Reinstatement Process

1.

The core, or coupon, removed from the pavement using the rotary cutter can be reinstated as a permanent repair using Utilibond, after the hole has been properly backfilled and compacted. The first step of reinstating is to properly prepare/clean the cored hole. Wipe clean all cut surfaces of the core and walls of the hole with a clean, damp cloth to remove all loose cutting debris and particulate from the cut surface. Proper bonding depends on achieving a clean surface for the bonding agent to adhere to.

2.

Line the bottom of the hole with a 1"-2" bed of pea gravel. Because the pea gravel is added fill that was not present before, the backfill should be left approximately 2 inches lower than the base of the pavement. Undercut the bottom of the existing pavement in the hole by about 1" all around to allow the pea gravel to fill under the pavement. Utilibond will impregnate the pea gravel and create a solid base / plug for the core to bond to. The pea gravel will help to compensate for any irregularities (protrusions or indentations) on the bottom of the core.

3.

Using the core puller / lifter, and following the orientation mark on the core and pavement, lower the core back into the hole and check for level and flushness with the existing pavement.

Adjust the pea gravel until the core is level with the surrounding pavement, and approximately 1/8" - 1/4" below the surface of the surrounding pavement. If necessary, remove the core and carefully adjust the pea gravel as needed.

This process is referred to as "dry fitting" the core. This is an essential step to a successful core reinstatement. Once the Utilibond has been added to the hole and the core has been reinserted, you will not get a second chance to change its level to make the core level with the surrounding pavement. Make sure it's done right the first time.

4.

Prepare the bonding compound as per instructions on the package. First, remove the bag(s) of Utilibond from the pail. Add water to the level indicted on the outside of the pail when using a 44 lb bag, or use the 1-litre plastic container included in each Twin Pack pail. Do not exceed or reduce the amount of water. Correct proportions of water to Utilibond are critical for effective performance. Even with the large 44 lb bag it may be easier and more accurate to use TWO cups of water using the 1 litre plastic cup included in each Twin Pack pail to achieve exact proper water proportions.

5.

Using a handheld drill the appropriate mixing blade, mix the bonding compound as you pour it from the bag into the pail. The consistency will start out lumpy and dry but do not add any more water.

Continue mixing, making sure that you get all of the dry powder from the bottom of the pail, until it is smooth and flowing and about the consistency of pancake batter. (Mixing time is approximately 3 minutes).

If the mix is too thick the core will not be able to displace the Utilibond on reinstatement, and if the mix is too thin the Utilibond will all be displaced and not support the core once it is flush and level with the road.

6.

Slowly and carefully, from a height just above the hole, so as not to disturb the pea gravel.

Pour the entire pail of Utilibond permanent pavement bonding compound into the hole.

7.

Again, following the orientation marks slowly lower the core down into the hole, on top of the Utilibond.

Rock the core gently back and forth with the core puller, to allow the bonding compound to flow up through the cut spaces around the core (the "kerf"), and out onto the surface of the pavement.

When the Utilibond completely surrounds the circumference of the core and spills out onto the street, remove the core puller and allow the excess Utilibond to flow up through the centre pilot hole.

Gently and carefully apply pressure to the top of the core, to get the core level with the pavement being very careful NOT to push the surface of the core below the level of the pavement. SLOW and STEADY.

8.

Using a trowel, carefully clean off the excess Utilibond from the surrounding pavement before it dries.

The bonding compound will begin to set up within approximately 15 minutes (at 70° F).

Use a wet whitewash brush to keep the exposed areas of Utilibond in the kerf and in the centre pilot hole "wet" while carefully cleaning off the excess Utilibond from the surrounding surfaces.

Thoroughly clean all mixing tools and pails before the bonding compound has a chance to set.

9.

Once the Utilibond has hardened and gained initial strength (15-20 minutes) use water (high pressure is recommended) to clean off any excess debris and thoroughly sweep the area before leaving.

Be careful not to flush the Utilibond out of the kerf or center pilot hole.

10.

After just 30 minutes at 70 degrees the road can safely be reopened to traffic.