MavPatch · MavPolyPatch · MavGrout · MavClad

Concrete Repair Systems

A coating is only as good as the concrete under it. The Maverick repair line — MavPatch Epoxy, MavRapidPatch, MavPolyPatch, MavGrout USP, and MavClad EM — rebuilds spalls, failed joints, bolt holes, and worn slabs to better-than-original strength, and accepts a finish coat the same day.

Scope a Repair View Typical Properties
System Overview

Repair It Once. Coat It the Same Day.

Concrete floor repair replaces deteriorated slab material — spalls, failed joint edges, cracks, and worn surfaces — with resin-based patching mortars that bond to sound, prepared concrete and reach traffic strength in hours. Repairs are saw-cut to a vertical edge, placed from 1/4″ per lift to 8″ in a single deep-fill placement, and accept a coating in as little as 8 hours. Maverick's repair line spans MavPatch Epoxy, MavRapidPatch, MavPolyPatch, MavGrout USP, and MavClad EM.

Generic patch material shrinks, debonds, and pops out under forklift traffic. MavPatch Epoxy is an epoxy-based patching compound that bonds tenaciously to prepared concrete, reaches traffic strength in hours, and restores damaged substrate to structural performance before coating application.

The line scales to the repair: MavRapidPatch polyurea hits walk-on strength in minutes for time-critical shutdowns, MavPolyPatch targets cracks, spalls, and divots with rapid gel time, MavGrout USP levels, pitches, and slopes from 1/2 inch to 3 inches, and MavClad EM builds epoxy mortar floors with 4–6″ integral cove base. Every repair can be overlaid with any MavCoat system for a uniform finished floor.

MavPatch Epoxy MavRapidPatch MavPolyPatch MavGrout USP MavClad EM

What the Repair Line Solves

  • Spalled and delaminated slab surfaces in traffic aisles and dock approaches — MavPatch Epoxy.
  • Time-critical maintenance shutdowns — MavRapidPatch reaches walk-on strength in minutes.
  • Cracks, spalls, and divots spot-filled with quick-setting MavPolyPatch before coating.
  • Infilling, leveling, pitching, and equipment pads — MavGrout USP places 1/2″ to 3″ thick with high compressive strength.
  • Seamless chemical-resistant overlays and 4–6″ integral cove base — MavClad EM epoxy mortar.
  • Compressed schedules — repairs accept MavCoat systems in as little as 8 hours.
Repair Detail

MavPatch Repair Cross-Section

Square saw-cut shoulder and full-depth placement in a single operation — the sequence that keeps patches in the floor instead of in the forklift's path. A feathered repair edge is the first thing to break out under hard-wheel traffic.

Cross-section of a saw-cut spall repair in a concrete slabSection through a concrete slab at a spall repair. The repair perimeter is saw cut to a square shoulder at least one half inch deep, never feathered. MavPatch Epoxy Mortar, extended with aggregate for trowel application, is placed full depth and struck flush with the surrounding slab. MavPrime EP primer and a MavCoat or MavSeal topcoat are then carried continuously over the repair. 1/4″–2″SAW-CUT REPAIR PERIMETERMAVPATCH EPOXY MORTAR —AGGREGATE-EXTENDED FOR TROWELAPPLICATION, PLACED FULL DEPTHAND STRUCK FLUSHMAVCOAT OR MAVSEAL TOPCOATMAVPRIME EP (3–8 MILS)CONCRETE SUBSTRATE — MECHANICALLYPREPARED TO CSP 3+ PER ICRI 310.2RSQUARE SAW-CUT SHOULDER,1/2″ MIN. DEPTH — NEVERA FEATHERED EDGESECTION — SAW-CUT SPALL REPAIR, FULL-DEPTH PLACEMENTNOT TO SCALEGENERAL NOTES1. SAW-CUT THE REPAIR PERIMETER TO A SQUARE SHOULDER, 1/2″ MIN. DEPTH. REMOVE ALL UNSOUND CONCRETE TO A SOLID SUBSTRATE.A FEATHERED REPAIR EDGE IS NOT ACCEPTABLE — IT IS THE FIRST THING TO BREAK OUT UNDER HARD-WHEEL TRAFFIC.2. PLACE MAVPATCH EPOXY MORTAR FULL DEPTH IN A SINGLE OPERATION AND STRIKE FLUSH WITH THE SURROUNDING SLAB.EXTENDING WITH AGGREGATE MAKES THE MATERIAL TROWELABLE AND CARRIES IT TO GREATER DEPTHS.3. FOR INFILL, LEVELING, PITCHING, AND EQUIPMENT PADS AT 1/2″–3″, USE MAVGROUT USP (7,800 PSI COMPRESSIVE, ASTM C-579).4. SUBSTRATE AND REPAIR TO BE CLEAN, SOUND, AND DRY. MECHANICALLY PREPARE TO CSP 3+ PER ICRI 310.2R BEFORE THE SYSTEM IS INSTALLED.
Drawn to the conventions of the Maverick standard detail library. MavGrout USP thickness and compressive strength per its technical data sheet; repair depth per Maverick field practice. Not to scale — see the Architect Center for dimensioned drawings.
System Components

Every Component, Documented

The products that make up the system, what each one does, and where to get its technical data. Components are supplied as factory-batched kits and installed by Maverick crews per the project specification.

