Concrete Pavement Repair

4.0 Construction
With good design and construction practices partial-depth repair should last as long as the
surrounding concrete pavement. The most frequent causes of performance problems are
related to misuse of the technique, poor repair material and careless installation.

4.1 Finding Unsound concrete
The first step in constructing a successful partial-depth repair is the identification and removal of
all deteriorated concrete. Unsound concrete is commonly located by "sounding out " the
delaminated area. Sounding is done by striking the concrete surface with a steel rod or ball-
peen hammer, or by dragging a chain along the surface. The rod, hammer, and chain will
produce a clear ring when used on sound concrete and a dull response on deteriorated
concrete.
" Sounding" with a ball-peen hammer

" Sounding" with a steel chain
4.2 Determine the Repair Boundaries
Marking Area for Removal
Include all deterioration within the repair boundaries. Clearly mark each boundary with brightly-
colored spray paint to outline the removal area. To assure the complete removal of all
unsounded concrete, use the following guidelines:
Repair boundaries should be square or rectangular.
Use a minimum length of 12 in (300 mm).
Use a minimum width of 4 in (100 mm).
Extend the repair limits beyond the delamination marks or visible spalls by 3-4 in (75-
100 mm).
Do not repair a spall that is less than 6 in (150 mm) long and less than 1.5 in (35 mm)
wide.
Combine repairs less than 12 in (300 mm) from each other.
Repair the entire joint length if there are more than two spalls along a transverse joint.
4.3 Removal of Concrete
a. By Sawing and Chipping
Diamond-bladed saw for the
Sawing and Chipping
When using a method that chips the concrete for removal by hand, saw along the perimeter of
the removal area. Use diamond-bladed saws set to a depth of about 1-2 in (25-50 mm). The cut
should be straight and vertical. Overrun the cut slightly so that the bottom of the cut intersects
the repair corner. Break the concrete using a light pneumatic hammers no heavier than 30 lb
(13.5 kg). Lighter, 15 lb (7 kg) hammers are preferable so that it is easier to control the depth of
chipping. Spade bits are preferable to gouge bits for control of chipping. Even light hammers
with gouge bits can damage sound concrete.
Chip the area until sound and clean concrete along the entire bottom of the repair is exposed.
The depth of the repair should not exceed about one-third the pavement thickness. If more
chipping is necessary to find sound concrete, or dowel bars are exposed, switch to a full-depth
repair.


b. By Carbide Milling
Milling Operation
Some States have successfully used carbide-tipped milling machines for partial-depth repair.
Use a milling machine with a kilowatt rating on the high-end for its class. Milling machines with
12 in to 18 in (300 - 450 mm) wide cutting heads have proven efficient and economical,
particularly when used for large area.
The milling machine must have a mechanism that will stop penetration of the milling head at a
preset depth. This will prevent excessive removals. Otherwise there is potential danger of
damaging dowel bars or reinforcement by milling too deep. Depending on the equipment and
the lane closure conditions, the milling machines can operate either across lanes or parallel to
the pavement centerline. Milling across lanes is effective for spalling along an entire joint. For
smaller, individual spalls, either orientation is effective. The milling head should be checked
occasionally for missing teeth. Replace them as needed.


4.4 Cleaning
Sand Blasting of Repair Areas

Airblow to Remove Dust and Debris
After removing the concrete within the delaminated area, check the bottom by sounding for
remaining weak spots. Either chip away the weak areas or consider a full-depth repair if the
deterioration goes too deep. The exposed faces of concrete should be sandblasted free of
loose particles, oil, dust, traces of asphaltic concrete and other contaminants before placing
patching materials.
High-pressure water blasting is an alternative to sandblasting where controlling dust is critical in
urban environments. Waterblast equipment for concrete removal should be capable of
producing a blast pressure of 100-200 MPa. (14,500 - 29,500 psi). However, to avoid damage,
the equipment must be capable of adjustments that will allow removal of only weakened
concrete.
Airblow the repair area to remove dust and sandblast residue. Direct the debris away from the
repair area so that wind and traffic will not carry it back. Dust and dirt prevent the repair material
from bonding to the old concrete. The air compressor should deliver air at a minimum of 2.6cy
(3.4 M
3
) per minute and develop 90psi (.63 MPa) nozzle pressure. Even if the equipment has a
filter, check the air for oil and moisture contamination. Place a clean cloth over the nozzle and
blow air through the cloth. Examine the cloth for any discoloration from moisture or oil residue.


