Repairing curled slabs

Advantages and limitations of different repair techniques

BY BRUCE A. SUPRENANT AND WARD R. MALISCH

ll slabs curl, some to an

“A objectionable degree,”
says Jerry Holland, struc-
tural engineering consul-
tant for Lockwood
Greene, Atlanta. “But even if the
amount of curl isn’t objectionable,
cracking caused by it may be.”
When concrete slabs on grade
curl, the curling sometimes has little
effect on floor performance. If the
total curl is less than 1⁄4 inch or curl-
ing occurs primarily in low-traffic
areas or under storage racks, the
owner often can live with it, pro-
vided that cracking isn’t excessive.
There are occasions, however,
when the amount of curling isn’t
tolerable and repairs are needed.
When choosing from the several re- Damage caused by slab curling at joints can be prevented by undersealing the
pair methods available, contractors, floor. A low-shrinkage fluid grout pumped at low pressure fills voids beneath the
engineers, and owners must evaluate curled edges and restores subgrade support. The worker shown here should be
wearing safety glasses and gloves.
the feasibility, cost, benefits, and
limitations of each.
top and bottom of the slab. The slab occur at sawcut joints or random
Anatomy of a curled slab edges curl upward when the surface cracks. The curl results in a loss of
Slab curling (Fig. 1) is primarily of a slab is drier or cooler than the contact between the slab and sub-
caused by differences in moisture bottom. Curling is most noticeable base. Generally, the length of lost
content or temperature between the at construction joints, but it can also subbase contact is about 10% of the
slab length (measured between
joints) at joints that have load trans-
fer (doweled or sawcut joints) and
Construction joint
Control about 20% for joints with no load
Construction joint 1 in.
joint
transfer. Upward slab corner curl can
be as high as 1 inch, but most re-
1 in. pairs are for slabs with edges that
have risen 1⁄4 to 1⁄2 inch or more from
5 10 15 20 25 30 35 40 the original plane.
The bump created at joints where
Distance across slab (feet )
slabs have curled isn’t always a prob-
Figure 1. This measured slab profile shows curling at the slab edges and at the lem. Even when there’s as much as 1⁄4
control joint at midspan (Ref. 6). Curling is most noticeable at construction joints, inch of curling, slow forklift traffic
but it can also occur at sawcut joints or random cracks. may not be affected if the forklift
loads are heavy enough. But loss of
subgrade support causes slab move-
ment as forklifts pass over the joint.
Joint edges start to chip and deterio-
rate. A crack may form parallel to
the joint, and rocking of the cracked
section accelerates joint deteriora-
tion. The speed at which joints de-
teriorate depends on how much
movement takes place in the curled
slab and the frequency of the load-
ing.
Is repair needed?
Curling generally requires repair if
it creates a problem for the floor
user. But there are other factors to
consider, including the cost-effec-
tiveness of the repair and the
future performance of the floor.
Without repairs, a curled floor can
deteriorate faster.
Some repair contractors determine
the need for curl repair and the po-
tential for distress based on mea-
sured differential movement from
one side of the joint to the other as a
forklift crosses the joint (Ref. 1):
n Movements less than 0.010 inch
indicate acceptable joint perfor-
mance and tolerable curling.
n Movements of 0.010 to 0.017 inch
(approximately 1⁄64 inch) are in the
gray area. Repairs may improve
floor performance but may not be
cost-effective. Without repairs, the
floor might deteriorate twice as
fast but could still last 10 years
without requiring major work.
n Movements of 0.017 to 0.030 inch
(approximately 1⁄32 inch) are severe
enough to cause deterioration
three to four times faster than
normal. Problems such as joint de-
terioration could occur within 2
years.
In our experience, this is a very
conservative repair approach. Slabs
with larger movements have per-
formed satisfactorily for 20 years.
The best criterion is to evaluate slabs
with similar traffic where the owner
has been satisfied with the slab per-
formance. Measure the joint move-
ment of these slabs to evaluate the
necessary repairs for the slab in
question. Take slab age into account
when interpreting the joint-move-
ment measurements. A joint move-
ment of 0.030 inch in a slab after 10
years of service isn’t likely to get
worse, but the same joint movement
at the beginning of the floor’s life
cycle can accelerate deterioration.
Even when a curled slab needs re-
pair, it’s unlikely that the entire slab
needs attention. Repair curling only
in the areas where it creates a prob-
lem. For instance, curled slab corners
may need to be repaired only where
there is forklift traffic (designated ve-
hicle aisles), but not in areas without
forklift traffic or covered by carpet or
tile.
