DIVISION 3 - CONCRETE

Section 03930 – Concrete Repair

SECTION 03930

CONCRETE REPAIR

PART 1 GENERAL

1.1 SUMMARY

A. This Section includes the following:

1. Removal of deteriorated concrete and subsequent patching and rebuilding.

2. Floor joint repair.
3. Epoxy crack injection.
4. Corrosion-inhibiting treatments.
5. Polymer overlays, including preparation.
6. Polymer sealers.
7. Steel structural reinforcement.
8. Composite structural reinforcement.

1.2 SUBMITTALS

A. Product Data: Include material descriptions, chemical composition, physical properties,

test data, and mixing and application instructions.

1. Include Material Safety Data Sheets, if applicable.

B. Shop Drawings: For formwork and supports, prepared by or under the supervision of a
qualified professional engineer. Design and engineering of formwork and supports are
Contractor's responsibility. Indicate proposed schedule and sequence for removal of
formwork and supports.

C. Samples: Cured samples of overlay and patching materials.

D. Product Certificates: Signed by manufacturers certifying that products furnished

comply with requirements and are recommended by manufacturer for uses indicated.

E. Qualification Data: For installers, to demonstrate their capabilities and experience.

Include lists of completed projects with project names and addresses, names and
addresses of architects and owners, and other information specified.

1. For products required to be installed by workers approved by product

manufacturers, include letters of acceptance by product manufacturers certifying
that installers are approved to apply their products.

F. Material Test Reports: From a qualified testing agency indicating and interpreting test
results for compliance of with requirements indicated.

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G. Repair program for each phase of the Repair process, including protection of
surrounding materials and Project site during operations. Describe in detail the
materials, methods, equipment, and sequence of operations to be used for each phase
of the Work.

1. If alternative materials and methods to those indicated are proposed for any phase
of Repair work, submit substitution request complying with Division 1 Section
"Product Requirements" and provide a written description of proposed materials
and methods, including evidence of successful use on other comparable projects,
and a testing program to demonstrate their effectiveness for this Project.

1.3 QUALITY ASSURANCE

A. Installer Qualifications: In addition to other requirements in Division 1 Section "Quality

Requirements," retain installers that employ workers trained and approved by
manufacturers to apply concrete repair materials.

B. Manufacturer Qualifications: In addition to other requirements in Division 1 Section

"Quality Requirements," manufacturers shall have factory-trained representatives who
are available for consultation and Project site inspection at no additional cost.

C. Source Limitations: Obtain concrete repair materials through one source from a single
manufacturer.

D. Source Limitations: Obtain each of the following through one source from a single
manufacturer:

1. Concrete patching and rebuilding materials.

2. Epoxy crack injection materials.
3. Composite structural reinforcement materials.

E. Mockups: Build mockups for floor joint repair, [epoxy crack injection, polymer overlays,
and polymer sealers, to demonstrate qualities of materials and execution.

1. Approved mockups may become part of the completed Work if undisturbed at time
of Substantial Completion.

1.4 DELIVERY, STORAGE, AND HANDLING

A. Deliver materials to Project site in manufacturer's original and unopened containers,

labeled with type and name of products and manufacturers.

B. Comply with manufacturer's written instructions for minimum and maximum

temperature requirements and other conditions for storage.

C. Store cementitious materials off the ground, under cover, and in a dry location.

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D. Store aggregates, covered and in a dry location, where grading and other required
characteristics can be maintained and contamination avoided.

1.5 PROJECT CONDITIONS

A. Environmental Limitations for Epoxies: Do not apply when air and substrate
temperatures are outside limits permitted by manufacturer. During hot weather, cool
epoxy components before mixing, store mixed products in shade, and cool unused
mixed products to retard setting. Do not apply to wet substrates unless approved by
manufacturer.

1. Use only Class A epoxies when substrate temperatures are below or are expected
to go below (5 deg C) within 8 hours.
2. Use only Class A or B epoxies when substrate temperatures are below or are
expected to go below (16 deg C) within 8 hours.
3. Use only Class C epoxies when substrate temperatures are above (16 deg C).

B. Cold-Weather Requirements for Cementitious Materials: Do not apply unless air

temperature is between (5 and 32 deg C) and will remain so for at least 48 hours after
completion of Work.

