Carbon Fiber Concrete Stitch & Staple Repair Kit — 15 Pre-Tensioned Stitches
15 Pre-Tensioned Carbon Fiber Stitches — Used by Contractors and Capable DIYers — 10x Stronger Than a Steel Stitch, Zero Corrosion
Pre-tensioned carbon fiber — resists crack movement with zero initial stretch, a feature no competitor offers 44 sq.cm bonding area per stitch — the largest of any stitch on the market Foundation walls, floor slabs, pool decks and retaining walls
Installs on walls, floors, and ceilings
Will not corrode — unlike steel staples which begin rusting immediately after installation Simple one-cut installation — hand grinder and vacuum only
5 minutes or less per stitch install time
No epoxy applicator gun required
Carbon fiber lab tested to ASTM C882, D648, D638, D792 Carbon Fiber: 2,884 MPa (418 ksi) — Epoxy: 31 MPa (4,496 PSI)
Contractor pricing and bulk quantities available — call 1-866-445-3984 10-Year Limited Warranty Free NextStar Technical Support — 1-866-445-3984
ASTM C882
ASTM D648
ASTM D638
ASTM D792
10-Year Warranty
Pre-Tensioned
Contractor Supply
Installation Video
VIDEO
Step-by-step installation guide. Full written instructions below. Questions? Call 1-866-445-3984 .
What Is a Carbon Fiber Stitch — How Pre-Tensioning Controls Crack Width
A carbon fiber stitch is a structural reinforcement set into a slot cut across a crack. You cut a shallow slot perpendicular to the crack, embed the stitch in industrial epoxy, and once cured it bridges the crack — carrying the tensile load that is trying to pull it open and locking the crack against further widening. Unlike a surface patch, it works through the full depth of the slot. Unlike a steel staple, it will never corrode.
What sets the NextStar stitch apart is that it is pre-tensioned during manufacturing — the carbon fibers are already under load before the stitch is ever installed. The moment it sets in the epoxy, it begins resisting crack movement with zero initial stretch . Competing stitches must first take up their own slack before they engage, allowing micro-movement that can let the crack re-open. Pre-tensioning is the reason NextStar stitches control crack width from the first day, not after the crack has already shifted. No other stitch on the market — including Rhino Crack Lock and the Fortress CrackStitch — is pre-tensioned.
44 sq.cm Bonding Area — How It Compares to Standard Staples
The holding strength of any installed concrete stitch is governed by its bonding surface area and the strength of the concrete it bonds to — not by the bare tensile rating of the stitch material. In a real repair the concrete-to-epoxy bond reaches its limit long before the stitch itself does, so a high bare-tensile number tells a buyer very little about installed performance. The figure that actually predicts how well a stitch holds is bonding area, and NextStar leads every competitor on it.
Product
Bonding Area
Relative Coverage
NextStar Carbon Fiber Stitch 44 sq.cm
Rhino Crack Lock
30 sq.cm
Steel Staple (3 sides)
18.7 sq.cm
Fortress Staple (1 side only)
16.8 sq.cm
Fortress Grid Stitch
9.5 sq.cm
Stitch Dog
6 sq.cm
Competitors often headline a bare per-stitch pull rating — for example a stitch rated at thousands of pounds in isolation. That number describes the stitch in a lab clamp, not bonded in concrete, where the surrounding material gives way first. Because the concrete fails before the carbon fiber does, the stitch with the largest bonding area transfers load across the most concrete and holds the longest. At 44 sq.cm, NextStar bonds to roughly 47% more concrete than Rhino Crack Lock and more than four times the area of a Fortress Grid Stitch.
Applications — Foundation Walls, Concrete Floors, Pool Decks
Carbon fiber stitches are used by foundation repair contractors, concrete restoration specialists, pool contractors, and capable DIYers wherever a crack needs to be permanently locked against further widening or movement. Common applications include poured concrete foundation walls with diagonal or vertical cracks, garage and shop floor slabs before coatings are applied, pool deck and pool shell repairs, cracked retaining walls, and any load-bearing concrete that requires tensile reinforcement across a crack. They install in any orientation — walls, floors, and ceilings.