4.5 Placing the Joint Insert
Joint Insert
Partial-depth repairs that abut working joint or cracks require a compressible insert. The
compressible insert reforms the joint or crack and keeps the new repair from bearing on the
adjacent concrete. The insert also makes a uniform face that is helpful when resealing the joint
or crack. Common compressible insert materials are Styrofoam or asphalt-impregnated
fiberboard. The insert should have a scored stop strip and extend 1 in (25 mm) below and 3 in
(75 mm) beyond the repair boundaries to prevent the repair material from flowing into the joint.
An additional saw cut may be necessary to allow the insert to fit properly.
Without the compressible insert, the repair may fail quickly. Pavement expansion in hot weather
will force the adjacent pavement to bear directly against the spall repairs. The is termed "point
bearing" and will fail by pop-out or delamination.


4.6 Applying Bonding Agent
Application of Bonding Agent
When a bonding agent (cementitious grout) is required, the materials should be applied in a thin
even coat. The contact time (it should not dry out ) for cement grout should not exceed about 90
minutes. Check the repair area for any dust or sandblasting residue before placing a bonding
agent. The area should be clean and dry. Wiping the area while wearing a dark brown or black
cotton glove will easily indicate a dust problem. Airblow again if the dust has settled back in the
repair area. Scrubbing the bonding materials in with a stiff-bristled brush works well to get the
materials into surface cavities. Epoxy agents may permit a less vigorous application. Be sure to
cover the entire area with the bonding agent, including the repair walls or edges. Overlapping
the pavement surface also will help promote good bonding.


4.7 Placing the Repair Material
The volume of material required for a partial-depth repair is usually small. Ready-mix trucks and
other large equipment may be used if a sufficient number of repair areas are prepared ahead of
time and if the working time of the material is sufficient long to allow placement of the entire
amount of the material. For partial-depth repair, repair materials are typically mix on site in small
mobile drums or paddle mixers.
Place concrete into the repair area from wheelbarrows, buggies, or other mobile batch vehicles.
For small repairs, shovel the patch material. Where the repair material is mixed in repair area
with the truck's chute, slightly overfill the repair area to compensate for consolidation. ??? Keith
Vibrate the fresh concrete to eliminate any voids, especially at the interface of the repair and
existing concrete. Use small spud vibrators with a diameter of less than 1 in (25 mm). Do not
drag the vibrator through the mix - this may cause segregation and loss of entrained air. Use
small penetrations of the vibrator throughout the repair area. It should be lifted up and down and
not moved horizontally. Hold the vibrator about 15 - 30 to vertical. On very small repairs, hand
tools should be sufficient to work the repair material and attain adequate consolidation.
4.8 Finishing
Finish the repair surface to meet the elevation of the surrounding pavement. Trowel the patch
outward, from the center toward the edges, to push the repair material against the walls of the
patch. This technique provides a smooth transition and increases the potential for high bond
strength. Most finishers tend to finish a repair from the edges toward the center, which pulls the
material away from the edges. For small repairs, and projects that include diamond grinding,
texturing is not important. For projects with many repairs, matching the existing surface texture
will produce a more uniform appearance.
4.9 Curing
Application of Curing Compound
For curing, apply a liquid-membrane-forming curing compound evenly and sufficiently. Use well-
maintained pressure spraying equipment that will allow an even application. An application rate
of about 5.0 M
2
/L is sufficient. Curing is very important because of the large surface area of
these small repairs compared to the small volume of repair material. This relationship is
conductive to a rapid moisture loss and is different from most other concrete applications.
Neglecting to cure the repairs or waiting too long to apply the compound will likely result in
excessive material shrinkage and possibly delamination of the repair.
Where early opening of the pavement to traffic is required, it may be beneficial to place
insulation mats over the repairs. This will hold in heat from hydration and promote increased
strength gain for cementitious materials.


4.10 Joint Sealing
After the patch has gained sufficient strength, the joint can be resealed. It is important that the
joint faces are clean and dry for good sealant performance. Sawing, to provide the proper joint
shape factor, and sandblasting, to remove dirt and saw residues from the joint faces, are
essential. Resealing the joint is extremely important, because it will help prevent moisture and
incompressibles from causing further damage.

5.0 Opening to Traffic
Compressive strength requirements for paving concrete are generally specified at 3,000 psi (
20.7 MPa) at 28 days. The repair concrete should develop an equal or greater strength by the
time it receives traffic loadings. However, to minimize lane closures, traffic loadings may be
allowed on a patched area when the repair concrete has attained the minimum strength needed
to assure its structural integrity. The compressive strength required for the opening of partial-
depth repairs to traffic may be lowered because of their lateral confinement and shallow depth.
The specifications of rapid-setting proprietary mixes should be checked for recommended
opening times. Cylinders or beams can be tested for strength to determine what opening time
will be allow the repair material to develop enough strength.
6.0 Performance
Example of a finished patch
The performance of partial-depth repairs depends on many factors. Studies show that when
partial-depth repairs are properly installed and when quality control during construction is good,
80 to 100 percent of the repairs perform well after 3 to 10 years of service. When properly
placed with an appropriate and durable material and combined with good joint sealant
maintenance practices, partial-depth repairs should last long as the rest of the pavement.
However, improper design and construction practices, combined with poor quality control and
inspection, result in poor performance. The most frequent causes of partial-depth repairs failure
are:
Inappropriate use of partial-depth repairs
Improper selection of repair materials
Poor construction techniques
Lack of bond between the repair and the pavement
Drying of bonding agent
Compressive failure
Variability of the repair material
Improper use of repair material
Insufficient consolidation
Incompatible thermal expansion between the repair material and the original slab
Late Curing
Feathering of the repair material

