ACI RAP Bulletin 1

American Concrete Institute ®

Advancing concrete knowledge

FIELD GUIDE TO Structural

CONCRETE REPAIR Crack Repair by
APPLICATION PROCEDURES Epoxy Injection

Structural Crack Repair by Epoxy Injection (ACI RAP-1) 1

2 Repair Application Procedures Bulletin
 ACI RAP Bulletin 1
(Reapproved 2009)

Field Guide to Concrete Repair Application Procedures

Structural Crack Repair by Epoxy Injection

Reported by ACI Committee E706

Brian F. Keane*
Chair

J. Christopher Ball H. Peter Golter John S. Lund George I. Taylor

Floyd E. Dimmick, Sr. Bob Joyce Richard Montani Patrick M. Watson
Peter H. Emmons Kenneth M. Lozen Jay H. Paul David W. Whitmore
Timothy R. W. Gillespie

*
Primary author.

It is the responsibility of the user of this document to Structural Disclaimer

establish health and safety practices appropriate to the specific
circumstances involved with its use. ACI does not make any This document is intended as a voluntary field guide for
representations with regard to health and safety issues and the use the Owner, design professional, and concrete repair con-
of this document. The user must determine the applicability of tractor. It is not intended to relieve the user of this guide
all regulatory limitations before applying the document and of responsibility for a proper condition assessment and
must comply with all applicable laws and regulations,
including but not limited to, United States Occupational structural evaluation of existing conditions, and for the
Safety and Health Administration (OSHA) health and specification of concrete repair methods, materials, or
safety standards. practices by an experienced engineer/designer.

ACI Repair Application Procedure 1.

Copyright © 2003, American Concrete Institute.
All rights reserved including rights of reproduction and use in any The Institute is not responsible for the statements or
form or by any means, including the making of copies by any photo pro- opinions in its publications. Institute publications are
cess, or by electronic or mechanical device, printed, written, or oral, or
recording for sound or visual reproduction or for use in any knowledge not able nor intended to supplant individual training,
retrieval system or device, unless permission in writing is obtained from responsibility or judgment of the user, or the supplier of
the copyright proprietors. Printed in the United States of America. the information provided.

Structural Crack Repair by Epoxy Injection (ACI RAP-1) 3

Introduction
Certain things in life are inevitable. Some are said to
include death, taxes, and concrete cracks! The latter is
subject to volumes of literature on causes and cures. Some of
the more typical causes for concrete cracking include:
• Drying shrinkage;
• Thermal contraction or expansion;
• Settlement;
• Lack of appropriate control joints;
• Overload conditions that produce flexural, tensile, or
shear cracks in concrete; and
• Restraint of movement
One of the potentially effective repair procedures is to
inject epoxy under pressure into the cracks. The injection
procedure will vary, subject to the application and location Fig. 1—Cracks must be clean and free of debris.
of the crack(s), with horizontal, vertical, and overhead
cracks requiring somewhat different approaches. The
approach used must also consider accessibility to the cracked How do I prepare the surface? (see Fig. 1)
surface and the size of the crack. Clean the surface area about 1/2 in. (13 mm) wide on each
Cracks can be injected from one or both sides of a concrete side of the crack. This is done to ensure that materials used
member. If access is limited to only one side, installation to seal the top of the crack (the cap seal) will bond properly
procedures may include variations in epoxy viscosities, to the concrete. Wire brushing is recommended because
injection equipment, injection pressure, and port spacing to mechanical grinders may fill the cracks with unwanted dust.
ensure full penetration of epoxy into the crack. Contaminants can also be removed by high-pressure water,
Depending on the specific requirements of the job, crack “oil-free” compressed air, or power vacuums. When using
repair by epoxy injection can restore structural integrity and water to clean out the crack, blow out the crack with oil-free,
reduce moisture penetration through concrete cracks 0.002 in. compressed or heated air to accelerate drying. Otherwise,
(0.05 mm) in width and greater. However, before any allow enough time for natural drying to occur before
concrete repair is carried out, the cause of the damage must injecting moisture-sensitive epoxies.
be assessed and corrected and the objective of the repair Where concrete surfaces adjacent to the crack are deterio-
understood. If the crack is subject to subsequent movement, rated, “V”-groove the crack until sound concrete is reached.
an epoxy repair may not be applicable. “V” grooves can also be used when high injection pressures
Note: Horizontal cracks of sufficient width can be filled require a stronger cap seal.
by gravity-fed epoxies where suitable for the repair (See
Crack Repair by Gravity Feed with Resin, RAP-2). How do I select the right material?
The appropriate viscosity of the epoxy will depend on the
What is the purpose of this repair? crack size, thickness of the concrete section, and injection
The primary objective for this type of repair is to restore access. For crack widths 0.010 in. (0.3 mm) or smaller, use a
the structural integrity and the resistance to moisture pene- low-viscosity epoxy (500 cps or less). For wider cracks, or
tration of the concrete element. where injection access is limited to one side, a medium to gel
viscosity material may be more suitable.
When do I use this method? ASTM C 881, “Standard Specification for Epoxy-Resin-
Injection is typically used on horizontal, vertical, and over- Base Bonding Systems for Concrete,” identifies the basic
head cracks where conventional repair methods cannot pene- criteria for selecting the grade and class of epoxies (see
trate and deliver the specific repair product into the crack. Table 1).
Prior to proceeding with a crack repair by epoxy injection, For concrete sections greater than 12 in. (305 mm), the
the cause of the crack and the need for a structural repair working time may need to be increased, and the viscosity
must be determined. If the crack does not compromise the decreased, as the crack gets smaller.
structural integrity of the structure, injection with polyure- In addition to the criteria used in Table 1 for epoxy selec-
thane grouts or other nonstructural materials may be a more tion, the following product characteristics may also have to
suitable choice to fill the crack. When a structural repair is be considered:
required, conditions that cause the crack must be corrected • Modulus of elasticity (rigidity);
prior to proceeding with the epoxy injection. If the crack is
• Working life;
damp and cannot be dried out, an epoxy tolerant to moisture
should be considered. Cracks caused by corroding reinforcing • Moisture tolerance;
steel should not be repaired by epoxy injection because • Color; and
continuing corrosion will cause new cracks to appear. • Compressive, flexural, and tensile strengths.

