Wood Repair

Epoxy Restoration specializes in Wood Repair to restore the structural integrity as well as the aesthetics of wood structures. We repair all types of wood structures including homes, churches, schools, commercial and government buildings. Below are examples of successfully repaired Hawaii structures, with the following types of damage.

• Rot Repair - includes dry rot and normal weathering. We can inject the rot with a high strength super penetrating epoxy resin which solidifies rotted sections to a super strong epoxy impregnated wood. In severe cases where sections have disintegrated we will cut out remaining rotted surfaces. We will then install steel anchors if necessary, then mold and fill voids with our high strength resins to form a fully restored member.
• Termite Repair - including drywood and the severe damage caused by ground (Formosan) termites. Drywood termites usually leave shallow damage which is readily repaired by removing deleterious sections of wood and filling with our super high strength, fiber reinforced polyester (6,000 psi compressive strength) paste patching material. Deep damage is repaired by sealing off the wood surface, drilling port holes and injecting the wood with our EZ Resin super strength (2,800 psi compressive strength) injection resin. The resin has the ability to fill all the voids left by termites and hardens to a strong fill that bonds to the surrounding wood.

A. Ala Wai Elementary School Library and Cafeteria Buildings

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Major termite and rot damage to main carrier beams

Termite damage to fascia beams

Some wood damage is sealed using high strength polyester paste prior to injection.

Once wood is sealed we inject the voids using EZ Resin. Low pressure pumps (15 psi) and injection guns are used. Little pressure is needed because the resin is super penetrating. Excessive pressure can warp the wood.

Beam in the process of injection. Plastic drop cloth is hung to catch drips.

Wood boards with PVC plastic liner are used to mold heavily damaged members. Spot cartridges of injection resin are used to finish filling after main pumping is done.

Damaged fascia boards sealed with polyester paste and injected.

Forms are stripped and surfaces are sanded.

Spot high strength polyester paste is used to finish off any surface defects.

Right side of library beams finish painted.

Long cafeteria corridor perimeter beams injected and finish sanded, ready for paint.

Left side library beams finish painted.

B. Heavy drywood termite rafter damage to Kailua residence

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Surface appears to only have minor damage.

Power wire brushes are used to remove loose wood to expose true extent of damage.

Guide forms are placed to create a straight edge for filling voids with super strong fiber reinforced polyester paste.

Injection cartridge is used to fill any remaining voids in the wood.

Holes for injection are plugged.

Surface is sanded smooth, ready for painting.

C. Deep rot to beam end, Nuuanu residence

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End of beam completely rotted off. All deleterious wood is removed by power wire brushing

Beam end is molded with plastic coated forms. Drop cloth is hung to catch drips. Our mold is then injected with EZ Resin

Forms are removed. Surfaces sanded, ready for painting.

D. Heavy load on a severely damaged garage header beam, North Shore

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Plastic drop cloth installed to catch drips. Holes are made at an angle and #3 rebar is inserted into hollow beam at top and bottom. Typically rebars slide easily into heavily damaged beams. Polyester paste is used to seal outside of beam.

Beam is injected using high volume resin pump.

E. Seashell restaurant creation of in place glulam beams, Kauai

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Never done before repair. Stacked 1x10 planks bolted together to form huge 28 foot long curved beams. Beams fell apart during Iniki hurricane. To repair beams we jacked up the beams to their original position. Seams between planks were caulked with clear caulk. Holes were drilled in from the bottom to the top of the stack. Holes were then injected with Unitex semi flexible injection resin. Resin progress could be seen through the clear caulk to insure a complete fill.

Beams were sanded ready for painting. Blue barrels were filled with water to 2000 pounds and hung from each beam for 48 hours. Beams were tested not only for load capacity but elastic ability to recover from loads. Each beam passed with flying colors. Testing done by JAI International Structural Engineers.

F. Aiea residence, heavily damaged beams

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Beams are so heavily damaged by termites they have cracked. Roof has large leaks due to sagging beams resulting in extensive rot.

Beams are jacked up, molded and injected with EZ Resin

Cracked beams are replaced with new pressure treated beams.

G. Cracked laminations in large beams, Church of Latter Day Saints Haaula

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Wide cracks in glulam beams are a big concern because of the heavy loads they carry.

Epoxy injection is used. The crack is surface sealed with epoxy paste. Plastic tubing is drilled into the crack at several intervals.

A very thin epoxy resin is injected into the ports which travels across the crack and welds it shut with a bond that is much stronger than the original wood.

Once cured the surface is sanded and painted.

A very high column, with numerous splits has been epoxy injected. It has been sanded and spackled and is ready for paint.

H. Heavily rotted beams and Girders, Hawaii Loa Ridge residence

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Beams and column were encased in plaster. For years water leaked into the plaster and rotted out this area of the post and column. The Owner peeled back the plaster to expose the damage.

Rotted wood is removed by power wire brushing. Wood is dried using a heat gun. Galvanized and stainless steel anchors are installed to hold patches firmly. Voids are filled with high strength fiber reinforced polyester paste.

Steel brackets are cleaned, treated with a rust neutralizing coating and polyester filled.

Holes are drilled and EZ Resin is injected to fill any remaining voids.

Repairs are sanded, ready for plaster patching.

I. Large Column repairs to Polynesian Cultural Center

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Columns heavily damaged by ground termites. Paint virtually falls off columns.

Very deep cavities left by ground termites.

Columns are surface veneered with polyester paste to seal holes and cracks.

EZ resin is injected into the voids. Column is sounded and test bored to insure a total fill.

Rezin flows through wood and drips out of tiny holes in the wood, indicating extent of fill. These columns continue through three stories of floors and curve inward. They are virtually impossible to replace. However, they are an easy fix for our repair system.

J. Large Glulam beam roof connections Polynesian Cultural Center

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Beams appear only slightly damaged.

Power wire brushing is used to expose full extent of damage.

Beginning to fill voids with high strength polyester paste.

Once filled, repairs are sanded smooth.

Beams are then painted. The significance of these repairs is important. The glulams continue for fifty feet unsupported, to support a cantilevered roof over the main dining facility. Most of the roof load force is at, or near, our repairs. Replacement of these beams would be very, very difficult. An easy fix for our repair system.