Today we're going to look at an issue which has been around for a long time, especially in the airport and distribution sector.

Over the past couple of years we have received feedback about a growing issue within these sectors and this issue is concrete surfaces getting worn down over time with continuous traffic use, weathering and general ageing leaving exposed aggregate and creating potential slip risk.

This would typically be the start of surface breakdown which speeds up over time rapidly. This continual degradation is normal for concrete surfaces, and the standard procedure is to break out whole concrete slabs and replace them when needed.

Client feedback was to find an easier, quicker, and cheaper way.  Our objective was to create a new concrete surface without the huge costs of machinery and labour needed for the current methods, and at the same time be able to speed up the whole process so the area can be opened to traffic a lot quicker, reducing costly downtime for places such as distribution hubs and airports.

We set to work on developing a product which can meet this objective and now after months of research and testing we have the PermaFyx W685.

PermaFyx W685 is a water based concrete system which has no dangerous or flammable components which makes it safe to use in sensitive areas like airports or fuel stations.   

This product is designed specifically for thin lay applications, with extremely high adhesion to the existing surface so you can create a completely new wearing surface without the need to break out any concrete at all, and it will provide a durable lasting surface for over 10 years abrasion resistant and resistant to weathering.

The surface needs to be prepared for application using a mechanical Scarifier to create a suitable key in the surface texture and we also recommend the LazerVac system to effectively remove all dirt and loose material from the surface before application. If the substrate is highly absorptive or porous, then the application area should be pre-wetted with water and left to naturally dry before application.

If expansion joints need filling or repairing, this can be done before or after application of PermaFyx W685, using a suitable flexible joint filler such as our UltraCrack L275.  If there are any cracks in the concrete slab, these must be cut out and filled with a flexible joint filler and must not be filled with the PermaFyx W685.  Our UltraCrack L275 can be supplied in grey to help these cracks blend in with the surrounding surface.

The application process is a lot simpler than current methods with no large equipment, all we recommend you need is a flat bladed squeegee and a mechanical mixer which can keep the product in movement during the application. 

We found the PortaMix Hippo mixing unit worked very well for us, as it can mix up large quantities and can be poured straight out onto the surface whilst being moved around easily.

The PermaFyx W685 is simply mixed by adding the powder component to the liquid component whilst mixing, and then kept mixing until there are no lumps and the mix is consistent.

The mix can then be poured out onto the surface with pre-taped edges and spread out with the squeegee.

We recommend using the 2 layer system, which includes the base layer which has been developed particularly for filling slightly deeper voids without shrinking or cracking, and then the top layer which has been pigmented to suit most concrete surfaces, and can be brush finished to create a slip resistant finish.

Once applied, the system takes only 60 minutes until it can be trafficked, reaching final strength after 28 days. 

This is a huge time saving over relaying a new slab, which would take 30 days per inch to cure sufficiently to be trafficked.

If you have the challenge of worn or damaged concrete and are looking for a way of extending the life of your surface for a further 10 years without huge amounts of downtime, we'd be more than happy to discuss the project further with you. 

There is a wealth of information on our website - - such as white papers, data sheets and more.

Give us a call on 023 9220 0606 or drop us an email at