Partial-Depth Repairs
7.0 Cost
When applied at appropriate locations, partial-depth repair can be more cost effective than full-
depth repair. The cost of partial-depth repair is largely dependent upon the size, number, and
location of repair areas, as well as the materials used. Lane closure time and traffic volume also
affect production rates and costs. In one of the New England State, the average costs for
general concrete removal and concrete removal by sawing are $110/ft
2
($1,200/M
2
) and $40/ft
2

($425/M
2
) respectively. The concrete placement costs are $3,075/cy ($4,000/M
3
) and $15.3/ft
2

($165/M
2
when using high early strength concrete.
Partial-Depth Repairs
Appendix
Generic Guide Specification Partial-Depth Repairs
Description
This work shall consist of partial-depth repairs of spalls, popouts, scaling, or other surface
distress in portland cement concrete pavements. The repair area shall be prepared by removal
of existing broken, damaged, or disintegrated concrete from the area indicated. Repairs shall be
made with approved repair materials in accordance with this specification and with the existing
pavement cross-section.
Materials
The materials used shall meet the requirements of the following AASHTO specifications:
Portland cement M-85
Aggregates M-80 & M-6
Curing Compound M-148
Concrete admixture M-194
Calcium chloride M-144
Epoxy resin adhesive (Class I and III) M-235
Rapid-setting repair materials Approved list specified
Fine aggregate for epoxy concrete gradation by epoxy manufacturer
Course aggregate - Size 89 AASHTO M-43
Repair mixtures
Accelerated Strength Portland Cement Concrete Mixture
Accelerated strength shall be obtained by using Type I or Type III portland cement and calcium
chloride or other accelerator to obtain a minimum strength of 3,000 psi (20.7 MPa) in 24 hours.
The plastic concrete shall have an air content of 6.5 percent 1.5 percent. The slump shall be 1
to 3 in (50 to 150 mm) at the time of placement.
Portland Cement Concrete Mixture
The specifications of the State highway agency will apply.
Rapid Setting Repair Materials
Rapid setting repair materials shall have a minimum compressive strength of 3,000 psi (20.7
MPa) within 24 hours.
Epoxy Resin Repair Mortars
Epoxy resin repair mortars shall be prepared in accordance with the manufacturer's
recommendation regarding aggregates and gradation of aggregate.
Equipment
The contractor shall furnish and maintain such equipment as necessary to complete the work in
accordance with the following specifications:
1. Sawing equipment shall be capable of sawing concrete to the specified depth.
2. Concrete removal equipment shall be capable of removing the concrete in the repair
area to the depth required without damaging sound concrete below the deteriorated
concrete. Where pneumatic hammers are used, the maximum size shall not exceed 30
pounds (13.6 kg).
3. Surface cleaning equipment shall be capable of removing all loose particles, oil, dust,
and traces of bituminous material from the repair surfaces.
4. Proportioning and mixing equipment shall meet the appropriate specifications and be
capable of uniformly producing a concrete mixture adequate in quality and consistency.
Mobile mixing equipment shall be permitted subject to the appropriate specifications.
5. Finishing and floating equipment and straightedges shall be capable of consolidating,
screeding, and floating the concrete. A dense, homogeneous concrete repair must be
produced and finished to the same surface slope as the existing concrete pavement.
Construction Methods
Areas to be repaired shall be determined by the engineer using a rod, hammer or other device
to determine defective or delaminated areas. The extent of the repair area will be marked by the
engineer. Areas less than 6 in (150 mm) in length and 1.5 in (35 mm) in width at the widest
point shall not be repaired under this specification but shall be filled with a joint sealant material
in accordance with the standard specifications.
Preparation of Partial-Depth Areas
A saw cut shall be made around the perimeter of the repair area to provide a vertical face at the
edges and sufficient depth for the repair. The saw cut shall have a depth of 1 to 2 inches (25-50
mm).
Concrete within the repair area shall be broken out to a depth of 1 to 2 inches (25-50 mm) with
pneumatic tools until sound and clean concrete is exposed. The maximum size pneumatic
hammer shall be 30 pounds (13.5 kg).
The exposed faces of the concrete shall be sandblasted free of loose particles, oil, dust, and
traces of asphalt concrete and other contaminants before placement of repair material. All
sandblasting residue must be removed just prior to placement of the concrete bonding agent.
Placing Repair Material
Accelerated portland cement concrete repair mixtures
Accelerated strength PCC (3000 psi in 24 hours) repair mixtures can be used where early
opening to traffic (4 to 6 hours) is required. An epoxy bonding agent is required when placing
