links offered. 

Got 3 more questions here :-

1) Color schema of the 3 products mentioned ?

2)  We were told previously that Gripset wasn't suitable for filling expansion joints, as it may get too hard overtime & create more cracks on other area of the Concrete. Hence the suggestion of using filler foams/foam rods, given the uneven gaps width (5mm to 20mm) between each of the different joints lines. Is there anything (if any) we may add to products mentioned, to make Dunlop mortal/Earls Cement more elastic? Hence lower chance of having more cracks coming after repairs, with large delivery truck/van getting onto people driveways becoming fairly common nowadays. Or they both already have the elastic nature built-in for use on concrete joints ?  

3) If possible, we prefer sticking with the existing tone of color (reddish brown) on the carport, to go with color of the house bricks. It doesn't look like White Knight Concrete Paving paints offers anything along red/brown tone color on link sent. Can the original color be matched ? If not, what other Concrete paints can we explore that may match up closer to the original reddish concrete ? 

Hope to receive further insights on the above. 

Thank You.

[MitchellMc · Accepted solution]

Hi @SK,

The products @EricL has mentioned are all various shades of grey. You need to paint over them to produce a seamless repair.

As a general rule, expansion joints shouldn't be filled with rigid products. I believe @EricL suggested these products for the cracks in your driveway, not the expansion joints. Using Sikaflex 11FC, which is a flexible polyurethane, would be your best option for the expansion joints. Once again, you'll need to paint over it to keep the colouring consistent across the whole driveway.

You'll have better luck with a reddish colouring in the Berger Jet-dry range.

Please let me know if you have further questions.

Mitchell

[SK]

Hi @@Mitchell

Thanks for clarification above.

One of the main purpose of getting the expansion lines filled was to prevent weeds growth.

Are there flexible polyurethane that we may purchase in Bulk like cement, to substitute for Sikaflex, and use with Sand and Spray Gun (like the method  suggested to control weed growth on bricks gaps).

Glad knowing that there're other red based Concrete Paints available. Can these paints go over the polyurethane, or they need be masked/applied only after painting are completed ?

Thank you once again.

[MitchellMc]

Hi @SK,

You can purchase sausages that are larger quantities of Sikaflex. No other bulk products. You could cut your current foam back but leave it filling the lower section of the crack. You can then fill over it with the Sikaflex and smooth it off to get a great finish.

Once the Sikaflex is cured, you can paint over it.

Mitchell

[SK]

Hi @MitchellMc,

So, the sausages types are in powdered form, where I can sweep  over the expansion joints (with sands & cement?) and spray water on top, and smooth them off before they're cured ? In what ratio can I mix them ? 

Thanks again ! 

[MitchellMc]

Sorry about that, @SK; the sausages are a larger quantity of the pre-mixed product. They are not in powder form.

Mitchell

[SK]

Thanks for clarifying @MitchellMc