C. Cold-Weather Requirements for Cementitious Materials: Comply with the following

procedures:

1. When air temperature is below (5 deg C), heat patching material ingredients and
existing concrete to produce temperatures between (5 and 32 deg C).
2. When mean daily air temperature is between (minus 4 and plus 5 deg C), cover
completed Work with weather-resistant insulating blankets for 48 hours after repair.
3. When mean daily air temperature is below (minus 4 deg C), provide enclosure and
heat to maintain temperatures above (0 deg C) within the enclosure for 48 hours
after repair.

D. Hot-Weather Requirements for Cementitious Materials: Protect repair work when

temperature and humidity conditions produce excessive evaporation of water from
patching materials. Provide artificial shade and wind breaks, and use cooled materials
as required. Do not apply to substrates with temperatures of (32 deg C) and above.

E. Environmental Limitations for High-Molecular-Weight Methacrylate Sealers: Do not

apply when concrete surface temperature is below (13 deg C) or above (32 deg C).
Apply only to substrates that have been dry for at least 72 hours.
PART 2 PRODUCTS

MANUFACTURERS
2.1

A. Available Products: Subject to compliance with requirements, products that may be

incorporated into the Work include, but are not limited to, the following:

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B. Products: Subject to compliance with requirements, provide one of the following:

1. Epoxy-Modified, Cementitious Bonding and Anticorrosion Agent:

a. Euclid Chemical Company; CORR-BOND.

b. Kaufman Products, Inc; SurePoxy HMEPL.
c. Sika Corporation; Armatec 110 EpoCem.
d. Sonneborn, Div. of ChemRex, Inc.; Sonoprep.
e. Sto Corp., Concrete Restoration Division; Sto Bonding and Anti-Corrosion
Agent.

2. Epoxy Bonding Agent:

a. Fosroc International Limited; Nitonond 881.

b. Kaufman Products, Inc.; SurePoxy HM EPL.
c. Master Builders, Inc.; CONCRESIVE LIQUID LPL.
d. Sika Corporation; Sikadur 32 and 35.
e. Sto Corp., Concrete Restoration Division; Sto Epoxy Adhesive.
f. Unitex; Pro-Poxy 204 or Slow Set Bonding Agent.

3. Latex Bonding Agent, Type II:

a. Dayton Superior Corporation; Day-Chem Ad Bond (J-40).

b. Euclid Chemical Company; FLEX-CON.
c. Kaufman Products, Inc.; SureBond.
d. Sonneborn, Div. of ChemRex, Inc.; Acrylic Additive.

4. Latex Bonding Agent, Type I:

a. Euclid Chemical Company; EUCO WELD.

b. Kaufman Products, Inc.; SureWeld.
c. Sika Corporation; SikaLatex.

5. Cementitious Patching Mortar:

a. Fosroc International Limited; Renderoc LA.

b. Kaufman Products, Inc.; HiCap.
c. Master Builders, Inc.; EMACO S66 CI, EMACO S77 CI, or EMACO S88 CI.
d. Sika Corporation; SikaRepair 223 or SikaRepair SHB.
e. Sto Corp., Concrete Restoration Division; Sto Full-Depth Repair Mortar.

6. Cementitious Patching Mortar, Rapid Setting:

a. Euclid Chemical Company; EUCO-SPEED.

b. Fosroc International Limited; Patchroc 10-60 or Patchroc 10-61.
c. Kaufman Products, Inc.; Duracrete.
d. Sika Corporation; Sikaset Roadway Patch.

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e. Sonneborn, Div. of ChemRex, Inc.; Road Patch.

f. Sto Corp., Concrete Restoration Division; Sto Rapid Repair Mortar.

7. Polymer-Modified, Cementitious Patching Mortar:

a. Fosroc International Limited; [Polyset] [or] [Renderoc HB2].

b. Kaufman Products, Inc.; [Patchwell,] [Patchwell Kit,] [Patchwell Kit D,] [or]
[Patchwell Kit HB].
c. Master Builders, Inc.; [EMACO R320 CI] [or] [EMACO R350 CI].
d. Sika Corporation; [SikaTop 121 Plus,] [SikaTop 122 Plus,] [SikaTop 123 Plus,]
[or] [SikaTop 126 Plus].

8. Polymer-Modified, Silica-Fume-Enhanced, Cementitious Patching Mortar:

a. Fosroc International Limited; Renderoc SD40.

b. Master Builders, Inc.; EMACO S88 CI.
c. Sika Corporation; Sika MonoTop 615.
d. Stop Corp., Concrete Restoration Division; Sto High-Strength Overhead
Mortar.