high-early-strength PCC repair for early opening to traffic. The epoxy prime coat shall be
applied in a thin coating and scrubbed into the surface with a stiff bristled brush. Placement of
the concrete should be delayed until the epoxy become tacky.
The repair mixture shall be placed and consolidated to eliminate essentially all voids at the
interface of the repair and the existing concrete. If a partial-depth repair area abuts a working
joint or crack which penetrates the full depth of the pavement, a compressible insert medium
shall be used to maintain working joints or cracks. Contact between the repair and any adjacent
pavement which could cause compression or other types of failure in the repair must be
prevented.
High-early-strength PCC
Repairs should not be placed when the air or pavement temperature is below 40 F (4 C). At
air temperature below 55 F (13 C), a longer cure period may be required. All repairs shall be
finished to the cross section of the existing pavement. The repair shall be textured to conform to
the existing pavement.
The curing compound shall be applied immediately after texturing at the rate of 150 square feet
per gallon (3.7 square meters per liter).
Portland cement concrete mixtures.
Normal setting (3,000 psi (20.7 Mpa) in 3 days) PCC repair materials may be used where the
repair is protected from traffic for 24 hours or more. Sand-cement grout may be used as a
bonding agent. The sand-cement grout shall be composed of one part portland cement to one
part sand by volume with sufficient water to produce a mortar with thick, creamy consistency.
The grout shall be scrubbed evenly over the surface of the repair. Excess grout shall not be
permitted to collect in pockets. The concrete repair material shall be placed before the bonding
grout dries. The repair mixture shall be placed and consolidated to eliminate essentially all voids
the interface between the repair and adjacent concrete. All repairs shall be finished to the cross
section of the existing pavement. The repair shall be textured to conform to the existing
pavement. The curing compound shall be applied immediately after texturing at the rate of 150
square feet per gallon (3.7 square meters per liter).
Rapid setting repair materials.
Rapid setting repair materials shall be installed in accordance with the manufacturer's written
instructions. The preparation of the repair area surface shall be as outlined under accelerated
PCC repair material except where written instructions specify otherwise. The method of
bonding, placing, and curing shall be as recommended by the manufacturer. The time period
recommended before opening to traffic shall also be observed.
Epoxy resin repair mortars or epoxy concrete.
Epoxy mortar and epoxy concrete mix designs shall be submitted to the laboratory for
verification and approval. Those designs determined to be compatible with concrete pavement
will be approved.
The epoxy resin and the catalyst shall be preconditioned before blending to produce a blended
liquid that is between 75 F (24 C) and 90 F (32 C). The epoxy components shall be mixed in
strict compliance with the manufacturer's mixing recommendations before aggregates are
added to the mixture. The mixture shall be blended in a suitable mixer ( as specified) to produce
a homogeneous mass. Only that quantity of material that is usable in one hour shall be mixed at
one time. Material that has begun to generate appreciable heat shall be discarded.
The entire surface of the repair area shall be primed with neat blended epoxy immediately
before the mixture is placed. Priming shall include overlapping the surface of the area adjacent
to the repair. The mixture shall be placed and tamped with sufficient effort to eliminate voids
and to thoroughly compact the product. The surface shall be screeded and textured to produce
the required finish. The repair area shall be allowed to remain undistributed for at least 3 hours
before it is subjected to traffic.
Saw cut "run-outs". The saw cut "run-outs" in the existing pavement shall be filled with the
mortar of the repair material.
Water conditions
Portland cement concrete repairs shall not be placed when the air or pavement temperatures
are below 40 F (4 C). At temperatures below 55 F (13 C), a longer cure period may be
required. Insulation may be used to improve the rate of curing.
Measurement and Payment
The area measured for payment will be the number of square feet of surface area of partial-
depth repair completed in placed and accepted.
Payment shall be made at the contract unit price per square foot (square meter). Such payment
shall be full compensation for (a) any required sawing; (b) removing asphalt concrete repair
material or spalled, broken, or damaged portland cement concrete; (c) cleaning the surface by
sandblasting; (d) furnishing, placing, finishing, and curing the concrete repair; and (e) forming a
new transverse and longitudinal joint, including all equipment, tool, labor and incidentals
necessary to complete the work.