Stitches are most effective used together with epoxy crack injection — the epoxy fills and seals the crack in compression, while the stitches handle the tensile load across it. The two systems complement each other for complete structural reinforcement, and contractors frequently bill both together as a single repair package. For multi-job contractor quantities or project pricing, call 1-866-445-3984
15 Stitches Included — Coverage and Spacing Guide
Install stitches 9 to 18 inches apart across the crack — closer spacing gives greater resistance to movement. To size your job, measure crack length and divide by your chosen spacing: a 10 ft crack at 12-inch spacing needs about 10 stitches. The 15-stitch kit covers most residential crack repairs. Larger or commercial jobs can step up to the 50-stitch upgrade, and contractors can order bulk quantities and custom kit sizes by phone.
Kit Components
15 Pre-Tensioned Carbon Fiber Stitches
Pre-impregnated, unidirectional, pre-tensioned. Under load from the moment of installation — no initial stretch before load resistance begins.
Carbon Fiber Epoxy — 450ml Set (A+B)
Two-part epoxy formulated for maximum bond between carbon fiber and concrete. Gels in 1 hour, fully cures in 24 hours.
4.5 Inch Diamond Turbo Blade
For cutting the installation slot across the crack. Requires a standard 4.5 inch hand grinder (not included).
Trowel
For packing epoxy into the slot and finishing the surface flush.
Gloves & Complete Instructions
Full step-by-step installation guide included with every kit.
Tools you will need (not included): 4.5 inch hand grinder and shop vacuum or compressed air.
Installation Steps
Cut the slot. Using a 4.5 inch hand grinder with the included diamond turbo blade, cut a slot 12 inches long, ¾ to 1.5 inches deep across the crack — perpendicular to it. The slot should straddle the crack evenly.Vacuum the slot. Remove all dust and debris with a shop vacuum or compressed air. Dust will prevent the epoxy from bonding to the concrete walls of the slot.Mix the epoxy. Mix the two-part carbon fiber epoxy by hand — no special applicator tool required.Butter the stitch. Apply a coat of mixed epoxy to the carbon fiber stitch.Fill the slot. Trowel epoxy into the cut slot to fill it approximately halfway.Install the stitch and finish. Press the epoxy-coated stitch firmly into the filled slot. Trowel additional epoxy over the top to fully embed the stitch flush with the surrounding concrete. Allow to cure — gel time 1 hour, full cure 24 hours.
Spacing: Install stitches 9 to 18 inches apart, depending on reinforcement required. Closer spacing provides greater resistance to movement.
Orientation: Always install stitches perpendicular to the crack — never parallel.
Multiple directions: For cracks with movement in more than one direction, install a second row at 90° to the first.
Used with injection: Do crack injection first, then stitch after the injection repair has cured.
Surface coating: The repaired area can be painted or coated after the epoxy has fully cured at 24 hours.
Common Questions About Carbon Fiber Concrete Stitches
What are carbon fiber concrete stitches and how do they work? A slot is cut perpendicular to the crack, the pre-tensioned stitch is embedded in industrial epoxy, and once cured it creates a structural bridge that distributes load away from the crack, prevents further widening, and resists freeze-thaw movement. Unlike surface patches they work through the full depth of the slot — and unlike steel staples, they will not corrode.
Is this kit suitable for contractors as well as DIYers? Yes. The kit is used by foundation repair contractors, concrete restoration companies, and pool contractors as well as capable DIYers. The one-cut installation process is fast enough for contractors to run multiple stitches per job efficiently, and the pre-tensioned design eliminates the variance that comes with hand-tensioning on site. Contractor pricing and bulk quantities are available — call
1-866-445-3984 .