9. Epoxy-Modified, Cementitious Patching Mortar:

a. Sika Corporation; Sikadur 45 EpoCem.

10. Epoxy Joint Filler:

a. Euclid Chemical Company; EUCO 700.

b. Fosroc International Limited; Nitoseal 280.
c. Kaufman Products, Inc.; SurePoxy Flexijoint.
d. Master Builders, Inc.; MASTERFILL 300.
e. Sika Corporation; [Sikadur 51 NS] [or] [Sikadur 51 SL].

11. Epoxy Crack Injection Adhesive:

a. Fosroc International Limited; [Nitobond 881-11,] [Nitobond 881-41,] [Nitobond

ULV 140,] [or] [Nitobond ULV 300].
b. Master Builders, Inc.; [CONCRESIVE STANDARD LVI] [or] [SCB
CONCRESIVE 1380].
c. Sika Corporation; [Sikadur 35 Hi-Mod LV,] [Sikadur 35 Hi-Mod LV LPL,]
[Sikadur 52,] [or] [Sikadur Injection Gel].
d. Unitex; [Pro-Poxy 50 SuperLV] [or] [Pro-Poxy 100 LV].

12. Corrosion-Inhibiting Treatments:

a. CORTEC Corp.; [MCI 2005] [or] [MCI 2020].

b. Sika Corporation; Sika FerroGard 903.

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13. Polymer Overlays:

a. Fosroc International Limited; Nitobond 881-33.

b. Kaufman Products, Inc.; [SurePoxy VLM] [or] [SurePoxy VLM-Class B].
c. Unitex; Pro-Poxy Type III D.O.T.

14. Epoxy Sealers:

a. Euclid Chemical Company; EUCO #512 Epoxy Sealer.

b. Kaufman Products, Inc.; SurePoxy Penetrating Sealer.
c. Master Builders, Inc.; MASTERSEAL GP.

15. High-Molecular-Weight Methacrylate Sealers:

a. Sika Corporation; SikaPronto 19.

b. Transpo Industries, Inc.; Sealate T70.

16. Methylmethacrylate Sealer/Brighteners:

a. Fosroc International Limited; [Nitocote EA-Sealer/Lo Lustre,] [Nitocote EA-

Sealer/Hi Lustre,] [Nitocote EA-Sealer WB,] [or] [Nitocote EA-Sealer WB Hi
Gloss].
b. Kaufman Products, Inc.; [Sureal] [or] [Sureal Emulsion].
c. Unitex; [Bright Rock Sealer] [or] [Luster Seal].

17. Composite Structural Reinforcement:

a. Master Builders, Inc.; MBrace Composite Strengthening System.

b. Sika Corporation; CarboDur and Sikadur 30.
c. Sumitomo Corporation of America; Replark

2.2 BONDING AGENTS

A. Epoxy-Modified, Cementitious Bonding and Anticorrosion Agent: Product that consists

of water-insensitive epoxy adhesive, portland cement, and water-based solution of
corrosion-inhibiting chemicals that forms a protective film on steel reinforcement.

B. Epoxy Bonding Agent: ASTM C 881, Type [II] [V].

1. Thin Film Open Time: Not less than 24 hours.

C. Latex Bonding Agent: ASTM C 1059, Type [II] [I] [II at exterior locations and where
indicated, Type I at other locations].

D. Mortar Scrub-Coat: 1 part portland cement complying with ASTM C 150, Type I, II, or
III and 1 part fine aggregate complying with ASTM C 144, except 100 percent passing a
No. 16 sieve.

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2.3 PATCHING MORTAR

A. Patching Mortar: Unless otherwise indicated, use one of the following:

1. Job-Mixed Patching Mortar: 1 part portland cement complying with ASTM C 150,
Type I, II, or III and 2-1/2 parts fine aggregate complying with ASTM C 144, except
100 percent passing a No. 16 sieve.
2. Cementitious Patching Mortar: Packaged, dry mix complying with ASTM C 928.
3. Polymer-Modified, Cementitious Patching Mortar: Packaged, dry mix complying
with ASTM C 928, that contains a non-redispersible latex additive as either a dry
powder or a separate liquid that is added during mixing.
4. Polymer-Modified, Silica-Fume-Enhanced, Cementitious Patching Mortar:
Packaged, dry mix complying with ASTM C 928, that contains silica fume
complying with ASTM C 1240 and a non-redispersible latex additive as either a dry
powder or a separate liquid that is added during mixing.
5. Epoxy-Modified, Cementitious Patching Mortar: Mixture of water-insensitive epoxy
adhesive, portland cement, and graded aggregates.

