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.
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
Saw-cut perimeter, epoxy bond coat, and full-depth mortar placement — the sequence that keeps patches in the floor instead of in the forklift's path.
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.
| Application | Product | Function in the System | Documents |
|---|---|---|---|
| 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 | Polyurea repair filling ⅛″ to 8″ deep in a single placement. | 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 joint filler restoring saw-cut joints after edge repair. | TDS (PDF) |
Where It Performs
Wherever Concrete Takes a Beating
- Manufacturing
- Warehouse & Distribution
- Food & Beverage
- Loading Docks
- Parking Structures
- Municipal & Infrastructure
Performance
Typical Properties
| Property | Test Method | Typical Value |
|---|---|---|
| Compressive strength | ASTM D695 | 8,710 psi |
| Tensile strength | ASTM D638 | 6,256 psi |
| Bond strength to concrete | ASTM D4541 | 350 psi |
| Working time | 75 °F | 35–45 minutes |
| Return to foot traffic | 75 °F | 6–8 hours |
| Ready for coating | 75 °F | 8–12 hours |
| Placement depth, neat | Per lift | 1/4″ to 2″ |
| Walk-on strength, MavRapidPatch | 75 °F | Minutes |
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 — and an epoxy bond coat with the mortar placed wet-on-wet for a monolithic bond. 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 fills cracks, spalls, and divots from 1/8 inch to 8 inches deep in a single placement; 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
From Repair to Finished Floor
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-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 CatalogMavGrout 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 CatalogMavClad 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.
MavClad EF-HD
Download PDF
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.
Details & Drawings
Joint rebuild, drain perimeter, and termination details across every Maverick system — the conditions where the MavPatch line does its work. PDF and DWG formats.
Browse the LibraryCSI 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 SpecificationsStop 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.