Concrete Pavement Repair Methodology

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Introduction to Concrete Repairs

Depending upon repair Thickness:-

Use Product- “Microcrete BSF 419 with 10 mm aggregates,” at ratio 1:0.5 for
situations where the depth of deteriorated concrete extends to more than 30 mm of the
slab.

Use Product “Microcrete BSF 419 in as is condition for situations where the
deteriorated concrete is shallower than 30 mm.

For emergency work or pothole repair, Product “Strextra EFS,” a rapid strength
gain (M-40 within 4 hours) for thickness of 10 mm to 150 mm depth shall be utilized.

Dryshake of “Topcrete 333” over the green mortar ensures higher abrasion
resistance of the repair patches. This when spread over Microcrete / Strextra improves the
abrasion resistance of the Repair Patch tremendously.

Repair Procedures

The following procedures need to be followed when repairing concrete pavement, each
step is explained in more detail:

1. Identify the repair limits.

2. Remove deteriorated concrete.
3. Clean the repair surfaces.
4. Apply bonding agent & Place the repair material.
5. Finish the surface.

1. Identify the repair limits

It is important to properly evaluate the extent of the deteriorated concrete and determine
the limits of the repair as shown in Figure 1. For example, when spalling occurs, the
damage often extends beyond the visible spalled area. Since most spalls are caused by
de-skinning, the extent of de-skinning should be identified. One of the most efficient ways
of evaluating the extent of de-skinning is the use of a sounding test. A hammer or steel
rebar can be used for sounding testing by tapping/ knocking near the spalls. If there is no

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hollow sound, the sound will be solid. On the other hand, a dull or hollow sound indicates a
high probability of de-skinning of the top layer.

Figure 1. Identify the repair limits.

Figure 2 shows an example of limits that were not properly identified.

Figure 2. Core next to the spalled repaired area.

The repair material applied (left side of the picture) has a greenish color. The core, taken
several inches away from the limits of the spall repair, revealed several defects at various
depths. The top portion of the core came out disintegrated. If a sounding test had been
conducted, areas with defects would have been identified and the areas could have been
included in the repair. To assure removal of all degraded concrete, it is good practice to

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extend the limits of the repair boundaries few inches beyond the limits determined by the
sounding tests.

2. Remove deteriorated concrete

After the repair limits are determined, remove the deteriorated concrete as shown in Figure
3. Cut the perimeter of the repair area to a minimum depth of 1.5 inches and then chip the
concrete out using light pneumatic tools.

Figure 3. Removing deteriorated concrete.

3. Clean the repair surfaces

Good bonding between the exposed concrete surface and repair material is essential.
Without good bonding, the repair material will be separated from the concrete due to
environmental and wheel loading. After deteriorated concrete is removed, the concrete
surfaces should have a rough texture. Clean the repair area with water to remove any dust
to improve bonding of the patching material as shown in Figure below.

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4. Place repair materials

Select the Product depending upon the thickness of repairs, and it is good construction
practice to apply a Bonding coat (Product - Anchorex 290 or Anchorex EPB) on the faces
of the substrate which will receive the repair mortar.

The general characteristics of Microcrete BSF 419 & Strextra EFS repair materials include:

 good bond strength,

 less volume change potential due to temperature and moisture variations, and
 strength and modulus of elasticity comparable to those of the existing concrete.
It is better to enhance the anchorage & bonding to the substrate, by using a suitable
Bonding agent, :-

1. For repair thickness of more than 20 mm:- Anchorex 290 is single component ready
to use type of bonding agent. Make the receiving concrete surface SSD but not
water logged with water; and on such a surface brush apply Anchorex 290. While
the Anchorex 290 is still tacky, pour the Microcrete into the patch.
2. For repair thickness less than 20 mm:- Anchorex EPB is two component bonding
agent, mix the Resin and Hardner components in a clean container, and apply it by
brush on the substrate, again place the Microcrete into the patch while Anchorex
EPB is still tacky. In case Anchorex EPB sets before placement of the repair
moirtar, abrade out the Anchorex using a grinder, apply a fresh coat of Anchorex
EPB & then place the repair mortar.

OPTION A) Next prepare the MICROCRETE BSF 419 in the following method:-

1) In a strong 20 kg bucket add water. Use a portable paddle mixer or putty stirrer
equipment, and keep adding Microcrete powder continuously mixing till a flowable
paste is obtained. 10 mm aggregates may be added (ratio of 1:0.5 Microcrete to
aggregates) if the depth of patch is more than 30 mm. Proportioning of water to
Microcrete is approx 1.7 lts /10 kgs for flowable consistency and about 1.4 ltrs
/10kgs for paste consistency. For additional aggregates; water additions may be
required.
2) Place this mortar into the pothole, while the Anchorex is still tacky.
3) Tamp the mortar using a rod to ensure compaction of the mortar in the pothole

OPTION B) Preparation of STREXTRA EFS in the following method:-

1) In a strong 20 kg bucket add 3.3 ltr water. Use a portable paddle mixer or putty
stirrer equipment, and keep adding Strextra Powder mortar continuously mixing till
a flowable paste is obtained. 10 mm aggregates may be added if the depth of patch
is more than 30 mm. Proportioning of water to is 1.1 lts /10 kgs for flowable
consistency and about 0.95 ltrs /10kgs for paste consistency. For additional
aggregates; water additions are not required. Additional 10 mm aggregates may be
proportioned at 0.5 kg per 1 kg of Strextra EFS

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 2) Place this mortar into the pothole, while the Anchorex is still tacky.
4) Tamp the mortar using a rod to ensure compaction of the mortar in the pothole.

Figure 5. Place repair materials.