4 Repair Application Procedures Bulletin

 Table 1—ASTM C 881 requirements for epoxy
resins that are used to bond hardened concrete to
hardened concrete
Type I* Type IV†
Viscosity, centipoise
Grade 1 (low-viscosity), maximum 2000 2000
Grade 2 (medium-viscosity), minimum 2000 2000
Maximum 10,000 10,000
Consistency, in.
Grade 3 (non-sagging), maximum 1/4 1/4
Gel time, min. 30 30
Bond strength, minimum, psi
2 days, moist cure‡ 1000 1000
14 days, moist cure 1500 1500
Absorption, 24 h maximum, % 1 1
Heat deflection temperature
7 days minimum, °F — 120
Linear coefficient of shrinkage
On cure, maximum 0.005 0.005
Fig. 2—Installation of entry ports. Compressive yield strength
7 days minimum, psi 8000 10,000
Compression modulus, minimum, psi 150,000 200,000
What equipment do I need? Tensile strength, 7 days minimum, psi 5000 7000
Equipment for epoxy injection by high-pressure or low- Elongation at break, minimum, % 1 1
pressure systems includes: *Type I: for use in non-load-bearing applications.
†Type IV: for use in load-bearing applications.
• Air guns;
Source: ASTM C 881, Standard Specification for Epoxy-Resin-Base Bonding Systems
• Hand-actuated delivery systems; for Concrete.
‡
• Spring-actuated capsules; and Moist-cured systems should be tested by assembling the sections to be bonded before
immersing in water.
• Balloon-actuated capsules.
Determine the delivery method that will best suit the repair
requirements by considering the size and complexity of the
injection repair and the economic limitations of the project. Preconstruction meeting
Prior to proceeding with the repair, a preconstruction
What are the safety considerations? meeting is recommended. The meeting should include repre-
Epoxy resins are hazardous materials and must be treated sentatives from all participating parties (owner, engineer,
as such. Job-site safety practices should include, but not contractor, materials manufacturer, etc.) and specifically
necessarily be limited to, the following: address the parameters, means, methods, final appearance,
• Having Material Safety Data Sheets (MSDS) available and materials necessary to achieve the repair objectives.
on site;
• Wearing protective clothing and protective eyewear Repair procedure
where required; 1. Port installation (see Fig. 2).
• Wearing rubber gloves or barrier creams for hand Install the entry ports only after proper surface prepara-
protection; tion. Two types of entry ports are available for the injection
• Having eye wash facilities available; process:
• Wearing respirators where needed; • Surface-mounted; or
• Providing ventilation of closed spaces; • Socket-mounted.
• Secured storage of hazardous materials; Entry ports (also called port adapters) can be any tubelike
• Having necessary cleaning materials on hand; and device that provides for the successful transfer of the epoxy
• Notifying occupants of pending repair procedures. resin under pressure into the crack. Proprietary injection
It is the responsibility of the user of this document to guns with special gasketed nozzles are also available for use
establish health and safety practices appropriate to the without port adaptors. Port spacing is typically 8 in. (40 mm)
specific circumstances involved with its use. ACI does not on center, with increased spacing at wider cracks. Port
make any representations with regard to health and safety spacing may also be a function of the thickness of the
issues and the use of this document. The user must determine concrete element. Surface-mounted entry ports are normally
the applicability of all regulatory limitations before applying adequate for most cracks, but socket-mounted ports are used
the document and must comply with all applicable laws and when cracks are blocked, such as when calcified concrete is
regulations, including but not limited to, United States Occu- encountered. Entry ports can also be connected by a manifold
pational Safety and Health Administration (OSHA) health system when simultaneous injection of multiple port loca-
and safety standards. tions is advantageous.

Structural Crack Repair by Epoxy Injection (ACI RAP-1) 5

 Fig. 5—Continue injection until refusal.
Fig. 3—Installation of seal cap.
Concrete temperature changes after installation of the cap
seal but prior to injection may cause the cap seal to crack. If this
occurs, the cap seal must be repaired prior to resin injection.
Prior to proceeding with installation of the cap seal, mark
the location of the widest portion of the crack and pay close
attention to the following:
• Use only materials that haven’t exceeded their shelf life;
• Accurate batching of components;
• Small batches to keep material fresh, and dissipate heat;
• Port spacing; and
• Consistent application of the material (1 in. wide x 3/16
in. thick [25 x 5 mm]) over the length of the crack.
3. Inject the epoxy (see Fig. 4 and 5).
For a successful epoxy injection, start with the proper
batching and mixing of the epoxy components in strict
accordance with the manufacturer’s requirements. Prior to
starting the actual injection, be sure that the cap seal and port
adapter adhesive have properly cured so they can sustain the
injection pressures.
Start the injection at the widest section of a horizontal
crack. (Be sure to locate and mark these areas before
Fig. 4—Start injection at widest segment of the crack. installing the cap seal.) Vertical cracks are typically injected
from the bottom up.
Continue the injection until refusal. If an adjacent port
2. Install the cap seal (see Fig. 3). starts bleeding, cap the port being injected and continue
Properly installed, the cap seal contains the epoxy as it is injection at the furthest bleeding port. Hairline cracks are
injected under pressure into the crack. When cracks penetrate sometimes not well suited to “pumping to refusal.” In those
completely through a section, cap seals perform best when cases, try injecting the epoxy at increased pressure (approx-
installed on both sides of the cracked element, ensuring imately 200 psi [1.3 MPa]) for 5 min. Closer port spacing can
containment of the epoxy. Cap seals have been successfully also be considered. When injection into a port is complete,
installed using epoxies, polyesters, paraffin wax, and sili- cap it immediately. Higher pressure can be used for injecting
cone caulk. The selection of the cap seal material should very narrow cracks or increasing the rate of injection.
consider the following criteria, subject to the type of crack to However, the use of higher pressure should be managed with
be repaired: care to prevent a blowout of the cap seal or ports.
• Non-sag consistency (for vertical or overhead); 4. Remove ports and cap seal (see Fig. 6).
• Moisture-tolerance; Upon completion of the injection process, remove the
• Working life; and ports and cap seal by heat, chipping, or grinding. If the
• Rigidity (modulus of elasticity). appearance is not objectionable to the client, the cap seal can

6 Repair Application Procedures Bulletin

 • Cores can be further tested for compressive and split
tensile strength per ASTM C 42; and
• Subsequently, patch the removed-core area (after
proper surface preparation) with an expansive cementi-
tious or epoxy grout compatible with the existing
substrate concrete and the surrounding environment.
2. Methods for nondestructive evaluation:
• Impact echo (IE);
• Ultrasonic pulse velocity (UPV); and
• Spectral analysis of surface waves (SASW).

