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Kevin505 · May 12, 2014, 01:17 PM

We built a new home. The home builder and concrete sub both agree the initial pour was too wet. This resulted in areas of flaking and chipping with very little pressure, i.e. I could chip these areas with my thumbnail.

My first thought was that it should all be replaced. The builder and concrete sub said they could grind down the areas where it was chipping then skim the entire drive. I let them take a shot at it. It was done three days ago. Now, directly over the areas where they ground down there are small holes in the skimmed concrete. I think we're back where we started which is we have areas where water can stand, freeze and expand, causing cracking/spallding (sp?)

I still believe this drive needs to be replaced. I did a bit of research on the concrete sub, they have an F rating with the BBB. I'd like to request a different sub tear out and totally replace all of the concrete that was poured too wet.

Is this reasonable?

smoothy · May 12, 2014, 01:47 PM

Get it replaced... you paid for new... not a patch job. It might separate 5 or 10 years down the road (then where does that leave you) where a properly poured driveway can last 30+ years.

Kevin505 · May 12, 2014, 02:00 PM

Originally Posted by smoothy

Get it replaced... you paid for new... not a patch job. It might separate 5 or 10 years down the road (then where does that leave you) where a properly poured driveway can last 30+ years.

Thanks, smoothy - We didn't think we were being unreasonable.

smoothy · May 12, 2014, 02:58 PM

I have a friend that made someone (actually three different contractors) do it three times before they got it right... yes they knew exactly what to expect and yes they didn't settle for less than they wanted. So I know someone that did exactly what you want to do. Be prepared to fight for it if they don't don't want to give you what you expect.

Fr_Chuck · May 12, 2014, 03:41 PM

I agree, you may need to get 2 other contractors to give you professional opinions if they will not just replace it. Hopefully they will without you having court action.

But yes I would have it replaced/

smearcase · May 12, 2014, 05:53 PM

Agree with others. Minimum thickness for standard concrete is in the 2 to 3 inch range. In special situations (some bridge decks being repaired with traffic still using portions the bridge and where disruption of traffic is just about possible) very unique and costly mixes are designed and in some cases special adhesives/epoxies may be used, to place approx 1 inch, but obviously not the case in your situation.
In addition to using a wet mix, sounds like they had finishing problems also and worked up all that water to the surface and created a very thin, very weak surface which cracks and breaks easily.
The slump (measure of ability of concrete to stand on its own in simplest terms) of the concrete was sufficient reason to reject the mixer load. But the supplier probably gave the concrete sub exactly what he asked for. Your request is not only reasonable, it is the only option.

Kevin505 · May 13, 2014, 09:28 AM

Thank you to all for your replies! You've given me enough facts that I can now address the builder with confidence.

All the best to all of you!

smoothy · May 13, 2014, 09:30 AM

I'd also make frequent visits to make sure they actually rip it up and replace it... and don't skim it and lie about it.

Kevin505 · May 13, 2014, 09:36 AM

Originally Posted by smoothy

I'd also make frequent visits to make sure they actually rip it up and replace it... and don't skim it and lie about it.

Good advice... we're living in the home (while they replace 50% of the flooring and other repairs - horrible builder) and I've already notified the builder that his sub is not allowed on our property. I am selecting a contractor through Home Advisor and getting references and going to look at their work. This is too much to go through again...