5. Finish the surface

Finish the repair surface to conform roadway surface. Match the repair surface texture with
adjacent concrete as shown in Figure 6.

Good curing is essential. Because the repair areas and depths are relatively small, this
makes the surface-to-volume ratio of the repair material applied higher than that of normal
concrete pavement. This high surface-to-volume ratio makes the repair material subject to
larger volume changes due to drying shrinkage if not properly cured. The loss of moisture
due to poor curing also results in evaporation heat loss.

The optimum time for the application of curing compounds is when the bleed water no
longer comes to the surface. However, repair materials have low water-cement ratios and
tend not to bleed. In that case, curing operations should begin as soon as possible, within
4 hours after placing the mortar. Apply RAZON CCC 105 AC curing compound on the
surface for best results.

Figure 6. Finish the surface.

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Introduction to Crack Repairs

Cracks should be repaired as soon as possible after identification to prevent further

deterioration and separation. Repairing the cracks early saves money in the long term.

Epoxy grouting is performed at cracks to maintain aggregate interlock and ensure a

monolith; thus minimize the relative movement of concrete slabs at the cracks. It is also
used at the cracks to keep the slabs from separating.

For repairs, cracks can be categorised into two types; those of width less than 3 mm &
more than 3 mm. Steps followed to repair cracks in concrete pavements are as follows:-

1) Make a groove in the crack

2) Drill holes in the crack and Insert nipples

3) Inject RAZON SUPER EPB 525 – a low viscosity Epoxy into the crevices

4) Cut out the protruding nipples & Seal the crack

Grouting of cracks upto 3 mm shall be done in the following methodology:-

a. Clean the surface of the crack using a wirebrush.
b. Using an angle grinder / saw cutter, at an incline cut both the faces of the cracks so
as to form a “V” groove of 5 mm depth along the entire length of the crack. Using
compressed air, blow out the dust from the groove
c. Drill holes of 12 mm dia and 60 mm deep at approx 300 mm distant from each
other. Insert plastic/ Steel nipples of 12 mm dia 60 mm length, where approx 2/3
height is embedded inside the concrete.
d. Mix Resin + Hardner of RAZON Bond 40 (1:1:: resin: hardner) and using this putty
seal the nipple-concrete joint using RAZON Bond 40(Fast Set).
e. Also use RAZON Bond 40 (1:1:: resin: hardner) to seal the groove with the help of a
putty knife.
f. Mix the components of SUPER EPB 525, low viscosity epoxy grout for injection (R :
H :: 1 : 0.5 viz the proportions provided) and using a grouting pump inject it into the
crack’s central nozzle, till the grout oozes out from the adjacent nozzle.
g. Next inject the grout from the next nozzle. Repeat till the end of the crack.

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 h. Cut off the nipple & Finish the surface of the crack using a putty knife, and level it to
the surroundings.
i. Consume all mixed product within its Pot life. Allow 24 hours for it to cure.
j. Immediately Clean all equipments, tools and surrounding concrete surface using
soapy water

Another approach of Injecting Epoxy is given as follows:-

1) Holes are to be drilled at an angle so that they intersect the cracks or joints at
about mid-depth of the slab. Inter nozzle distance is not over 250 mm. Seal
the nipple-concrete interface joint using RAZON Bond 40 & allow 24 hours
for curing.

2) Dust is removed by compressed air.

3) Mix the components of SUPER EPB 525, low viscosity epoxy grout for
injection (R : H :: 1 : 0.5 viz the proportions provided) and using a grouting
pump inject it into the crack’s central nozzle, the grout will rise to the surface,
and you will be able to see it progress along the crack till the next nozzle.
Then inject the grout from the next nozzle. Repeat till the end of the crack.

4) Cut off the nipple & Finish the surface of the crack using a putty knife, and
level it to the surroundings.

5) Consume all mixed product within its Pot life. Allow 24 hours for it to cure.

6) Immediately Clean all equipments, tools and surrounding concrete surface

using soapy water

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Grouting of cracks more than 3 mm which may be through the slab shall be done in
the following methodology:-

Ensure that no voids are the cause of failure in the slab. If voids are present under faulted
slabs, the pavement should be undersealed by using our “Flexituff” (a Tuff grout which
expands and seals areas under constraints) and to re-establish uniform support for the
slabs prior to performing grouting operations.

1) Using an angle grinder / saw cutter, at an incline cut both the faces of the
cracks so as to form a “V” groove the face of the of the groove should be
atleast 25 mm wide and 25 mm deep .

2) Using compressed air, blow out the dust from the groove

3) Drill holes of 12 mm dia and 60 mm deep at approx 350 mm distant from

each other. Insert plastic/ Steel nipples of 12 mm dia 60 mm length with
approx 2/3 height embedded inside the concrete. Seal the nipple-concrete
joint using RAZON Bond 40.

4) Mix the components of SUPER EPB 525-GREY, epoxy grout for injection (R
: H :: 1 : 0.5 viz the proportions provided) and using gravity or a low pressure
pump inject it into the crack’s central nozzle. You will be able to trace the flow
of the grout from the V groove, ensuring progress of the grout till the next
nozzle.

5) Next inject the grout from the next nozzle; Repeat till the end of the crack.

6) Consume all mixed product within its Pot life. Allow 24 hours for it to cure.

7) Cut off the nipple & Finish the surface of the crack using a putty knife, and
level it to the surroundings. Immediately Clean all equipments, tools and
surrounding concrete surface using soapy water

Illustration of EPB 525 GREY

Super EPB 525 ensures proper load transfer across the crack in the pavement, preventing
separations, and improving load transfer ability across the crack. This improves the life of
the pavement tremendously

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