Sources for additional information

ACI Committee 224, 1993, “Causes, Evaluation, and
Repairs of Cracks in Concrete Structures (224.1R-93),”
American Concrete Institute, Farmington Hills, Mich., 22 pp.
ACI Committee 364, 1994, “Guide for Evaluation of
Concrete Structures Prior to Rehabilitation (364.1R-94),”
American Concrete Institute, Farmington Hills, Mich., 22 pp.
ACI Committee 503, 1998, “Use of Epoxy Compounds
with Concrete (ACI 503R-93 (Reapproved 1998)),” Amer-
ican Concrete Institute, Farmington Hills, Mich., 28 pp.
ACI Committee 546, 1988, “Guide for Repair of Concrete
Fig. 6—Remove seal cap. Bridge Structures (546.1R-80 (Reapproved 1988)),” Amer-
ican Concrete Institute, Farmington Hills, Mich., 20 pp.
ACI Committee 546, 1996, “Concrete Repair Guide
be left in place. If complete removal is required for a subsequent (546R-96),” American Concrete Institute, Farmington Hills,
application of a cosmetic coating, prepare the concrete Mich., 41 pp.
surface by grinding. ASTM C 881-90, 1990, “Standard Specification for
Epoxy-Resin Based Bonding Systems for Concrete,” ASTM
How do I check the repair? International, West Conshohocken, Pa., 5 pp.
To ensure that the injection has been successful, quality Emmons, P. H., 1994, Concrete Repair and Maintenance
assurance measures may include test cores or nondestructive Illustrated, R. S. Means Co., Inc., Kingston, Mass., 300 pp.
evaluation (NDE). “Guide for Verifying Performance of Epoxy Injection of
1. Test cores: Concrete Cracks,” 1998, ICRI Technical Guideline No.
• Core locations should be chosen to avoid cutting rein- 03734.
forcing steel, drilling cores in areas of high stress, or Murray, M. A., 1987, “Epoxy Injection Welds Cracks
creating core holes below the waterline. The engineer Back Together,” Concrete Repair, V. 3.
should determine core locations when these types of Promboon; Y.; Olsen, L. D.; and Lund, J., 2002,
conditions exist; “Nondestructive Evaluation (NDE) Methods for Quality
• Be sure the epoxy has set before extracting a core; Assurance,” ICRI Bulletin, V. 15, No. 1, Jan.-Feb., pp. 12-16.
• Take cores (normally 2 in. [50 mm] diameter) to check “State-of-the-Art Adhesives for Concrete Construction,”
that the penetration of the epoxy is adequate; 1998, Construction Canada Magazine, May-June.
• Inspect the core visually to determine the penetration of Trout, J. F., 1998, Epoxy Injection in Construction, The
the epoxy into the crack; Aberdeen Group, 80 pp.

Structural Crack Repair by Epoxy Injection (ACI RAP-1) 7

 ACI RAP Bulletin 2

American Concrete Institute ®

Advancing concrete knowledge

FIELD GUIDE TO Crack Repair by

CONCRETE REPAIR Gravity Feed
APPLICATION PROCEDURES with Resin

Crack Repair by Gravity Feed with Resin (ACI RAP-2) 1

2 Repair Application Procedures Bulletin
 ACI RAP Bulletin 2
(Reapproved 2009)

Field Guide to Concrete Repair Application Procedures

Crack Repair by Gravity Feed with Resin

Reported by ACI Committee E706

Brian F. Keane
Chair

J. Christopher Ball H. Peter Golter John S. Lund George I. Taylor

*
Floyd E. Dimmick, Sr. Bob Joyce Richard Montani Patrick M. Watson
Peter H. Emmons Kenneth M. Lozen Jay H. Paul David W. Whitmore
Timothy R. W. Gillespie

*
Primary author.

It is the responsibility of the user of this document to Structural Disclaimer

establish health and safety practices appropriate to the specific
circumstances involved with its use. ACI does not make any This document is intended as a voluntary field guide for
representations with regard to health and safety issues and the use the Owner, design professional, and concrete repair con-
of this document. The user must determine the applicability of tractor. It is not intended to relieve the user of this guide
all regulatory limitations before applying the document and of responsibility for a proper condition assessment and
must comply with all applicable laws and regulations,
including but not limited to, United States Occupational structural evaluation of existing conditions, and for the
Safety and Health Administration (OSHA) health and specification of concrete repair methods, materials, or
safety standards. practices by an experienced engineer/designer.

ACI Repair Application Procedure 2.

Copyright © 2003, American Concrete Institute.
All rights reserved including rights of reproduction and use in any The Institute is not responsible for the statements or
form or by any means, including the making of copies by any photo pro- opinions in its publications. Institute publications are
cess, or by electronic or mechanical device, printed, written, or oral, or
recording for sound or visual reproduction or for use in any knowledge not able nor intended to supplant individual training,
retrieval system or device, unless permission in writing is obtained from responsibility or judgment of the user, or the supplier of
the copyright proprietors. Printed in the United States of America. the information provided.

Crack Repair by Gravity Feed with Resin (ACI RAP-2) 3

Introduction
This topical application for crack repair uses a thin
polymer resin to fill the crack. Penetrating by gravity alone,
the resin fills the crack and forms a polymer plug that seals
out water, salts, and other aggressive elements. In some
cases, a structural repair of the crack can be achieved.
Before any concrete is repaired, the cause of the damage
must be assessed and the objective of the repair must be
understood.
Typical causes of concrete cracking include steel corro-
sion, freezing and thawing, sulfate attack, and alkali-aggre-
gate reaction (AAR). Poor practices during the original
construction can cause excessive shrinkage or settlement in
the structure. Improper joint spacing and load imbalances
also contribute to cracking.

What is the purpose of this repair?

The primary objective of this repair is to fill the crack and
structurally bond the concrete on both sides of the crack.
This repair is to seal cracks that are not moving—for Fig. 1—Cracks must be clean and free of debris.
example, shrinkage cracks, and settlement cracks that have
stabilized. By penetrating and filling the cracks, the resin is
able to form a polymer plug that seals the crack, keeping out
future damage around the crack, but it certainly will not stop
water, chlorides, carbon dioxide, sulfates, and other aggres-
it indefinitely. In these situations, a complete repair and
sive liquids and gases.
protection approach is required to address the entire area
This repair method is, therefore, a way to reduce possible affected, not just the cracks.
future deterioration caused by freeze-thaw cycles, steel
corrosion, and chemical attack of the concrete. How do I prepare the surface?
A common secondary objective of this repair is the protection Proper preparation of the cracks for gravity feed of resin is
of the entire deck or floor with a penetrating sealer. Instead of essential to a successful repair. All potential barriers to penetra-
gravity feeding individual cracks, a flood coat on the entire tion must be removed. Clean away all dirt, oil, grease, paints,
deck or floor is often done to seal the concrete surface, in striping, curing compounds, and sealers. To prepare large areas
addition to “healing” the cracks. This is why the term sealer/ for flood treatments, consider dry sand- or shot-blasting.
healer is often associated with this application and material. For cleaning individual cracks, begin with wire brushes
Finally, it is occasionally an objective to achieve a struc- and wheels, followed by high pressure, oil-free compressed
tural repair of the cracks using this method. Consult a quali- air to remove dust from the surface of the crack.
fied structural engineer if it is determined that a structural If the crack surface is packed solid with dirt and/or debris,
repair is needed. While many of these resin materials exceed remove it prior to applying the resin. In this case, remove the
the strength of the concrete, ensuring a structural repair with debris by routing the crack surface with crack-chasers or
full depth penetration by gravity is difficult. Special care grinders and follow up with compressed air to remove fines.
must be taken in these instances to ensure the cracks are This routing of the crack has the advantage of producing a
open, clean, and not contaminated with any bond-inhibiting wider surface opening. Vacuum cleaning of cracks can
materials such as oil and grease, which can often be the case prevent dust from getting packed into the crack, which can
on horizontal decks and floors exposed to traffic. If a struc- hamper resin penetration.
tural repair of the crack is critical, pressure injection may be Allow the repair area to dry for at least 24 hours before
a preferred option (see RAP 1). applying the resin. Moisture within the cracks and the concrete
pores can prevent penetration because the resin materials are
When do I use this method? very thin and are not able to easily displace water.
This repair can only be applied to horizontal concrete
elements such as bridge and parking decks, floor slabs, plaza How do I select the right material?
decks, and similar surfaces. The two most common polymer materials used for gravity
Gravity feed of resin is not effective for repairing moving feed crack repairs are epoxies and high molecular weight
cracks. This is because the materials are unable to act as a flex- methacrylates (HMWM). Both must be formulated to have a
ible joint material. In these cases it is most often necessary to very thin consistency (low viscosity) and low surface tension
rout and seal the crack to create a joint capable of movement. to enable them to easily penetrate fine cracks by gravity
Likewise, gravity feed of resin should not be viewed as a alone. Viscosities below 200 centipoise (cps) should be a
long-term solution to cracking caused by corrosion, sulfate minimum requirement. Many epoxies are available with
attack, or AAR. At best, this repair will keep out water, viscosities below 100 cps. Most HMWMs have viscosities
chlorides, and sulfates, which may slow the progress of below 50 cps.