Is it time to repair?
A slab can continue to curl for
months. Before implementing a re-
pair scheme, it’s important to con-
sider how much curl has occurred
and if it’s continuing. Measuring the
slab weekly with a rod and level can
help pinpoint curl locations and
rates.
Implementing a solution when
the curl is continuing can com-
pound the problem. On one project,
for instance, more than 100,000
square feet of a 6-inch-thick con-
crete slab over compacted clay had
curled when the general contractor
told the tile contractor to place vinyl
tiles. But the slab continued to curl,
and uplifted tiles could be seen at
the slab corners. The general con-
tractor tore off the tiles, ground the
concrete slab to level, and replaced
the tiles. A month later, uplifted tiles
were again noticeable because the
slab had not yet stopped curling.
The repair process had to be re-
peated.
Recognize that a concrete slab has
a moisture cycle: from initial satura-
tion as fresh concrete, to slow dry-
ing, to rain wetting when exposed to
the environment, to protected dry-
ing as the building is enclosed, and
finally to a controlled drying envi-
ronment as the building’s heating or
cooling system is turned on. The du-
ration of this cycle can be affected
by the construction sequence (how
soon the building is enclosed after
floor placement), water transfer by
capillary action from the ground
Curl reduction study
Elevation of slab corner, in.
Ponding water
0.10
at room temp.
Heat lamps
Dry
Hot
.050
water
6'' slab on clay
0
20 60 100
Time, days
Figure 2. Ponding water on the slab
surface can reduce curling by equaliz-
ing the moisture content in the top
and bottom of the slab. However, this
result is reversed when the water is re-
moved and the slab dries (Ref. 4).
below, or even water accumulation
from broken pipes or from down-
spouts that aren’t properly draining
water away from the building. The
repair option might differ if the slab
is dry, still drying, or has the poten-
tial for long-term cycles of wetting
and drying.
Repair options
Here are some corrective measures
and repair schemes that have been
suggested or used on curled slabs.
However, some of the options, as
noted, have little or no benefit or
work better in combination with
other methods.
1. Wait and hope
Measure the slab curl, wait, remea-
sure, and hope that the curl will de-
crease to a tolerable level within a
reasonable time. The degree of curl-
ing is often significantly reduced
with time as the slab dries and mois-
ture content becomes more uniform
(Ref. 2). Creep caused by the weight
of the unsupported slab will also re-
duce the amount of curl. However,
because of tight construction sched-
ules, waiting usually isn’t feasible. In
one study, a curled 18x25-foot, 7-
inch-thick concrete slab was dried in
a controlled laboratory environment
(Ref. 3). It took 5 months of drying
to bring the slab back to a reason-
ably level surface.
2. Wet the top of the slab
Build a dam, seal joints and
cracks, and pond water on the slab
surface. Since curling is caused by
the top of the slab being drier than
the bottom, wetting the top of the
slab should reverse the curling
process. If ponding is feasible, this
technique can temporarily reduce
the amount of curl.
In a laboratory study that used
this method, however, the original
elevation of slab corners wasn’t re-
stored by simply rewetting the sur-
face (Ref. 4). Surface water at room
Factors to consider when
selecting a repair option
No single repair technique is
appropriate for all curled slabs.
To select a repair option best
suited for a project’s specific
demands, ask the following
questions:
n What is the intended floor use?
Does the owner anticipate any
future changes in usage?
n What are the expected or fu-
ture floor coverings?
n What are the traffic loadings,
frequencies, and patterns?
n Is load transfer needed at
joints?
n What flatness tolerances are
acceptable?
n What is the expected repair
cost?
n What is the expected repair
life?
n What are the maintenance
costs of the repaired work?
For instance, if new joints are
cut to reduce curling, the
floor owner will have more
joints to maintain.
temperature reduced the curling
about 40%. Heat lamps produced a
further 20% reduction before heat-
induced drying caused the slab to
start curling again. Ponding with hot
water then brought the corners
down to their initial elevation (Fig.
2). But when the water was removed
and the slab dried, the slab returned
to its original curled condition.
One suggested curling remedy is
ponding the slab until it’s level again
and cutting additional control joints
where the slab has curled (Ref. 2).
The success of this method varies,
depending on the extent and cause
of the curling.
3. Cut more joints
Cut slab corners on a diagonal, or
cut at the centerlines of the slab
panels (Fig. 3). The cut slab segments
reportedly lay flatter. Holland says
diagonal cuts are much more effec-
tive than centerline cuts, but even
diagonal cuts reduce curl no more
than 50%, and the reduction is usu-
ally much less.