B. Overhead Patching Mortar: For overhead repairs, use patching mortar recommended
by manufacturer for overhead use and as specified above.

C. Coarse Aggregate for Adding to Patching Mortar: Washed aggregate complying with
ASTM C 33, Size No. 8, Class 5S. Add only as permitted by patching mortar
manufacturer.

2.4 CONCRETE

A. Preplaced Aggregate: Washed aggregate complying with ASTM C 33, Class 5S, with
95 to 100 percent passing a (37.5-mm) sieve, 40 to 80 percent passing a (25-mm)
sieve, 20 to 45 percent passing a (19-mm) sieve, 0 to 10 percent passing a (12.5-mm)
sieve, and 0 to 2 percent passing a (9.5-mm) sieve.

B. Preplaced Aggregate: Washed aggregate complying with ASTM C 33, Class 5S, with
100 percent passing a (37.5-mm) sieve, 95 to 100 percent passing a (25-mm) sieve, 40
to 80 percent passing a (19-mm) sieve, 0 to 15 percent passing a (12.5-mm) sieve, and
0 to 2 percent passing a (9.5-mm) sieve.

C. Fine Aggregate for Grout Used with Preplaced Aggregate: Fine aggregate complying
with ASTM C 33, but with 100 percent passing a No. 8 sieve, 95 to 100 percent passing
a No. 16 sieve, 55 to 80 percent passing a No. 30 sieve, 30 to 55 percent passing a No.
50 sieve, 10 to 30 percent passing a No. 100 sieve, 0 to 10 percent passing a No. 200
sieve, and having a fineness modulus of 1.30 to 2.10.

D. Grout Fluidifier for Grout Used with Preplaced Aggregate: ASTM C 937.

E. Portland Cement for Grout Used with Preplaced Aggregate: ASTM C 150.

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F. Pozzolans for Grout Used with Preplaced Aggregate: ASTM C 618.

2.5 MISCELLANEOUS MATERIALS

A. Epoxy Joint Filler: 2-component, semirigid, 100 percent solids, epoxy resin with a
Shore A hardness of at least 80 per ASTM D 2240.

B. Epoxy Crack Injection Adhesive: ASTM C 881, Type I, IV, Grade 1

C. Epoxy Capping Adhesive: Product manufactured for use with crack injection adhesive
by same manufacturer.

D. Corrosion-Inhibiting Treatment Materials: Water-based solution of alkaline corrosion-

inhibiting chemicals that penetrates concrete by diffusion and forms a protective film on
steel reinforcement.

E. Polymer Overlay: Epoxy adhesive complying with ASTM C 881, Type III.

1. Aggregate: Oven-dried, washed silica sand complying with ACI 503.3.

F. Polymer Sealer: Low-viscosity epoxy penetrating sealer recommended by

manufacturer for application to exterior concrete traffic surfaces.

G. Methylmethacrylate Sealer/Brighteners: Clear low-viscosity sealer recommended by

manufacturer for sealing exterior exposed-aggregate concrete, and formulated to bring
out color of aggregates and give concrete a wet look.

H. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

1. After fabricating, prepare surfaces to comply with SSPC-SP 6/NACE No. 3,

"Commercial Blast Cleaning."
2. After preparation, apply 1 coat of lead- and chromate-free, universal, modified-
alkyd primer complying with FS TT-P-664 and 1 coat of alkyd-gloss enamel
complying with FS TT-E-489.
3. After preparation, apply 2-coat high-performance coating system consisting of
organic zinc-rich primer, complying with SSPC-Paint 20, at 2.5-mil (0.065-mm) dry
film thickness and topcoat of high-build, 2-component, epoxy-polyamide, high-
performance coating at 6-mil (0.15-mm) dry film thickness.
a. Available Products: Subject to compliance with requirements, products that
may be incorporated into the Work include, but are not limited to, the following:
b. Products: Subject to compliance with requirements, provide one of the
following:
1. Carboline Company; Carboline 621 and 190 HB.
2. PPG Industries, Inc.; Aquapon Zinc-Rich Primer 97-670 and High-Build
Polyamide-Epoxy 97-131.

