Major steps in surface repair:

1.

Analysis, Strategy & Design

2.

Material Requirements & Selection

3.

Surface Preparation

Structural needs:
Surface repair must:
Replace damaged concrete
Restore required structural function
Protect itself and possibly the
underlying concrete
Restore lost
performance/serviceability

Type
Typical
Concrete

Advantages

Limitations

Applications

Readily available
Easy to produce, finish, cure
Proportioned to match existing
concrete

Bad in aggressive
environment
Shrinkage

Dry Park Mortar

Low shrinkage
-low water

Bad for shallow repairs

Bad for filling behind rebar

High volume repairs, +2 in repair

Bridge Deck overlays, partial or full
depth repair
Marine applications (reduced
shrinkage)
Hand Packed

Low Cracking
Increased Durability reduced
shrinkage/cracking

Not suitable for all repairs

Curved surfaces no forming

Resistance to Plastic Shrinkage

cracking and Service related
cracking

Hard to finish
Corrosion Potential
High Permeability

Structures prone to vibration

Domes/Arches
Reduced Shrinkage cracking

Economical, Easy to prepare

Minimum Crack width of 3mm

Large Dormant Cracks

Anchor bolts in hardened concrete
Honeycombs

1 part cement; 2.5/3

parts sand
Very low water

Ferrocement
Portland Cement Mortar
with wire mesh

Fiber Reinforced
Concrete
Metallic or Polymeric
Fiber

Grouts
Cement Sand and
Admixtures

Rapid Setting
Cement

High Early

Bridges
Airports

ShotCrete

Dry-mix- blended right before

spraying
Wet-mix- mixed wet, delivered w/
co2

Can use fibers, pea gravel,

sand, silica fume(thicker),
accelerators(layers),
fibers(reduced shrinkage),
Latex (Flexural)

Expansive
Cements

Similar characteristics to Portland

Cement (higher CA and CSulfate)

Type 3 Cement, Calcium

Aluminate Cement

Type M,S,K
Shrinkage
Compensating

Needs longer curing for expansion to

develop
May damage substrate
Reduced workability/ higher water
demand

Portland Cement with aggregate,

Common Polymers
Polymer
mixed with organic polymers
Styrene Butadiene
Cement
Freeze Thaw durability
Acrylic Latex
Reduced
Permeability/
Good
bond
Concrete (PCC)
Increased Flexibility Strength
(Latex Modified
Concrete LCC)
Polymer
Full Depth Repair

Concrete
(PC) Repair
Partial Depth
Hand
held
breakers30 to 90 lbs,
Reinforcement Repair
Pneumatic Chipping
hammer:
15 to
Fast Setting,
High Strength
can
damage
rebar around
Steel Cleaning:
Remove
concrete
the full bar
SurfaceStep
Prep1:
Procedures
Patching
30 lbs
Hydraulically
mounted
breakersWater
circumference
to facilitate
cleaning
rebar,
new3k-10k
1.Locate
the repair (hammer
sound
testingBlastingand chain
Rotary
Milling
Machine:
Some
concrete
removal
good
for high
volume
repairspsi
water cleans
off it
material
to bond,
and
uniform
material
around
drag/delamination
Can remove
concrete
methods
damage
the above rebar
bobcat/tractor
concrete
Step 2: Heavy rust
needs to
be removed
concrete
(undercut
rebar @
HydroRemoval:
20k-40k psi. 2.Remove deteriorated
concrete
near the surface.
Splitters:
hydraulic
edge,
fluid
Needle
ScalersStep
3:
May
need
to
place
additional
steel next to old
least in.)
undercutting
rebar impossibleThis
damage isofcalled
pressure,
expansive
cements
Tiny
steel
rods clean
if section loss affects capacity(+25%
loss ofoff
3.Edge steel
conditioning
blowouts
commonly
bruising
and
must be occur
HydroDemolition concrete
steel)
4.Surface
Cleaning
Pneumatic
Scrabblerremoved
for the
repair to in. removal,Step 4:
Blasting/SandBlasting
SandBlasting
Special coatings or other
protective methods
easy to properly.
use
function
Concrete
to 24
in.
Wire
Brushing
may be
required Cutting- up

Strengthening: adding
capacity to a member or
structure
Stabilization: stopping an
unwanted situation from
progressing (settlement of
footing)
Strengthening and
Stabilization can come
together.
Enlargement
Composite construction
Post-tensioning
Stress Reduction (cut new
Passive design: repairs do not participate in active
current stresses, used to accommodate more loads
Active design: repair immediately takes part in
shearing load, reduces stress/adds strength