For best results, cut the slab after
most of the drying shrinkage has oc-
curred, since further shrinkage can
cause curling of corners and edges at
the new cuts. On one project, a con-
tractor tried to reduce the amount of
corner curl by sawcutting com-
pletely through the slab at the panel
centerlines. However, slab curling
continued and the contractor found
he now had twice as many curled
slab corners to fix.
Cutting additional joints is most
likely to be a successful solution for
curled floors that receive no forklift
traffic and will be covered with car-
pet. Drawbacks of this solution
when used for slabs with forklift traf-
fic include:
n Loss of load transfer due to loss of
aggregate interlock at full-depth
sawcuts
n Increased joint maintenance due
to the larger number of joints
n A potential hazard for oncoming
forklift traffic due to slab-segment
rocking as forklift wheels load one
edge and cause the other edge to
raise
For slabs with light forklift traffic
L or L
4 5
Sawcuts L
Diagonal cuts at curled corners
L
L
2
L
2
L
Cuts at panel centerline
Figure 3. Sawcuts at the slab locations
shown may allow the cut segments to
lay flatter, reducing the amount of
vertical deflection. However, if more
drying shrinkage occurs, the sawcuts
increase the number of possible loca-
tions for further curling. Depending
on sawcut depth, this solution may al-
so decrease the amount of load that’s
transferred by aggregate interlock.
and loading, one alternative to full-
depth cutting is making a sawcut to
one-third the slab thickness. This
provides some load transfer through
aggregate interlock below the new
sawcuts but still hinges the slab
enough to reduce elevation of the
curled corners and edges. On some
projects, cutting to only one-third
the slab depth reportedly reduced
curled elevation 50%.
4. Grind
Perform an elevation survey,
choose an acceptable floor profile,
and diamond grind the curled slab
edges and corners to achieve the de-
sired profile. Typically this involves
grinding to a distance of 2 to 6 feet
from the curled edges. Grind only
those areas that need a new profile,
such as traffic aisles or areas that will
be tiled instead of carpeted.
Grinding is a common curling re-
pair option that doesn’t create any
new joints and maintains existing
aggregate interlock to provide load
transfer. As with cutting, however,
grinding should be done after most
of the drying shrinkage has oc-
curred. If grinding is done too soon,
continued curling may require re-
grinding.
Grinding provides a flat profile
suitable for tile and carpet coverings
or an exposed floor surface. Grind-
ing without any additional repair
steps is suitable for floors receiving
light traffic but should be used with
caution if there is forklift traffic.
Since grinding makes the slab thin-
ner and doesn’t restore underslab
support, forklift traffic can crack a
curled corner after it’s been ground.
Frequent or heavy forklift traffic can
cause joint deterioration requiring
more extensive and expensive joint
repair.
When a higher overall slab eleva-
tion is acceptable and there’s no
forklift traffic, some contractors find
it more economical to fill in the low
spots with a self-leveling, flowable
cementitious mix than to grind the
high spots. Though the cementitious
mix is featheredged at the curled
joint, spalling is unlikely if the floor
will be covered by carpeting and is
exposed primarily to foot traffic.
5. Remove and replace part of the
concrete
Sawcut around the curled area, use
1 Joint
Slab
Void
Slab lifts slightly off ground.
4 Epoxy mortar
Edges sawcut and filled with epoxy.
Figure 4. Partial-depth patches eliminate the need for grinding. The underslab should be grouted to provide support, but
some contractors skip this step if the floor receives only light traffic.
4 • CONCRETE CONSTRUCTION / MONTH 1999
a chipping hammer to remove con-
crete below the desired profile, and
place and finish patch material to
the desired elevation (Fig. 4). Be sure
to maintain joint integrity by recut-
ting a joint in the patching material
(Ref. 5). If only a few curled areas
need repair, this partial-depth patch
repair may cost less than hiring a
grinding contractor. And if the joint
edges show no deterioration, it may
not be necessary to grout the under-
slab void created by curling. How-
ever, grouting will probably be re-
quired if forklift traffic is
anticipated. “Patching can get pretty
pricey if a lot of joints are involved,”
says Holland, “so I usually look for
other solutions.”
6. Grout and grind
Drill or core a 1- to 2-inch-diame-
ter hole at the elevated joint corners
and at slab edges, where necessary.
Use a flowable, low-shrinkage grout
to fill the underslab voids, or use a
stiff, low-shrinkage grout to make
cowpie columns that support the
four corners and any curled edges.
