Ultra-Poz Sapphire Rebar Rust Stain Repair

Ultra-Poz Sapphire Rebar Rust Stain Repair

Rust Stain Before   Rebar Before   Rebar Before
Rebar After   Clean Steel   Finished Repair

Here is a golf ball sized rebar rust stain on the bench back of this Ultra-Poz Sapphire finished pool. These can be a bit more difficult to repair than rebar rust stains on the floor or wall of a pool. Most of these involve patching flat and curved surfaces at the same time. I got a little bit lucky on this one as it didn’t roll too far into the seat area, but I still had a inside curve to deal with. Inside and outside rounded edge repair on Ultra-Poz, 3M Quartz or Pebble are tricky at best. Photos one through six are start to finish of the repair. In the second picture you will notice intense rust on one end of the rebar and clean non-rusted steel on the bottom right edge of this picture. This was what I call a dead end rebar, only one end is connected to more rebar, the other end should have had an overlapping piece tied over it. The third picture shows the cut and removed rebar to the side of the repair area. The forth picture is where I cut the rebar clean and flush with the shotcrete, the shiny silver spot in the center is the cut rebar, notice there is no visible rust on the cut end of the embedded rebar or the removed piece in the fifth picture. I always inspect the bottom of the removed piece of steel to ensure I removed all of the rusted rebar, if it is rusted on the bottom I continue exposing and cutting until I find clean steel. It is the only way to ensure that it wont come back, after all, I guarantee my work. The final picture is the finished patch.

You may notice the patched area is a little brighter than the surrounding finish, this is normal and not unexpected. The patch is much newer cement that will blend in better in a day or two.

This repair took less than two hours and that includes taking pictures and talking to the neighbors who dropped by as I was in the middle of the repair. Seems they were curious about the guy in the wetsuit and scuba equipment. Even the carpet cleaning guys had to see what I was doing.