4 Repair Application Procedures Bulletin

Fig. 2—On individual cracks, a sealant can be used to
create a reservoir.

While both resin types are able to form the desirable

polymer plug within the crack, they do have their differences.
The epoxies tend to bond better when moisture is present
within the concrete pores and they are easier and can be safer Fig. 3—Continue to gravity-feed the resin and “top off”
until crack is completely filled.
to mix and apply. HMWMs are generally lower in viscosity
and surface tension and have less critical mixture ratios than
epoxies. They can also be formulated to set faster. Successful • Protective eyewear. Face shields are recommended as a
applications of both polymer types have been documented in minimum;
concrete cracks less than 0.006 in. (0.15 mm) wide. • Wear rubber gloves for hand protection;
• Have eye wash facilities available;
What equipment do I need? • Take special precautions with flammable or combustible
For small to midsize projects (up to 10,000 ft2 [930 m2]): materials;
• Mixing buckets, drills, mixing paddles; • Ventilate closed spaces. Wear appropriate masks to
• Flat rubber squeegees, brooms, or rollers; protect against fumes;
• Small cans or squeeze bottles for pouring into indi- • Store hazardous materials in a secured area;
vidual cracks; and • Have necessary cleaning materials on hand; and
• Grinder and air compressor. • Notify occupants within the structure being repaired
For large projects (over 10,000 ft2 [930 m2]): prior to beginning work.
• Mixing buckets, drills, mixing paddles; It is the responsibility of the user of this document to
• Mixing tanks with spray bar (low pressure pumps, no establish health and safety practices appropriate to the
atomization); specific circumstances involved with its use. ACI does not
• Flat rubber squeegees, brooms, or rollers; make any representations with regard to health and safety
• Sand spreaders or blowers; and issues and the use of this document. The user must determine
• Grinder and air compressor. the applicability of all regulatory limitations before applying
the document and must comply with all applicable laws and
What are the safety considerations? regulations including, but not limited to, United States Occu-
Epoxies and HMWMs are hazardous materials and should pational Safety and Health Administration (OSHA) health
be treated as such. Job-site safety practices should include, and safety standards.
but are not limited to, the following where applicable: Special note regarding HMWM mixing: These polymers
• Material Safety Data Sheets (MSDS). Adhere to all utilize a two-part catalyst usually consisting of an initiator
manufacturer recommendations for special safety equip- (such as a peroxide) and a promoter (such as cobalt
ment and requirements; napthanate). These two materials must never come into
• Protective clothing. Cover the body fully and use direct contact with one another or a violent reaction may
adequate footwear; occur. It is important that the promoter first be added to the

Crack Repair by Gravity Feed with Resin (ACI RAP-2) 5

 minutes may pass before resin has fully penetrated tight
cracks and more resin may still be required.
4. Remove excess resin.
Once all cracks have been filled to refusal, remove the
excess surface resin with a flat rubber squeegee.
5. Apply sand.
For safety purposes, lightly broadcast sand into the
remaining resin to produce a skid-resistant surface. Apply
about 1 to 2 lb/yd2 (0.5 to 1.0 kg/m2) of an ordinary 8/20
blasting sand (or similar) within 20 to 30 minutes after the
last application.
6. Finish smooth (if desirable).
After the polymer has fully cured, remove sealant and
grind smooth. Be careful not to inhale vapors during the
grinding of the polymers.

How do I check the repair?

Quality control tests should be taken on site to verify:
• Resin properties—taken in the form of cured prisms
(ASTM D 495 type) to be checked for compressive
strength as an indicator of proper mixture ratio and cure;
• Penetration depths—verified by cores taken at regular
Fig. 4—Removal of sealant and grinding of excess resin. intervals. For very fine cracks, the cores may be
analyzed under “black light” to highlight resin penetra-
tion depth within the cracks; and
HMWM monomer and mixed uniformly throughout before • For structural repair checks, take cores and follow
adding the initiator. Some formulations are available as a ASTM C 496, “Splitting Tensile Test.”
two-component system (pre-promoted) to avoid this poten-
tially dangerous situation. Always refer to the material Sources for additional information
manufacturer’s instructions. California Department of Transportation, “Specifications
and Special Provisions for Use of High Molecular Weight
Preconstruction meeting Methacrylate Monomers to Seal Bridge Decks,” Contract
Prior to proceeding with the repair, a preconstruction No. 04-001754.
meeting is recommended. The meeting should include repre- Jerzak, H. P., 1991, “High Molecular Weight Methacry-
sentatives from all participating parties (owner, engineer, late Resins in California,” State of California Department of
contractor, materials manufacturer, etc.) and specifically Transportation, Jan.
address the parameters, means, methods, and materials Krauss, P. D., 1991, “Bridge Deck Repair Using Poly-
necessary to achieve the repair objectives. mers,” paper presented at International Congress on Poly-
mers in Concrete, San Francisco, Calif. Sept. 24-27.
Repair procedure Murray, M. A., and Eisenhut, W. O., 1995, “A Concrete Healer
1. Mix the resin. and Sealer,” Concrete Repair Digest, V. 6, No. 3, June-July.
After preparing the surface, mix the resin according to the Pfeifer, D. W., and Perenchio, W. F., 1982, “Coating, Pene-
manufacturer’s instructions. If cracks run all the way trants, and Specialty Concrete Overlays for Concrete Surfaces,”
through and the underside of the deck or slab is accessible, paper presented at NACE seminar, Chicago, Sept. 27-29.
seal the underside of cracks at least temporarily to prevent Rodler, D. J.; Whitney, D. P.; Fowler, D. W.; and Wheat,
resin loss (see RAP 1). D. L., 1989, “Repair of Cracked Concrete with High Molec-
2. Pour the resin. ular Weight Methacrylate Monomers,” Polymers in
Pour the mixed material (within the pot life of the resin) Concrete: Advances and Applications, SP-116, P. Mendis
over the top of the cracks and allow it to penetrate. Keep and C. McClaskey, eds., American Concrete Institute, Farm-
filling the cracks until they will no longer accept resin. ington Hills, Mich., pp. 113-128.
For flood coat applications, distribute the resin evenly Sprinkel, M. M., “Use of High Molecular Weight Methac-
over the deck initially and then puddle the resin over the rylate Monomers to Seal Cracks in Bridge Decks, Retard
cracks. On smooth surfaces, use flat rubber squeegees; on Alkali-Silica Aggregate Reactions, and Prime Bridge
tined or irregular surfaces, use brooms or rollers. Surfaces for Overlays,” Virginia Department of Transporta-
3. Inspect the filling. tion Research Council.
Look for signs of penetration such as air bubbles escaping Wiss Janney Elstner Associates, 1986, “Corrosion Protection
from the cracks as the resin displaces the air. Tests on Reinforced Concrete Treated with Sikaguard 70 and
ALLOW TIME FOR PENETRATION. Twenty to 30 SikaPronto 19 Crack Healer for Sika Corporation, Lynd-
minutes should be a minimum. Also, be aware that several hurst, N.J.,” Report No. 831298, Sept.