Monitor and control the grout pres-
sure (typically limited to 10 psi) to
avoid or minimize slab uplift during
grouting. After the grout hardens,
grind the slab surface at curled eleva-
tions, if needed, to produce the de-
sired floor profile.
2 Edge
break
Wheel breaks edge of joint.
5 Sealant
Joint is recut.
Sealant is gunned into cut.
Although cementitious grouts
work well for most repairs, Holland
says he’s seen a few cases where the
underslab voids were so small that
they couldn’t be filled without rais-
ing the slab. “In those situations, I
recommend using a urethane grout
that’s pumped with the same equip-
ment used for stopping leaks in
walls,” he says. “These grouts flow
more easily and require less pump
pressure, and thus aren’t as likely to
raise the slab.”
The grout-and-grind method is
typically used on floors subjected to
frequent forklift traffic or heavy
forklifts. Grouting re-establishes sup-
port for forklift traffic, reducing re-
liance on aggregate interlock for
load transfer. However, if the grout
shrinks or the slab continues to curl,
slab support will again be reduced. If
objectionable joint movement re-
curs, regrouting may be necessary.
Holland says grinding often isn’t
needed if the problem is differential
joint movement. He suggests grout-
ing first and then observing the re-
sults: “If that solves the problem,
forget the grinding, which just adds
to the repair cost.” Some contractors
prefer to grout the underslab voids
and then use partial-depth patches
to level the curled edges.
7. Add dowel bars
3 Grout
Grout installed to fill void.
6
Result is smooth, flat joint.
 Steel dowels can be installed
across a curled joint to improve load
transfer and minimize differential
movement under traffic. Garber sug-
gests the following steps for in-
stalling dowels in an existing joint
(Ref. 6):
1. Saw the floor at right angles to the
joint, making each sawcut 1⁄4 inch
wide, 4 inches deep, 36 inches
long at the bottom, and 12 inches
on center.
2. Blow each sawcut clean with com-
pressed air.
3. Place a 1⁄4x2x36-inch steel flat bar
in each sawcut, making sure the
bar rests firmly on the bottom of
the cut. Grease each bar to inhibit
bonding.
4. Fill each sawcut with high-
strength epoxy grout, leaving the
surface slightly crowned. Do not
let epoxy enter the joint.
5. Fill the joint with a semi-rigid
epoxy—not with the high-
strength grout used in the sawcut.
6. After the high-strength grout and
joint filler have hardened, grind
them flush with the surrounding
floor surface.
Garber says this procedure is suit-
able for 6-inch or thicker slabs. Be-
cause of the cost, he recommends
using it only in high-traffic areas
where differential movement at the
curling location is a problem. Dow-
els can be used alone or in combina-
tion with other procedures such as
partial-depth patching, grinding, or
grouting and grinding.
Based on a computer analysis,
Holland believes 18-inch-long bars
are as effective as 36-inch bars. He
also cautions that the grease layer
must be as thin as possible because
excessive amounts may reduce the
strength of the grout at the interface
with the bar, and the grease itself
may compress under loading, reduc-
ing load transfer.
Do only what’s required
Though many of these repair
methods can be successful, they can
also be costly, especially if they’re
done too soon and curling contin-
ues. Holland sums up his recom-
mendation succinctly: Grout to re-
store subgrade support, and do
nothing else unless you have to.
For a large floor, grinding can
Publication #C99E058
Copyright© 1999, The Aberdeen Group
a division of Hanley-Wood, Inc.
All rights reserved
quickly run up costs, says Holland.
“The degree of curvature in a curled
slab increases as you get closer to the
edge, but you may still have 6 feet of
concrete that requires grinding.”
Installing dowels can get expen-
sive too. “I think dowels are a viable
option only when extremely soft
subgrade soil makes grouting less
satisfactory,” Holland explains.
References
1. Ron Bartelstein and Ed Weiner, “Re-
pairing Industrial Floors,” Concrete Re-
pair Digest, Spring 1990, pp. 7-12.
2. “Concrete Slab Surface Defects:
Causes, Prevention, Repair,” Portland
Cement Association, Skokie, Ill., 1997,
pp. 4-5.
3. W.K. Hatt, “The Effect of Moisture
on Concrete,” ASCE Transactions,
Paper No. 1577, 1925.
4. L.D. Childs and J.W. Kapernick,
“Tests of Concrete Pavements on
Gravel Subbases,” Bulletin D21, Port-
land Cement Association, 1958.
5. Peter Craig, “How to Handle the
Curled Joint,” Concrete Repair Bulletin,
May 1990.
6. George Garber, Design and Con-
struction of Concrete Floors, Halsted
Press, New York, 1991, pp. 157-158.