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3. Tnemec Company, Inc.; Tneme-Zinc 90-97 and Series 69 Hi-Build

Epoxoline II.

I. Bolts: Steel bolts complying with ASTM A 307, Grade A (ASTM F 568, Property Class
4.6); with ASTM A 563 (ASTM A 563M) hex nuts and flat washers; hot-dip galvanized
to comply with ASTM A 153/A 153M, Class C.

J. Postinstalled Anchors: Anchors as described below, with capability to sustain, without

failure, a load equal to four times the load imposed, as determined by testing per ASTM
E 488, conducted by a qualified independent testing agency.

1. Type: Expansion anchors.

2. Corrosion Protection: Stainless-steel components complying with ASTM F 593 and
ASTM F 594, Alloy Group 1 or 2 (ASTM F 738M and ASTM F 836M, Alloy Group 1
or 4) for bolts and nuts; ASTM A 666 or ASTM A 276, Type 304 or 316, for
anchors.

K. Composite Structural Reinforcement: Manufacturer's complete system consisting of

fiber reinforcement and epoxy primers, fillers, adhesives, saturants, and topcoats.
System is designed for use as external structural reinforcement for concrete.

1. System uses unidirectional carbon-fiber preimpregnated sheets.

2. System uses carbon-fiber tow sheet with field-applied saturant.
3. System uses carbon-fiber reinforcement, in the form of either preimpregnated
sheets or tow sheet with field-applied saturant.

2.6 MIXES

A. Mix products in clean containers according to manufacturer's written instructions.

1. Add clean silica sand and coarse aggregates to products only as recommended by
manufacturer.
2. Do not add water, thinners, or additives unless recommended by manufacturer.
3. When practical, use manufacturer's premeasured packages to ensure that
materials are mixed in proper proportions. When premeasured packages are not
used, measure ingredients using graduated measuring containers; do not estimate
quantities or use shovel or trowel as unit of measure.
4. Do not mix more materials than can be used within recommended open time.
Discard materials that have begun to set.

B. Mortar Scrub-Coat: Mix with enough water to provide a consistency of thick cream.

C. Dry-Pack Mortar: Mix with just enough liquid to form a damp cohesive mixture that can
be squeezed by hand into a ball but is not plastic.

D. Grout for Use with Preplaced Aggregate: Proportion according to ASTM C 938. Add
grout fluidifier to mixing water followed by cementitious materials and then fine

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aggregate.

PART 3 EXECUTION

3.1 EXAMINATION

A. Notify Architect seven days in advance of dates when areas of delaminated concrete
and reinforcing bars will be located.

B. Locate areas of delamination using hammer or chain drag sounding and mark
boundaries. Mark areas for removal by simplifying and squaring off boundaries of
delaminated areas.

C. Locate at least three reinforcing bars using a pachometer, and drill test holes to
determine depth of cover. Calibrate pachometer, using depth of cover measurements,
and verify depth of cover in removal areas using pachometer.

3.2 PREPARATION

A. Protect people, motor vehicles, equipment, surrounding construction, Project site,

plants, and surrounding buildings from injury resulting from concrete Repair work.

1. Erect temporary protective covers over pedestrian walkways and at points of

entrance and exit for people and vehicles that must remain in operation during
course of concrete Repair work. Construct covers of tightly fitted, (19-mm)
exterior-grade plywood supported at (405 mm) o.c. and covered with asphalt roll
roofing.
2. Protect adjacent equipment and surfaces by covering them with heavy polyethylene
film and waterproof masking tape or a liquid strippable masking agent. If practical,
remove items, store, and reinstall after potentially damaging operations are
complete.
3. Neutralize and collect alkaline and acid wastes for disposal off Owner's property.
4. Dispose of runoff from wet operations by legal means and in a manner that
prevents soil erosion, undermining of paving and foundations, damage to
landscaping, and water penetration into building interiors.

B. Shoring: Install temporary supports before beginning concrete removal.

C. Concrete Removal: Saw-cut perimeter of areas indicated for removal to a depth of at

least (12.7 mm). Make cuts perpendicular to concrete surfaces and no deeper than
cover on reinforcing. Remove loose and deteriorated concrete by breaking up and
dislodging from reinforcing.