6 Repair Application Procedures Bulletin

 RAP-3

www.concrete.org

Spall Repair
by Low-Pressure Spraying
Reported by ACI Committee E 706
Brian F. Keane*
Chairman

J. Christopher Ball H. Peter Golter Jay H. Paul

Floyd E. Dimmick, Sr. Bob Joyce George I. Taylor
Peter H. Emmons§ Kenneth M. Lozen Patrick M. Watson‡
Timothy R. W. Gillespie John S. Lund David W. Whitmore
Richard Montani†
*
Primary author of RAP Bulletin No. 1.
†
Primary author of RAP Bulletin No. 2.
‡Primary author of RAP Bulletin No. 3.
§
Primary author of RAP Bulletin Nos. 4 and 5.

The committee would like to thank Brandon Emmons for his illustrations in these bulletins.

It is the responsibility of the user of this document to Structural Disclaimer

establish health and safety practices appropriate to the specific
circumstances involved with its use. ACI does not make any This document is intended as a voluntary field guide for
representations with regard to health and safety issues and the use the Owner, design professional, and concrete repair con-
of this document. The user must determine the applicability of tractor. It is not intended to relieve the user of this guide
all regulatory limitations before applying the document and of responsibility for a proper condition assessment and
must comply with all applicable laws and regulations,
including but not limited to, United States Occupational structural evaluation of existing conditions, and for the
Safety and Health Administration (OSHA) health and specification of concrete repair methods, materials, or
safety standards. practices by an experienced engineer/designer.

ACI Repair Application Procedure 3.

Copyright © 2003, American Concrete Institute.
All rights reserved including rights of reproduction and use in any The Institute is not responsible for the statements or
form or by any means, including the making of copies by any photo pro- opinions in its publications. Institute publications are
cess, or by electronic or mechanical device, printed, written, or oral, or
recording for sound or visual reproduction or for use in any knowledge not able nor intended to supplant individual training,
retrieval system or device, unless permission in writing is obtained from responsibility or judgment of the user, or the supplier of
the copyright proprietors. Printed in the United States of America. the information provided.
 ACI RAP Bulletin 3

Spall Repair
FIELD GUIDE TO
CONCRETE REPAIR by Low-Pressure
APPLICATION PROCEDURES
Spraying
by Patrick “Doc” Watson

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 1

Introduction
Similar to wet-mix shotcrete but sprayed at a much lower
velocity, low-pressure spall repair spray comes in the form
of prepackaged mortar. The spray is applied using small concrete
pumps or heavy-duty grout pumps to force the low-slump
mortar through a hose. Air is added at the nozzle to impel the
mortar. Bond with the prepared substrate is achieved through
a combination of proper surface preparation, low-velocity
impact, and the material properties of the prepackaged mortar.
Compared with either wet- or dry-mix shotcreting, this
method allows the spray nozzle to be much closer to the
repair surface. This means it can be used in tight spaces. Due
to the viscous, sticky nature of the mixture and the low pressures
involved, there is considerably less rebound than with high-
velocity shotcreting.
Before any concrete repair is carried out, the cause of the
damage must be assessed and the objective of the repair must
Fig. 1—Typical plus or minus 1/4 in. profile. (From ICRI Guide
be understood.
No. 03732 Profile No. 7). This is the standard recommended
Typical causes of concrete deterioration include steel
surface profile for low-pressure spray-applied mortars.
corrosion, sulfate attack, alkali-aggregate reactions
(AARs), excessive deflection, and freeze-thaw damage.
Poor practices during the original construction can lead
to premature deterioration. Improper joint spacing and load
imbalances also contribute to cracking and spalling.
What is the purpose of this repair?
Depending on the mortar mixture selected, low-pressure
spray is used for surface repairs, structural repairs, or cosmetic
renovation. The spray can be formulated for freeze-thaw
durability, sulfate resistance, low permeability, and other
desired or specified characteristics.
When do I use this method?
Low-pressure spray is typically used for vertical and over-
head repairs. Successful applications have included structural
repairs to bridges, bridge and building piers, structural slab
undersides, tank walls (interior and exterior), stadiums, tunnels,
and retaining walls. Structural repairs utilizing low-pressure
spray are best done under the guidance of a qualified engineer.
The placement thickness can be 1/2 to 4 in. (13 to 100 mm) in
a single lift. Thicknesses greater than 6 in. (150 mm) are
possible in multiple lifts. If the repair application requires more
than a 4 in. (100 mm) thickness, other methods may be more Fig. 2—Chipping surface.
economical (see ICRI Guideline No. 03731, “Guide for Selecting
Application Methods for the Repair of Concrete Surfaces”).
The ingredients that make up the mortar vary widely, and Concrete Resulting from Reinforcing Steel Corrosion.”
the ingredients selected will depend on the specific repair situation. Because many of the materials applied using low-pressure
Formulas may contain ingredients such as corrosion in- spray are prepackaged, the manufacturer’s recommendations
hibitors, air-entraining agents, and bonding additives. should also be consulted.
The initial material costs are generally higher with this A typical roughness or profile recommendation for this re-
method than for a typical shotcrete application, but in-place pair method is ICRI Concrete Surface Profile (CSP) No. 7 or
costs are often lower or comparable because this method higher, as per ICRI Guideline No. 03730. A CSP No. 7 is
produces less rebound and requires less cleanup. Certified equivalent to an amplitude of approximately 1/4 in. (7 mm)
nozzle operators are not required. (see Fig. 1).
Factors that will influence the specific surface preparation
How do I prepare the surface? include, but are not limited to:
Consult the recommendations of ICRI Guideline No. 03732, • Desired roughness profile of the prepared surface (CSP);
“Selecting and Specifying Concrete Surface Preparation for • Method of preparation. These may include, but are
Sealers, Coatings, and Polymer Overlays,” or ICRI Guideline not limited to, hydrodemolition, sandblasting, and
No. 3730, “Surface Preparation for Repair of Deteriorated use of pneumatic hammers (see Fig. 2);

2 Repair Application Procedures Bulletin 3

Fig. 3—Presaturate prepared surface with water.