ApplicationProductFunction in the SystemDocuments
Structural spall repair MavPatch Epoxy Epoxy mortar patching for spalls, joint edges, and structural defects. TDS (PDF)
Rapid-set repair MavRapidPatch Fast-setting repair mortar for same-shift turnaround. TDS (PDF)
Deep-fill repair MavPolyPatch High-solids polyurea that permanently fills voids and chased cracks in the slab. TDS (PDF)
Slope & pitch rebuild MavGrout USP Urethane slope grout ½″–3″ restoring pitch-to-drain before the flooring system installs. TDS (PDF)
Joint rebuild MavJoint JF Semi-rigid polyurea joint filler restoring saw-cut joints after edge repair. TDS (PDF)
Overlay resurfacing MavClad EM Epoxy mortar at ¼″ trowel-applied, resurfacing a worn or repaired slab as a seamless monolithic topping. TDS (PDF)
Thermal-shock resurfacing MavCrete UM Urethane cement mortar at ¼″–⅜″, rebuilding slabs in washdown and thermal-shock service to 250 °F. TDS (PDF)
Self-leveling rebuild MavCrete UM-SL Self-leveling urethane cement for re-establishing a flat plane over a repaired slab. Request TDS
Where It Performs

Wherever Concrete Takes a Beating

  • Manufacturing
  • Warehouse & Distribution
  • Food & Beverage
  • Loading Docks
  • Parking Structures
  • Municipal & Infrastructure
Performance

Typical Properties

Typical MavPatch Epoxy properties — request the product data sheet for project-specific values.
Property Test Method Typical Value
Compressive strengthASTM D6958,710 psi
Tensile strengthASTM D6386,256 psi
Bond strength to concreteASTM D4541350 psi
Working time75 °F35–45 minutes
Return to foot traffic75 °F6–8 hours
Ready for coating75 °F8–12 hours
Placement depth, neatPer lift1/4″ to 2″
Walk-on strength, MavRapidPatch75 °FMinutes
FAQ

Common Questions

How soon can a concrete repair be coated?

MavPatch Epoxy is ready for coating in 8–12 hours at 75 °F, and repairs across the line accept MavCoat systems in as little as 8 hours — so a slab can be repaired and finish-coated the same day.

What keeps a repair from popping out under forklift traffic?

Each repair gets a saw-cut vertical perimeter at least 1/2 inch deep — no featheredge failures — with the mortar placed full depth in a single operation and struck flush. MavPatch Epoxy bonds to prepared concrete at 350 psi (ASTM D4541), unlike generic patch material that shrinks, debonds, and pops out.

Which Maverick repair product fits which problem?

MavPatch Epoxy rebuilds spalls, joint edges, and structural defects; MavRapidPatch reaches walk-on strength in minutes for time-critical shutdowns; MavPolyPatch is a high-solids polyurea that permanently fills voids and chased cracks in the slab; MavGrout USP levels, pitches, and slopes from 1/2 inch to 3 inches; and MavClad EM builds seamless chemical-resistant epoxy mortar overlays with 4–6 inch integral cove base.

How strong is MavPatch Epoxy?

Typical values run 8,710 psi compressive strength (ASTM D695) and 6,256 psi tensile strength (ASTM D638), placed neat from 1/4 inch to 2 inches per lift — restoring damaged substrate to structural performance before coating application.

Related Products
Rapid Cure · Shutdown Work

MavRapidPatch

Polyurea rapid cure patching compound. Walk-on strength in minutes with high compressive and tensile bond — built for time-critical maintenance shutdowns.

View in Catalog
MavPolyPatch polyurea patch being troweled
Crack & Spot Repair

MavPolyPatch

Polyurea-based quick-setting crack and spot patch filler. Rapid gel time and excellent adhesion for targeted spall, crack, and divot repairs before coating.

View in Catalog Sloping & Leveling

MavGrout USP

Cementitious urethane grout placed 1/2″ to 3″ thick for infilling, leveling, pitching, sloping, and equipment pads. High compressive strength with excellent bond.

View in Catalog Mortar Overlay · Cove Base

MavClad EM

Epoxy mortar system for horizontal floor surfaces and 4–6″ integral cove base. Seamless chemical-resistant protection over the restored substrate.

View in Catalog
Shop Drawings

Isometric Shop Drawings

Repair-line system build-ups drawn isometrically — substrate, mortar body, and terminations on one sheet, ready for the project record. Direct downloads, no forms.

MavGrout USP isometric shop drawing preview

MavGrout USP

Isometric Shop Drawing · PDF · 2.6 MB

Download PDF
MavClad EF-HD isometric shop drawing preview

MavClad EF-HD

Isometric Shop Drawing · PDF · 2.1 MB

Download PDF

Browse the Full Shop Drawing Library

For Specifiers

Details & Specifications

Repair work lives or dies in the details — saw-cut perimeters, joint rebuilds, drain restorations. Our standard detail library and 3-part specifications cover them all.

Standard Detail Library

Details & Drawings

Joint rebuild, drain perimeter, and termination details across every Maverick system — the conditions where the MavPatch line does its work. PDF format.

Browse the Library Section 03 01 30 · Concrete Repair

CSI 3-Part Specification

Edited 3-part guide specification for MavPatch epoxy mortar repair and MavGrout USP overlayment, including surface preparation, mixing, and placement requirements.

View Specifications

Stop Patching the Same Spot Twice.

Send us photos and rough dimensions of the damage. We'll scope the repair, recommend the right MavPatch, MavGrout, or MavClad build, and respond within 48 hours.

Get a Quote Call 313-889-2526