FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Methacrylate Flood Coat
Flood-coating a concrete slab using methacrylates is used when there is a need to fill and bond small cracks, such as shrinkage cracks, as well as to seal the slab against the penetration of water, salts, or deleterious chemicals. Methacrylates have the added benefit of repairing some cracks and improving resistance to traffic wear. Cracks bonded using methacrylates can usually resist stresses caused by traffic vibration, but not structural stresses. Prior to installation, special care should be taken to ensure the cracks are open, clean, and free of any contaminants or other bond-inhibiting materials such as oil and grease. If structural repair of cracks may be required, consult a qualified structural engineer for evaluation. Ensuring a full-depth structural repair using gravity feed methods can be difficult, and although vacuum injection of methacrylates can be done, pressure injection using epoxies may be a preferred option (see RAP Bulletin 1, “Structural Crack Repair by Epoxy Injection”).
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Concrete Repair by Shotcrete Application
The shotcrete process is typically used to restore structural integrity, increase concrete cover over reinforcement, or both. It’s typically used when forming requirements are difficult or prohibitively expensive or as another repair tool in the designer’s and contractor’s tool kits.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Slabjacking
Slabjacking is used to level and align concrete slabs-onground that have shifted due to settlement, erosion, flooding, or shrinkage of the soil or base below the slab.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Leveling and Reprofiling of Vertical and Overhead Surfaces
Leveling or reprofiling is indicated whenever concrete with an unacceptable finish is exposed to the elements or in contact with aggressive chemicals. Leveling or reprofiling can be used on exterior or interior façades, foundations, beams, columns and soffits found in buildings, parking structures, retaining walls, bridges, storage tanks, and tunnels. It can also be used on interior façades and soffits of
process tanks, water treatment tanks, and secondary containment with different chemical exposures. Usually, leveling or reprofiling is used to improve the aesthetic appearance or prepare the surface for subsequent coating or application.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Spall Repair of Horizontal Concrete Surfaces
Horizontal surface repair is common on slabs either elevated or on grade. Deterioration may be caused by corrosion of embedded reinforcement resulting in delamination and spalling. Other common causes include freezing-and-thawing
deterioration and chemical attack. After an evaluation of the deterioration by an engineer, a plan should be developed including objectives and specifications for the repair. Steps for repairs that include layout, removals, edge preparation,
mixing, bonding, placement, and curing have been included below as a step-by-step guide for use by field personnel.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Vertical and Overhead Spall Repair by Hand Application
One of the most common application methods for repairing concrete is by hand troweling mortars to replace damaged concrete. This method can be used to repair spalled or deteriorated concrete (Fig. 1) or to resurface vertical, overhead, and horizontal concrete surfaces. Applying repair materials by hand does not require extensive or complicated equipment and is ideal for shallow surface repairs, especially in areas with limited or difficult access. While both portland cement-based and resin-based repair mortars have been used for trowel-applied vertical and overhead repairs, this field guide focuses on the application of portland cement-based repair materials.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Surface Repair Using Form-and- Pump Techniques
The form-and-pump repair technique is a multi-step process of preparing and constructing formwork, and pumping repair material into the cavity confined by formwork and existing concrete. The form-and-pump technique allows the use of
many different repair materials. The necessary requirement for material selection is pumpability. Various pumps are used, depending on the mixture design with focus on aggregate size. Prior to construction of formwork, any surfaces that may
cause air to become trapped during the pumping process must be trimmed, or vent tubes installed.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Surface Repair Using Form-and- Pour Techniques
The form-and-pour placement technique is a multistep process of preparation, formwork construction, and placement of repair materials. Repair materials are placed in the cavity between the formwork and the prepared substrate with
buckets, pumps, chutes, or buggies. The form-and-pour technique allows the use of many different castable repair materials. Placeability is the primary consideration material selection. Depending on the consistency of the repair
material, consolidation is accomplished by vibration, rodding, or when the material has extremely high slump (self consolidating), no additional steps may be required.
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FIELD GUIDE TO CONCRETE REPAIR APPLICATION PROCEDURES
Concrete Repair by Low-Velocity Spraying
Low-velocity spray mortars can be used for structural or non-structural repairs based on the design. Low-velocity sprayed concrete repair materials are prepackaged mortars applied using purpose-built mortar pumps or small concrete pumps that force the mixed, low-slump mortar through a hose to the nozzle where air is added to accelerate and expel the mortar. This document reviews when to use this repair method, how to prepare the surface, material selection, equipment used, and safety considerations.
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