• Possible contamination of the surface by chemicals,

oils, soaps, or carbonation. Test for carbonation with
a pH indicator. The pH should be 11.5 or higher; (a)
• Methods of treatment for contaminated surfaces.
• Required substrate saturation (see Fig. 3);
• Reinforcing requirements from the mortar manufac-
turer, the engineer, or the owner; and
• Treatment of existing cracks and joints: Repair the
cracks? How? Fill the joints? If so, how and with what?
How do I select the right material?
Low-pressure spray-applied repair materials are proprietary,
prepackaged cementitious products. Specifiers, applicators,
and owners should consult ICRI Guideline No. 03733, “A
Guide for Selecting and Specifying Materials for Repair of
Concrete Surfaces.” Consult the American Concrete Institute
publications on concrete repair by ACI Committee 546,
Repair of Concrete. Refer to manufacturers’ data sheets for
material properties.
Physical property requirements such as bond strength,
freeze-thaw durability, permeability, and flexural strength will
vary from project to project.
When low-pressure spray-applied materials are used, some
repair applications may require that the material be coated
with a protective barrier system. When this is the case, (b)
confirm the required curing and drying time before installing
the coating. Fig. 4(a) and (b)—Application of mortar with pressure
equipment and nozzle.
What equipment do I need?
Be sure that all necessary equipment and tools are on site • Air compressor with pressure gages and controls.
and in proper working order. Have backup equipment or (Some pumps come equipped with built-in air
alternate methods planned and available. Typical equipment compressors and controls.);
needed for low-pressure spray application of repair mortars • A suitable mixer for mixing the mortar is needed. A
includes, but is not limited to: backup mixer is recommended in case of breakdown.
• Concrete or grout pumps suitable for low-pressure (Some repair type pumps come equipped with mor-
spray. Field experience has shown that ball valve tar mixers.); and
pumps are not suitable. Short stroke, swing-type • A water measuring device, preferably a meter. (Many
piston pumps or heavy-duty rotor-stator pumps repair-type pumps equipped with mixers include
perform well; built-in water meters.).
• If using a rotor-stator or “moyno” type pump, have a • A means of communication between the pump and
backup rotor on hand at the job site; mixer operators and the nozzleman.

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 3

Fig. 5—Skilled worker applying final finish to surface. Fig. 6—Application of curing compound.

• All finishing, handling, and testing tools required by must comply with all applicable laws and regulations including,
specification or good concreting practices. but not limited to, United States Occupational Safety and Health
What are the safety considerations? Administration (OSHA) health and safety standards.
Prepackaged mortars are hazardous materials and should Preconstruction meeting
be treated as such. Job-site safety practices should include, Prior to proceeding with the repair, a preconstruction meeting
but are not limited to, the following where applicable: is recommended. The meeting should include representatives
• Material Safety Data Sheets (MSDS) should be on from all participating parties (owner, engineer, contractor,
hand; materials manufacturer, etc.), and specifically address the
• Safety equipment: all machinery and equipment being parameters, means, methods, and materials necessary to
used must have the correct safety equipment, guards, achieve the repair objectives.
and warnings in place;
• Protective clothing: protective gloves for workers in Repair procedure
contact with wet, cementitious material; 1. The prejob (preconstruction) meeting agenda might
• Protective eyewear: safety glasses or face shields will include:
be needed for all workers; • On-site availability of power;
• Eyewash facilities should be provided; • On-site availability of water;
• Respirators: dust masks will be needed for workers • Site accessibility;
operating the material mixer; • Debris removal and disposal;
• Ventilation of closed spaces: confirm that adequate • Dust, odor, and emissions control;
ventilation is available before operating equipment • Confirmation that all materials documentation is on
that emits dangerous exhaust; hand—for example, MSDS sheets;
• Secured storage should be available for all hazardous • Methods of curing and time required for curing;
materials; • Possible emergencies and breakdowns—what to do
• Fuel for equipment operation needs a safe storage if they occur;
area, well marked and visible; and • Finish requirements;
• A safety meeting with all involved should be held • Testing required; and
and led by the prime contractor’s safety manager • All other concerns that could affect the progress of
prior to beginning repair operations. the repair.
It is the responsibility of the user of this document to establish 2. Apply the repair.
health and safety practices appropriate to the specific • Inspect and approve the surface preparation. (See
circumstances involved with its use. ACI does not make any ICRI and ACI references);
representations with regard to health and safety issues and the • Presaturate the prepared substrate. Twenty-four hours
use of this document. The user must determine the applicability is standard. Prepared saturated surface should be saturated
of all regulatory limitations before applying the document and surface-dry when the repair mortar is sprayed;

4 Repair Application Procedures Bulletin 3

 • Install the specified reinforcement; How do I check the repair?
• Install/apply bonding agents, corrosion inhibitor Requirements may include:
sacrificial anodes, if called for; • Before and after photos;
• Mix the repair mortar and load it into pump hopper. • Confirmation of acceptable surface preparation. This
• Begin spray operations with pump, compressor, and can include the prepared surface profile and the pH
suitable spray nozzle; and of the prepared surface. A pH of 11.5 or greater is
• Apply the mortar at the thickness recommended by recommended;
the material manufacturer. Most low-pressure spray • Confirm repair depth;
materials require application in lifts when the thickness of • Material property tests performed by a qualified
the total application layer exceeds 3 in. (76 mm). testing agency. This is usually done to confirm the
3. Finish the repair. material manufacturers’ published material properties;
Confirm the final finished appearance of the repair with the • In-situ direct tensile strength tests of the prepared
owner. This may vary from rough as-sprayed to smooth troweled. surface;
If smooth troweling is specified, production may be reduced • In-situ bond direct tensile tests of the hardened, cured
and additional labor may be required. One nozzle operator repair; and
may require multiple finishers to keep pace. This will be • Confirmation that all materials used were as speci-
influenced by such factors as: fied, cross checking material purchase orders with
• The installed thickness of the material being applied; quantities estimated and with actual quantities billed.
• The drying conditions caused by ambient and substrate
temperatures;
Sources for additional information
• The setting characteristics of the repair mortar; and
ACI Committee 308, 1998, “Standard Specification for Curing Concrete
• Whether the repair is vertical or overhead. (ACI 308.1-98),” American Concrete Institute, Farmington Hills, Mich.,
Because of the non-bleeding, sticky nature of these materials, 1998, 9 pp.
use of an evaporation control film when finishing is recommended. ACI Committee 308, 2001, “Guide to Curing Concrete (ACI 308R-01),”
American Concrete Institute, Farmington Hills, Mich., 2001, 31 pp.
Proper curing is important and should be conducted in ACI Committee 503, 1993, “Use of Epoxy Compounds with Concrete
accordance with ACI 308.1-98, “Standard Specification (ACI 503R-93),” Appendix A, Farmington Hills, Mich., 28 pp.
for Curing Concrete.” Additional curing information is avail- ACI Committee 506, 1995, “Guide to Shotcrete (506R-90 (Reapproved
1995)),” American Concrete Institute, Farmington Hills, Mich., 41 pp.
able from ACI 308R-01, “Guide to Curing Concrete.” ACI Committee 546, 1996, “Concrete Repair Guide (ACI 546R-96),”
For most cementitious low-pressure spray-applied mortars, American Concrete Institute, Farmington Hills, Mich., 1996, 41 pp.
application of a curing compound that complies with the mois- “Guide for Selecting Application Methods for the Repair of Concrete
Surfaces,” ICRI Guideline No. 03731, 1996.
ture retention requirements ASTM C 309 is satisfactory. As “Guide for Selecting and Specifying Materials for Repair of Concrete
an alternate, moist cure for 7 days. Surfaces,” ICRI Guideline No. 03733, 1997.
Always refer to the mortar manufacturer’s instructions for “Selecting and Specifying Concrete Surface Preparation for Sealers,
Coatings, and Membranes,” ICRI Guideline No. 03732, 1997.
specific curing methods and materials recommenced for the “Surface Preparation for Repair of Deteriorated Concrete Resulting from
product selected. Reinforcing Steel Corrosion,” ICRI Guideline No. 03730, 1995.

