How to Bulk Fill Large Voids and Cracks with Belzona 4124

This video demonstrates an alternative system to traditional cementitious materials for filling large uneven areas, deep voids, gaps and cracks in concrete or stonework.

Deterioration of concrete surfaces due to abrasion, chemical attack or impact can result in uneven, unsightly and hazardous areas. Once the damage has occurred, it can be difficult to repair. Repairing concrete with new concrete can prove problematic as concrete shrinks and often does not successfully bond to the old concrete. Other cementitious repair products typically require 28 days to cure creating a long return to service time.

In this how-to video, you will learn how to use a highly cost-effective Belzona repair system to rebuild damaged floor areas.

Materials Used:

To fill this floor area, we used Belzona 4154, Belzona 4124 and Belzona 4111 (Magma-Quartz)

How-to Guide:

Step 1: Prior to the rebuild, remove all paint, tar and other coatings and ensure the surface is be clean, firm and dry. 
Step 2: Using a mechanical mixer, empty the contents of the Base and Solidifier units of Belzona 4154 (resin) into the mixing bucket. 
Allow 1-2 minutes for mixing to achieve a homogenous consistency. 
Step 3: Immediately with the mixer still running, start adding Belzona 4124 Aggregate into the resin.   
To obtain the right consistency it is recommended to add the aggregate in parts.
Step 4: Once the materials have a homogeneous consistency, pour the mixture into the prepared surface. Continue doing so until the void has been filled to the top leaving at least ¼” for top coat. 
Step 5: Spread evenly and tamp down firmly with the trowel or float to remove entrapped air, to compact Belzona 4154 and to ensure good adhesion with the surface. 
This system should be over coated with a Belzona 4100 series repair mortar within 24 hours. 
Step 6: Using a stiff bristled brush, apply Belzona 4911 (TX Conditioner) between the layers covering the entire application area to condition the surface.
Step 7: In this case Belzona 4111 has been chosen as a top coat due to its outstanding chemical and abrasion resistant properties. Combine the contents of this material which includes Belzona 4151 (Magma-Quartz Resin) along with the aggregate Belzona 4111 in a mechanical mixer. 
Step 8: Once a homogeneous consistency has been obtained, empty the contents of the bucket onto the conditioned surface.
Step 9: Using a trowel, evenly spread the mortar mixture making sure the entire area is covered well. 
Step 10: Tamp down to remove any entrapped air, to compact the Belzona 4111 and to ensure good adhesion with the surface