CONCRETE REPAIR IN

ACTION: USING THE

MANUAL AS A GUIDE
Christen Longoria, P.E.
San Antonio District Project Engineer
 TxDOT CONCRETE REPAIR MANUAL

 Step-by-Step repair procedures for

use on new and existing concrete

 Ch. 1 Introduction
 Ch. 2 Damage Assessment and
Repair Types
 Ch. 3 Repair Materials and
Procedures

 Each section is a stand-alone

document

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Defining Spalls

 Minor Spall
Less than 1 in deep
Less than 12 sq in

3
 Defining Spalls

 Intermediate Spall
– Exposes outer
reinforcing steel
– Max depth 6 in

4
Defining Spalls
 Major Spall
Extends beyond outer cage
Significant stresses

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Minor Spalls - Materials

Neat Epoxy or Epoxy Mortar

 DMS 6100 “Epoxies

and Adhesives

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Minor Spalls - Materials

Neat Epoxy or Epoxy Mortar

 MPL for Epoxies and

Adhesives
 Type VIII Epoxy Mortar

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Minor Spalls – Repair Procedure

Surface Preparation

 Remove damaged/loose concrete

 Avoid damage to reinforcement
 Hand tools or 15 lb hammer
 Clean and sound
 Do NOT remove reinforcing steel

Mixing

 Manufacturers
Instructions
 Low speed drill and
mixing paddle
 Slowly add sand or
aggregate
 Time

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Minor Spalls – Repair Procedure

Epoxies

 Epoxy Mortar Application

 Bonding layer
 Trowel application
 Limit depth to 1 inch
 Neat Epoxy Application
 Clean and dry
 Brush, Roll or Scrub
 Total coverage

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Intermediate Spalls – Materials

Materials

 Proprietary, bagged Concrete

 Compressive strengths
 Slower strength development
 DMS 4655
 MPL for Concrete Repair Materials
 Type A-3 (Vertical, overhead, less
than 3 in)
 Type A-4 (Vertical, overhead, up to 6
in deep)
 Limit thickness

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Intermediate Spalls – Repair Procedure

Surface Preparation Reinforcement Perimeter

 Remove damaged or loose  Clearance  Saw cut patch

concrete
 Pre-stressing strands  Hand-held grinders or saws
 Avoid damage to reinforcement  Remove rust  Roughen substrate
 Hand Tools or 15 lb hammer
 Clean and Sound

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Intermediate Spalls – Repair Procedure

Epoxy Anchors

 Drill and clean anchor holes

 Proper embedment
 Cover
 Blast clean

Dowels

 Hole size and depth

 Brush clean
 Air compressor
 Epoxy 1/3 full
 Insert dowel

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Intermediate Spalls – Repair Procedure

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Intermediate Spalls – Repair Procedure

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Intermediate Spalls – Repair Procedure

Mixing Application

 Follow manufacturer’s  Temperature Ranges

instructions  Saturated Surface-Dry (SSD) Substrate
 Mixing less than 1 CY  Trowel application
 Low speed drill  Form and pour application
 Mixing more than 1 CY
 Mortar mixer
 Short working times
 Don’t overmix

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Intermediate Spalls – Repair Procedure

Curing Finishing

 Moist curing  Aesthetics

 Forms in place  Blending
 72 hr min

16
Major Spall Repair

Batched concrete

 Same mix as design

mix
 Follow concrete
specifications

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Major Spall Repair

Method

 Surface Prep
 Mixing
 Anchors or Dowels
 Forming
 Curing

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Major Spall Repair

Batched concrete

 Match parent concrete

 TxDOT specifications

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Major Spall Repair

Batched concrete

 Fails at bond line

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Bridge Deck Spall Repair

Defined by Depth

 Partial Bridge Deck

Repairs

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Bridge Deck Spall Repair

Defined by Depth

 Deck Repairs over

Precast Panels

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Bridge Deck Spall Repair

Defined by Depth

 Full Depth Repairs

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Bridge Deck Spall Repair

Defined by Speed

 Immediate need to
return to service

 4 hours (Type B)

 8 hours (Type A)

 24 hours (Class K)

 2 to 4 Days (Class S)

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Bridge Deck Spall Repair
 Concrete Removal
 Tools
 Uniform depth
 No damage to surrounding
concrete or steel

25
Bridge Deck Spall Repair

 Surface Preparation
 Blast clean
 SSD condition
 Reinforcing Steel
 Plans/Engineer
 Bend and secure

26
Bridge Deck Spall Repair

 Placement

27
Bridge Deck Spall Repair

 Finishing
 Curing

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Bridge Deck Spall Repair

Improper Method

 Maintenance
issues

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Other Repair Methods

 Crack repairs
 Pressure Injected Epoxy
 Gravity Fed Epoxy
 Surface Sealing

 Voids due to Honeycombing

 Damage over traffic

 Piling repairs – Post fabrication and during driving

 Taking, Marking, and Patching Cores

 Trimming or cutting pre-stressed concrete girder ends

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 THANK YOU!
Special Thanks:

Bonnie Longley, P.E.

San Antonio Bridge Engineer

James Meuth and the S.A. Bridge Crew

For questions please contact:

Christen.Longoria@txdot.gov

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