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 5

 RAP-4

www.concrete.org

Surface Repair
Using Form-and-Pour Techniques
Reported by ACI Committee E 706
Brian F. Keane*
Chairman

J. Christopher Ball H. Peter Golter Jay H. Paul

Floyd E. Dimmick, Sr. Bob Joyce George I. Taylor
Peter H. Emmons§ Kenneth M. Lozen Patrick M. Watson‡
Timothy R. W. Gillespie John S. Lund David W. Whitmore
Richard Montani†
*
Primary author of RAP Bulletin No. 1.
†
Primary author of RAP Bulletin No. 2.
‡Primary author of RAP Bulletin No. 3.
§
Primary author of RAP Bulletin Nos. 4 and 5.

The committee would like to thank Brandon Emmons for his illustrations in these bulletins.

It is the responsibility of the user of this document to Structural Disclaimer

establish health and safety practices appropriate to the specific
circumstances involved with its use. ACI does not make any This document is intended as a voluntary field guide for
representations with regard to health and safety issues and the use the Owner, design professional, and concrete repair con-
of this document. The user must determine the applicability of tractor. It is not intended to relieve the user of this guide
all regulatory limitations before applying the document and of responsibility for a proper condition assessment and
must comply with all applicable laws and regulations,
including but not limited to, United States Occupational structural evaluation of existing conditions, and for the
Safety and Health Administration (OSHA) health and specification of concrete repair methods, materials, or
safety standards. practices by an experienced engineer/designer.

ACI Repair Application Procedure 4.

Copyright © 2003, American Concrete Institute.
All rights reserved including rights of reproduction and use in any The Institute is not responsible for the statements or
form or by any means, including the making of copies by any photo pro- opinions in its publications. Institute publications are
cess, or by electronic or mechanical device, printed, written, or oral, or
recording for sound or visual reproduction or for use in any knowledge not able nor intended to supplant individual training,
retrieval system or device, unless permission in writing is obtained from responsibility or judgment of the user, or the supplier of
the copyright proprietors. Printed in the United States of America. the information provided.
 ACI RAP Bulletin 4

Surface Repair
FIELD GUIDE TO
CONCRETE REPAIR Using Form-and-
APPLICATION PROCEDURES Pour Techniques
by Peter Emmons

Surface Repair Using Form-and-Pour Techniques (ACI RAP-4) 1

Introduction
The form-and-pour placement technique is a multistep pro-
cess of preparation, formwork construction, and placement
of repair materials. Repair materials are placed in the cavity Prepared concrete surfaces
between the formwork and the prepared substrate with with formwork ready for
buckets, pumps, chutes, or buggies. The form-and-pour tech- erection.
nique allows the use of many different castable repair materials.
Placeability is the primary consideration material selection.
Depending on the consistency of the repair material, consoli-
dation is accomplished by vibration, rodding, or when the
material has extremely high slump (self consolidating), no Fig. 1(a).
additional steps may be required.
What is the purpose of this repair?
Section view through repair
The primary purpose of this type of repair is to restore the
showing formwork and chute
structural integrity, or concrete cover requirements, or both,
at top for placement of
for the damaged element.
repair material.
When do I use this technique?
This technique is commonly used on vertical surfaces such
as walls, columns, and other combinations such as beam sides
and bottoms. When used to repair slab soffits, the repair
material is typically placed through holes or openings cut
through the slab. Adhesive bonding agents or grouts are not
commonly used with this technique. A trial installation is Fig. 1(b).
highly recommended for each project, to verify the preparation,
material, and placement technique using quality-control
procedures outlined at the end of this document.
The form-and-pour technique offers many advantages:
• Many different types of repair materials can be used;
• Repair material can be placed around reinforcing
steel; and
• Formwork protects against early-age drying that
promotes cracking.
The primary limitation of the form-and-pour technique is
that formwork installation makes it more labor-intensive than
alternative placement methods such as shotcrete or hand
application (see Fig. 1).
How do I prepare the surface? (Fig. 2)
Regardless of the repair method, surface preparation is
essentially the same. Concrete is removed until sound con-
crete is located. Exposed bars are undercut, and surfaces are
cleaned with high-pressure water, or are abrasively blasted.
With form-and-pour techniques, it is important to understand
how the existing surfaces will permit the repair material to
penetrate and flow. On partial-depth vertical repairs, the
upper edges of vertical surfaces should be trimmed to eliminate
potential pockets of entrapped air and promote complete filling
from the location of the chute. Refer to page 3 for step-by-
step preparation procedures.
Step 1—Sound the concrete to locate areas of delamination.
Step 2—Remove unsound concrete with a 15-lb chipping
hammer. Hammers larger than a 15-lb class may cause
damage to the substrate and reinforcement.
Step 3—Mark the perimeter of the repair area. Layout should
be simple square or rectangular shapes.
Step 4—Sawcut the perimeter of the repair. Note: sawcut
should not be deeper than the cover over reinforcement.
Step 5— Repair reinforcement as necessary. When reinforcing Fig. 2—Lapping of supplemental reinforcing.

2 Repair Application Procedures Bulletin 4

steel is heavily corroded and the diameter is reduced, consult STEP 3 STEP 4
a structural engineer for repair procedures. For many appli-
cations, supplemental reinforcement can be lapped to adja-
cent damaged bars, as shown (see Fig. 2)
Step 6—Clean reinforcing steel and concrete with abrasive
blasting.
How do I select the proper repair material?
Constructibility requirements for repair materials used with
the form-and-pour technique are limited only by their ability
to be transported to the formwork cavity. Maximum aggre-
gate size should not exceed 25% of the space between the
formwork and the substrate, or 50% of the distance between
the reinforcing steel and the substrate—whichever is smaller.
In general, the largest practical maximum size aggregate
Mark perimeter of repair Sawcutting perimeter of re-
should be used to minimize drying-shrinkage and reduce the
area. Layout should be pair. Note: sawcut should not
potential for cracking of the repair. Mixtures with high
simple geometric shapes. be deeper than cover over re-
flowability (high slump) will make the placement easier;
however, do not sacrifice a low water-cement ratio (< 0.40) inforcement. Remove sound
for high slump. Use high-range water-reducing admixtures concrete within sawcut area.
as necessary. Prepackaged repair materials, which are designed
for high-flow placement, include shrinkage-compensating STEP 5: Reinforcement repair. When reinforcing steel is heavily
additives, and are appropriate for many applications. All corroded and the diameter is reduced, consult a structural engineer
mixture proportions should be optimized to minimize dry- for repair procedures. For many applications supplemental rein-
ing shrinkage. Shrinkage testing in accordance with ASTM forcement can be lapped to adjacent damaged bars, as shown.
C 157 measured over a 120-day period is recommended. Important Note: If cor-
roded reinforcing bars are
What equipment do I need?
encountered in the prepa-
Placement equipment may include either concrete buggies,
ration process, then con-
buckets, or concrete pumps. Concrete pumps should be sized
crete surrounding the bars
for the type of repair material being placed. If the repair is
must be removed to fully
mixed on site, a portable mixer is required. Check with the
expose the full circumfer-
manufacturer of the product to determine the recommended
ence. Clearance under the
type of mixer.
bar should not be less than
What are the safety considerations? 3/4 in. (19 mm), or 1/4 in.
Job site safety practices include, but are not limited to, the (6 mm) greater than the
following where applicable: largest aggregate size of
• Material Safety Data Sheets (MSDS) available; the repair mixture, which-
ever is greater.

