my concrete pond restoration

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pondkeeper

Feeder Fish
MFK Member
May 26, 2009
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Pacific NorthWest
I built my current ornamental pond some 20+ years ago. I had built a few before but this was the first all concrete pond, at my own house.

There was a tiny little pond built with pvc plastic, left by the previous owners. The location was right outside the family room, which I liked. But there was a 125ft tall fir tree and a 50ft maple right there.

I cut the trees down because they were way too close to the house and did my best to get all the root systems dug out. Then I built this pond and stream. You can see it in my gallery.

But I made some mistakes. Back then, there wasn't a lot of people doing this and there wasn't any web to look stuff up.

I used 6x10 wire mesh to reinforce the concrete and although I used the standoff blocks on the bottom, I did not use them on the sides, or maybe I didn't use enough of them. The other issue was that I did not do a good enough job of lacing the overlapping sections of mesh.

A year or two ago I started to get some leakage out of the pond. I found some cracks near the edge and patched those and thought I was ok. But then it leaked again and just got worse. So this year I drained it all out and cleaned it. Then started chipping away for bad concrete.

As you can see from the photos, there were several bad cracks. I used my pneumatic chisel to break all the weakened concrete out, down to the steel mesh. The concrete was way too thin in some places and the steel mesh was right at the bottom instead of the middle of the pour. The places that cracked were all very thin and occured where the mesh sheets overlapped. I didn't find any wire lacing the sheets together, although I know I did. Apparently not nearly enough!

More posts to follow the progress:

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I also found one of the sediment trap sections of the stream had cracked in half.

Most of this damage was actually caused by moles, gophers and ground squirrels digging tunnels under the concrete. They are a huge problem.

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At this point I was very close to just filling it in with dirt and planting flowers!

Before I could fix the cracks I went on a rodent genocide program and filled in all the tunnels I could access. I poured close cell foam down the ones that were deep under the pond.

I then cleaned up and laced all the mesh that I could get to. I left wire ties sticking up out of the concrete so that I could tie new reinforcement to the old.

I then filled in the cracks with hydraulic concrete with the wire ties sticking out.

Then I put down new mesh, tied it to the wires from the old mesh and put down a new layer of concrete. The old concrete was etched and sandblasted (that is why you see so much exposed aggregate.

Sorry I don't have photos of these intermediate steps.
Oh, there is a shot of the stream section after the concrete repair. This was also reinforced with a layer of mesh.
And a shot of the marginal shelf after the new concrete.

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The next step was to smooth out as much rough stuff as I could stand, with a body grinder. Ugh, what a pain.

Then I used fiberglass cloth and Pond Armor to seal some of the cracks that did not get a steel mesh layer added.

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I then started the process of coating the entire pond with Pond Armor.

The first thing I realized was that their coverage figures are for an ideal surface. It was clear that I would need almost 3x that. :(
Had I realized that in the beginning I would probably not have used it. The total amount ended up costing over $1000. :WHOA:
It is a lot of work to put on old rough concrete, let me tell ya.

The worst part was when I realized I wasn't goint to make it, I called them up and they were out of hardener. I had to wait 2 weeks. Then UPS lost my shipment. Three weeks later I am good to go. The folks at Pond Armor did replace my order AND they overnight shipped it for me so I would be able to apply it the next weekend before the rains hit again. THANKS GUYS!!!

Unfortunately while I was waiting, it did storm on us and all the cleaned concrete got dirty and stained again. So I had to do the sandblasting all over again! Argh. :cry: I needed to rough up some of the first coating anyway...

But, I have to say, this is really tough stuff. I tried to knock off some drips from the previous treatment. No way. That stuff seriously bonds to the concrete. I pulled out the body grinder again and smoothed down the bad ones and ignored the others.

As it turned out I had just barely enough to finish the main pond. I was hoping to do the whole stream and upper catch basin but no luck. I will use another sealer for those. Something cheaper that I can source locally. I just can't afford more PA.

Here is the main pond after the Pond Armor. It sure looks nice and is nice to touch as well. It will make working in the pond a lot nicer!

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Hoyo12;3459311; said:
NICE!
Can't wait until the water is added.:popcorn:

Yeah me too! Hopefully this weekend. It rained today and it was windy so right now it just dirty again.

Saturday we start the task of dividing up all the lillies and iris and repotting them all. OMG there are so many!! We will fill up the pond as we get the plants in there. Just in time for all the fall leaves to fill it up! sigh.

But it will look pretty next year when it blooms out again.

The good news about fall is that the bass fishing on the irrigation ponds is picking up, so I will be able to stock this pond right away :grinno:
 
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