How do I install the stitches — is professional help needed? No professional is required for a capable DIYer, and the process is fast enough for contractors to run efficiently on multi-crack jobs. Cut a ¾ to 1.5 inch deep, 12 inch long slot across the crack with a hand grinder, vacuum the dust, mix the epoxy by hand, butter the stitch, fill the slot and press the stitch in.
What tools are needed beyond the kit? A 4.5 inch hand grinder (for the included diamond turbo blade) and a shop vacuum or compressed air. No epoxy applicator gun is required.
How strong are NextStar stitches compared to competitors? NextStar stitches have a 44 sq.cm bonding surface area — the largest of any competitor. Because the installed concrete-to-epoxy bond fails before the carbon fiber does, bonding area, not bare stitch tensile rating, is the true measure of installed performance. Pre-tensioning also means zero initial stretch before load resistance begins, where competitors must first take up slack, allowing micro-movement that can re-crack the repair.
Why is bonding area more important than a stitch's pull rating? A pull rating quoted for the bare stitch describes it clamped in a lab, not bonded into concrete. In a real repair, the concrete surrounding the slot gives way before the carbon fiber reaches its limit, so the stitch that bonds to the most concrete holds the best. That is why NextStar reports bonding area (44 sq.cm, the largest available) rather than only a bare tensile number.
Will the stitches corrode over time? No. Carbon fiber does not corrode, rust, or degrade over time. Steel staples begin corroding almost immediately after installation as moisture penetrates the repair.
What types of concrete structures can they repair? Poured concrete foundation walls, garage and shop floor slabs, pool decks and pool shells, retaining walls, and any poured concrete with cracking that requires tensile reinforcement. They install in any orientation — walls, floors, and ceilings.
How far apart should stitches be installed? Typical spacing is 9 to 18 inches apart depending on the reinforcement required. Closer spacing provides greater resistance to crack movement. For extensive cracking or weaker concrete, use the tighter end of the range.
How do NextStar stitches compare to Fortress and Rhino stitches? NextStar stitches are pre-tensioned — they resist load with zero initial stretch. Rhino Crack Lock and the Fortress CrackStitch are not pre-tensioned, so they allow micro-movement before engaging. NextStar also has the largest bonding area at 44 sq.cm versus Rhino at 30 sq.cm, the Fortress Staple at 16.8 sq.cm (one side only), and the Fortress Grid Stitch at 9.5 sq.cm.
Why choose carbon fiber stitches over epoxy injection alone? Epoxy injection fills the crack in compression but has limited tensile strength on its own. Carbon fiber stitches handle the tensile load — resisting forces that try to pull the crack open. Used together, epoxy holds the compression and stitches hold the tension, providing complete structural reinforcement for load-bearing concrete cracks.
What ASTM standards do the stitches meet? NextStar carbon fiber stitches have been lab tested to meet ASTM C882, D648, D638, and D792.
How long does the epoxy take to cure? The epoxy gels in approximately 1 hour and fully cures in 24 hours. The repaired area can be painted or coated after full cure.
How many stitches do I need for my project? Measure your crack length and divide by your chosen spacing (9 to 18 inches). A 10 ft crack at 12 inch spacing requires approximately 10 stitches. The 15-stitch kit covers most residential crack repairs. Contractors running multiple jobs or larger commercial projects can order bulk quantities and custom kit sizes — call
1-866-445-3984 for contractor pricing.
What does the 10-year warranty cover? The 10-year limited warranty covers the stitch itself against failure under tensile load when installed according to the included instructions. It does not cover the surrounding concrete or replacement installation costs. For warranty questions call
1-866-445-3984 .
10-Year Limited Warranty. Questions during your installation? Contractors looking for bulk pricing or project support? Call our free technical support line at
1-866-445-3984 — our team is available to help contractors and DIYers throughout every project.
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