What can I do to make my driveway last?

[ScaldedDog]

I had a new concrete driveway placed a year and a half ago, when the garage was done. One section is insulated with 2" Dow Hiload40, and heated for snowmelt purposes. Another new section isn't heated, and the third section is from the existing driveway. All are 4" thick, with rebar on 2' centers. The heated section also has steel mesh that the PEX was zip-tied to, and both new sections have the microfiber mesh. The new sections were placed in November and kept covered for several days, especially at night.

I've got several issues:

1) The heated section is spalling in places

2) The heated section has a couple of spots near the edges that are crumbling.

3) Both new sections have lots of thin cracks, with more developing all the time. You can see some in the photos above.

Can I do anything to fix this and, most importantly, prevent further damage? Would sealing it be worthwhile, if only to keep water from seeping into the cracks?

I obviously can't replace all this, but I'd consider other options short of that.

Thanks!!!

Mark

 

[Torque1st]

Clean up the spalled areas and coat it all with 2" of asphalt.

 

[ScaldedDog]

That would be tough due to drainage issues, but coating it with something isn't out of the question. Other ideas?

I saw a brand name (it started with an 'A', IIRC) in another thread that sold products to refinish concrete. I've searched, but can't find it again. Does anyone remember, and would something like that work?

Mark

 

[rikmeister]

concrete will always crack eventually it is just known what day it will happen.

 

[hook982]

concrete will always crack eventually it is just known what day it will happen.

....after only a year??????

I'd call the contractor who did it and see what can be done...looks like a bad mix!!

 

[nate379]

Why did you only do a 4" slab? On the one with the Pex, that amounts to under 3" over the tubing if the 4" slab is 3.5" (usually is since 2x4s used for the forms)

 

[ixlr8]

I wanted to put in a concrete driveway here in Maine. The contractor told me he wouldn't use less than 6" of concrete, 1/2" rebar 18" OC and fiberglass to hopefully keep it from cracking. Cracking with 4" of concrete, or less due to PEX, does not surprise me. I can't think of a reason for the spauling so soon, I would question the mix. Did they add something to change the speed of the curing?

 

[ScaldedDog]

Good questions, all:

Thickness - The heated area is actually closer to 5". If I had it to do over again, I'd have not put foam insulation under the driveway, but would have used that otherwise near worthless reflective stuff, instead. The 2" foam insulates too well, so that the insulated part of the driveway has snow on it even when the other sections don't. That would have allowed for additional thickness, without having to dig out more of the extraordinarily hard ground.

Mix - I have no way of knowing if it was a bad mix, or not, but sure can't rule it out.

Calling the contractor - I intend to do this, but wanted to gain some knowledge here first.

Cracks - I'm actually not too concerned about the cracks, as I think the rebar, mesh and even the PEX will keep the concrete from going anywhere. My biggest concern with them is that water will get into them and cause more damage. If I seal the surface, can I count on that sealer getting into the cracks and preventing water from entering them?

Here's a better photo that shows a little context:

This is facing north. The heated area is the two sections to the left, going all the way north and around the garage. The non-heated new section is the northern half of what you see to the right, and the southernmost sections were preexisting.
Thanks,

Mark

 

[cat06]

spalling looks like it was from salt coming off vehicles, go to a commercial coatings place and talk to them about seal coatings. It will cost more but will last longer and do a better job in the long run