D.S. Brown Blog

Delpatch is big solution to Naval Air Station runway repair

Jan 16, 2023 4:00:00 PM / by D.S. Brown

To complete a recent $4.8 million runway repair project at Naval Air Station Joint Reserve Base Fort Worth, D.S. Brown and base teams poured 23,000 five-gallon buckets of Delpatch™ Elastomeric Concrete to reestablish 12,000 feet of runway length.

Delpatch™ Elastomeric Concrete is a 2-part polyurethane patching material mixed with proprietary aggregates and has been specified and installed on airport runways and highways since 1983. For more than 37 years, Delpatch has proven to be extremely durable and cost-effective.

“The NAS JRB Fort Worth Runway 18 repair project is in fact our single largest project to date that utilized Delpatch,” said Ethan Fuller, D.S. Brown’s pavement division manager. “We were certainly excited to team up with the Navy and provide a permanent solution for the runway at NAS JRB Fort Worth.”

Delpatch is self-leveling and has a rapid cure time. This minimizes expensive downtime and allows for the return of traffic often within an hour of final pour. It also protects work crews by minimizing their exposure to heavy traffic. During the record-breaking project repairs at Naval Air Station Joint Reserve Base Fort Worth crews were working on an active runway.

In this typical Delpatch™ Elastomeric Concrete repair, most of the work took place along the joints of each concrete panel. Crews removed damaged concrete around the joints, until reaching solid concrete, then filled with Delpatch.

The former Carswell Air Force Base was home of the legendary Strategic Air Command during the Cold War Era. The currently named Naval Air Station Joint Reserve Base Fort Worth became the first Joint Reserve Base in 1994.

Delpatch Elastomeric Concrete Advantages

D.S. Brown understands the demands and needs of a quality repair material to perform well, and to perform well the first time it’s installed. Delpatch is a material with optimal installation and performance qualities for customers. Here are a few of the advantages of Delpatch Elastomeric Concrete:

  • High-load bearing capacity – Handles the weight of C-4s, 747s, and heavy truck traffic.
  • Outstanding anti-spalling properties – Delpatch is a long-term solution for high-performance pavement repairs.
  • Excellent adhesion to concrete and steel – Laboratory tests show Delpatch withstands over 400 psi with concrete and 500 psi with steel.
  • Impact resistant – Under bitter cold conditions Delpatch withstands heavy impact, unlike epoxy and concrete-based materials that shatter.
  • High compressive strength – Delpatch can handle heavy pounds per square inch pressure before deflecting, and its memory allows it to return to its near original state after deflection.
  • Chemical resistant – Delpatch resists commonly used chemicals such as ASTM Oil #1, ASTM Fuel A, Ethylene Glycol, Freon, Isopropyl Alcohol, JP-4 JetFuel, Silicone Grease, Sodium Chloride, Mineral Oil, Trisodium Phosphate, and Potassium Acetate.
  • Easy to install – Delpatch is self-leveling and has a rapid cure time to minimize expensive downtime and allow for the return of traffic within an hour of final pour.
  • Flexibility – Cement, Phosphate, Epoxy and most other high early strength repair materials prematurely fail because they are rigid. Rigid repair materials installed in rigid pavement require that the materials have similar coefficient of expansion. Most do not and, as a result, destroy the patch and the surrounding concrete. Delpatch utilizes a unique urethane chemistry to provide a flexible patch that will deflect as surrounding concrete expands and contracts, rather than destroy it.

The key to Delpatch’s success is its unique characteristics. These have built the great reputation of Delpatch’s performance and use. The flexibility of Delpatch allows the material to perform well in extreme freeze-thaw conditions, such as found at Denver International Airport and Kansas City International Airport, while also providing strong bonding capabilities to handle high-traffic and heavy load airports, found at the Los Angeles International Airport and Charlotte Douglas International Airport. Many commercial and general aviation airports benefit from Delpatch’s ease of use, whether it’s on a maintenance schedule or on capital-funded projects.

For a more in-depth look at Delpatch, watch this installation video on instructions and applications. Questions or inquiries regarding Delpatch Elastomeric Concrete? Reach out to the D.S. Brown team at 419.257.3561.

About the D.S. Brown Company

Founded in 1890, the D.S. Brown Company is a leading worldwide designer, supplier and manufacturer of engineered products for the bridge and highway industry. D.S. Brown’s home office and manufacturing facilities are in North Baltimore, Ohio.

D.S. Brown is fully integrated, performing and controlling all manufacturing processes internally:

  • Research and Development
  • Engineering Design/CAD Detailing
  • Extruding, Molding and Testing
  • Custom Steel Fabrication and Machining

D.S. Brown has the most comprehensive product-line serving the transportation industry. We manufacture solutions for the most challenging infrastructure applications. Our high-quality engineered products are available worldwide for new construction and rehabilitation of bridges, highways, airfields, pavements, and parking structures.

  • Bridges: Since the early 1960s, D.S. Brown has provided expansion joint systems and specialty products for bridges around the globe.
  • Pavements: Building highways and airport pavements to last is a challenging engineering assignment, especially when the pavement must withstand heavy traffic, weather extremes, debilitating fuels and de-icing chemicals. You need reliable products with a proven track record.
  • Architectural: D.S. Brown provides a variety of expansion joint products for parking garages and other architectural applications.
  • Concrete Repairs: D.S. Brown offers a variety of cementitious and composite solutions for various concrete repair projects.

Contact the D.S. Brown Company

Connect with our D.S. Brown pavement representatives Uriah Carpenter (International), Ryan Sypherd (West), Darren Johnson (East) and Ethan Fuller (Central) for more detail.

Find information about D.S. Brown products, projects and other resources on FacebookTwitterLinkedIn, YouTube and Instagram.


Tags: Delpatch Elastomeric Concrete, pavements

D.S. Brown

Written by D.S. Brown

D.S. Brown Sales and Engineering Teams.