STEP 1 STEP 2 STEP 6

Sounding of concrete to lo- Unsound concrete removed

cate areas of delamination. with 15-lb chipping hammer.
Hammers larger than a 15-lb
class may cause damage to sub-
strate and reinforcement. Cleaning of reinforcing steel and concrete with abrasive blast.

Surface Repair Using Form-and-Pour Techniques (ACI RAP-4) 3

 • Protective clothing worn by workers handling or of this document. The user must determine the applicability
exposed to hazardous materials; of all regulatory limitations before applying the document
• Use of protective eyewear during pumping and and must comply with all applicable laws and regulations,
placement of repair materials; including but not limited to, United States Occupational Safety
• Availability of eye wash facilities; and and Health Administration (OSHA) health and safety stan-
• Use of respirators and ear protection during demolition. dards.
It is the responsibility of the user of this document to establish
Preconstruction meeting
health and safety practices appropriate to the specific circum-
stances involved with its use. ACI does not make any repre- Prior to proceeding with the repair, a preconstruction meeting
sentations with regard to health and safety issues and the use is recommended. The meeting should include representatives

Repair material is
Section through overhead
brought to the repair
repair showing opening in
site via concrete
slab above for placement of
buggy or other
repair material.
suitable means.
Five-gallon buckets
make useful tools to
deposit repair
material into form.

After the repair material is

placed into cavity, vibrators
Placement of repair material
are inserted into placement
through opening in slab
and consolidated. It is
recommended that
consolidation be done in lifts
of no more than 2 to 3 ft (0.7
to 1 m).

Curing compound is
immediately rolled or
Pencil vibrator is sprayed onto repaired
used to consolidate surfaces after formwork is
repair material in removed. Proper curing
cavity. will help ensure repair
material does not have
premature drying and
cracking, and the material
develops its full strength.

Fig. 3—Material placement: horizontal application. Fig. 4—Material placement: vertical application.

4 Repair Application Procedures Bulletin 4

from all participating parties (owner, engineer, contractor, require openings for placement of repair materials. Gener-
materials manufacturer, etc.), and specifically address the ally, placement occurs through openings in the slab from
parameters, means, methods, and materials necessary to above.
achieve the repair objectives. Material placement—Prior to placement of the repair
material, moisture conditioning of the prepared surface should
Repair procedure
provide for saturated-surface dry conditions. It is important
Formwork construction—Formwork must accommodate the not to overwet the surface. Saturated surfaces will prevent
mass and pressure of the repair material. Design of the forms proper bonding because the surface pores are clogged with
should follow standard practice for cast-in-place concrete water, unable to absorb the repair material. Mixed repair
construction. Formwork is best attached directly to the concrete material is brought to the formed area via whatever transport
surface with expansion anchors or rock anchors designed for technique is appropriate for the situation. This may include
coil rod. In cases of repair of slab soffits (underside), scaffold buckets, pumpline, buggies, or wheelbarrows. For vertical
frames or shoring posts can be used to support the formwork surfaces, material is placed into the chute or opening. External
tight against the concrete surfaces. When expansion/rock or internal vibration is a must for almost all mixture consis-
anchors are used, ensure anchors are firmly set in place to tencies. Some self-leveling repair materials, also known as
prevent slippage under load. Preloading of rock anchors with self-consolidating, can be placed without vibration. When the
coil rod can be accomplished with a center-hole jack applying cavity is filled, extra care should be taken to ensure that the
loads to the coil rod with a stand-off. Forms should be uppermost surfaces are filled adjacent to the chute or opening
constructed to fit tightly against existing surfaces. Preformed where placement occurs. Rodding or tamping can ensure
gaskets or cast-in-place foam work well on difficult-to-match proper filling. Formwork should be left in place for the
surfaces. Placement openings or chutes are required to place prescribed curing period. After stripping of formwork, any
the repair material behind vertical forms. Chutes should be spaces not filled should be trimmed, cleaned, and dry-packed.
constructed to permit development of a hydraulic head above Placement of a membrane curing compound is recommended
the prepared upper edges of the concrete surface. This will immediately after removal of formwork.
provide for repair material supply into these upper horizontal
zones after concrete is consolidated. For large, vertical surfaces How do I check the repairs?
exceeding 10 ft (3 m) in height, multiple lifts should be con- After stripping of forms, various tests can be performed to
sidered to reduce free-fall segregation and excessive form- confirm that the repair material was thoroughly consolidated
work pressures. Formwork for overhead surfaces does not and that adequate bond to the substrate was achieved. A

Fig. 5—Test procedure.

Surface Repair Using Form-and-Pour Techniques (ACI RAP-4) 5

uniaxial bond test can be performed by drilling through the Sources for additional information
repair into the substrate. A bonded plate attached to the 1. “Guide for Surface Preparation for the Repair of Deteriorated Concrete
Resulting from Reinforcing Steel Corrosion,” No. 03730, International Con-
core is pulled until rupture occurs. The location of the failure crete Repair Institute, 1995, 5 pp.
should be reviewed. Bond values typically exceed 100 psi 2. “Guide for Selecting and Specifying Concrete Repair Materials,” No.
(0.7 MPa) and, in most cases, exceed 150 psi (1 MPa). These 03733, International Concrete Repair Institute, 1996, 34 pp.
3. ACI Committee 347, “Guide to Formwork for Concrete (ACI 347-01),”
tests are performed in accordance with ACI 503R Appen- American Concrete Institute, Farmington Hills, Mich., 2001, 32 pp.
dix (see Fig. 5). 4. ACI Committee 546, “Concrete Repair Guide (ACI 546R-96 (Reapproved
The complete repair area should also be hammer-sounded to 2001)),” American Concrete Institute, Farmington Hills, Mich., 1996, 41 pp.
5. ACI Committee 503, “Use of Epoxy Compounds with Concrete (503R-93
locate voids and delaminations within the top 6 in. (150 mm). (Reapproved 1998)),” American Concrete Institute, Farmington Hills, Mich.,
Any hollow sounds may indicate poor bond or voids. 1998, 28 pp.

6 Repair Application Procedures Bulletin 4