Posted by Billy NY on May 22, 2009 at 06:25:15 from (74.67.3.238):
In Reply to: Concrete repair posted by showcrop on May 22, 2009 at 04:41:15:
Portland is Portland Cement, the cementitious material that bonds the aggregate together in concrete, mortar etc. There are 2 types; Type I & Type II Portland cement and I don't know the differences between them, believe it or not and I should, seeing it was part of my construction career.
You should clean the substrate, (column) back to good material, hopefully the spalling is not occurring through the middle of the column, meaning the column is failing or will fail, you should determine this, or your work is a waste of time, meaning time to replace it. Also have to wonder what caused the problem, poor materials, moisture, things like that, so you can prevent it from happening again.
Once you have determined that the majority of the column is still good, clean the substrate and wash it down, get rid of loose fines etc. There are a myriad of materials you could encase or parge the column with. I would suggest panzer mesh, or similar woven reinforcing, then use a portland based non sag material to parge it with, and follow the MFR's instructions closely, surface prep and application. You can attach the mesh to the substrate, leaving some space between it and the substrate, just don't bubble it out beyond the thickness of your parge coat. Dryvit makes a great system that you can apply to something like this, it's meant for exterior use, but the base (Primus-what they call it) does trowel/plaster on nicely, and can look good if you are good with those tools. The mesh will really reinforce it and tie back to the substrate, powder actuated fasteners, masonry fasteners, are fine, use something that won't rust. You may also find materials that require something to bond the parge coat, like an epoxy, like when doing this to a cold joint on concrete, always pay attention to the MFR's instructions.
If using a portland based mortar, which is superior to say anything acrylic, gypsum based etc. make sure when you apply it that the substrate is not bone dry, when you apply a material like that, the substrate will quickly and too rapidly absorb the water out of your portland/water based material, causing it to fail, I always soak the substrate or existing material so that this does not occur, it can prevent it from bonding and cause it to fracture.
If you form out and pour, you will need a little more thickness for rebar and the material, and I think a concrete would be better than a mortar. You still have to prep and reinforce the column, have enough thickness to cover the aggregate, use a woven wire mesh at this point you would be better going out 4"-6" and just pouring a box around it, using vertical and horizontal rebar. I don't see forming out a thin coat/wall around something like this working out well as you describe, better off using a parge/stucco system like Dryvit with a mesh, pouring a wall, or using C.M.U. ( concrete masonry units- block) to encase the existing column, you could also fill the cells in the block, would be load bearing too. All I can think of right now.
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