1. Remove concrete between cuts to a depth of at least (12.7 mm).

2. Where half or more of the perimeter of reinforcing bar is exposed, bond between
reinforcing bar and surrounding concrete is broken, or reinforcing bar is corroded,
remove concrete from entire perimeter of bar to provide at least a (19-mm)

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clearance.
3. Test areas where concrete has been removed by tapping with hammer, and
remove additional concrete until unsound concrete is completely removed.
4. Provide fractured aggregate surfaces with a profile of at least (3 mm) that are
approximately perpendicular or parallel to original concrete surfaces. At columns
and walls, make top and bottom surfaces level.
5. Thoroughly clean removal areas of loose concrete, dust, and debris.

D. Reinforcing Bar Preparation: Remove loose and flaking rust from reinforcing bars by
wire brushing until only tightly bonded light rust remains.

1. Where section loss of reinforcing bar is more than 25 percent, or 20 percent in 2 or

more adjacent bars, cut bars and remove and replace. Remove additional
concrete as necessary to provide at least a (19-mm) clearance at existing and
replacement bars. Splice replacement bars to existing bars according to ACI 318,
by lapping, welding, or using mechanical couplings.

E. Preparation of Floor Joints for Repair: Saw-cut joints full width to edges of spalls and
to a depth of at least (25 mm). Clean out debris and loose concrete; vacuum or blow
clear with compressed air.

F. Surface Preparation for Corrosion-Inhibiting Treatment: Clean concrete by sand

blasting to remove dirt, oils, films, and other materials detrimental to treatment
application. Allow surface to dry before applying corrosion-inhibiting treatment.

G. Surface Preparation for Overlays: Remove delaminated material and deteriorated

concrete surface material. Roughen surface of concrete by sand blasting, to produce a
surface profile per ICRI 03732. Sweep and vacuum roughened surface to remove
debris followed by low-pressure water cleaning.

H. Surface Preparation for Sealers: Clean concrete by shot blasting, to remove dirt, oils,
films, and other materials detrimental to sealer application.

I. Surface Preparation for Sealers: Acid etch surface of concrete to produce a surface
profile matching CSP 1 per ICRI 03732.

1. Remove excess acid solution, reaction products, and debris by squeegeeing or

vacuuming.
2. Scrub surface with an alkaline detergent, rinse, and squeegee or vacuum.
3. Check acidity of surface with pH test paper and continue rinsing until pH is
acceptable.
4. When pH is acceptable and surface is clean, vacuum dry.

J. Surface Preparation for Composite Structural Reinforcement: Remove delaminated

material and deteriorated concrete surface material. Clean concrete where
reinforcement and epoxy patching mortar is to be applied by low-pressure water
cleaning to remove dirt, oils, films, and other materials detrimental to epoxy application.

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Roughen surface of concrete by sand blasting.

3.3 APPLICATION

A. Epoxy-Modified, Cementitious Bonding and Anticorrosion Agent: Apply to reinforcing

bars and concrete by stiff brush or hopper spray according to manufacturer's written
instructions. Apply to reinforcing bars in two coats, allowing first coat to dry two to three
hours before applying second coat. Allow to dry before placing patching mortar or
concrete.

B. Epoxy Bonding Agent: Apply to reinforcing bars and concrete by brush, roller, or spray
according to manufacturer's written instructions, leaving no pinholes or other uncoated
areas. Apply to reinforcing bars in at least two coats, allowing first coat to dry before
applying second coat. Apply patching mortar or concrete while epoxy is still tacky. If
bonding agent dries, recoat before placing patching mortar or concrete.

C. Latex Bonding Agent, Type II: Mix with portland cement and scrub into concrete
surface according to manufacturer's written instructions. If bonding agent dries, recoat
before placing patching mortar or concrete.

D. Latex Bonding Agent, Type I: Apply to concrete by brush roller or spray. Allow to dry
before placing patching mortar or concrete.

E. Mortar Scrub-Coat: Dampen repair area and surrounding concrete (150 mm) beyond
repair area. Remove standing water and apply scrub-coat with a brush, scrubbing it
into surface and thoroughly coating repair area. If scrub-coat dries, recoat before
applying patching mortar or concrete.

F. Patching Mortar: Unless otherwise recommended by manufacturer, apply as follows:

1. Wet substrate thoroughly and then remove standing water. Scrub a slurry of neat
patching mortar mixed with latex bonding agent into substrate, filling pores and
voids.
2. Place patching mortar by troweling toward edges of patch to force intimate contact
with edge surfaces. For large patches, fill edges first and then work toward center,
always troweling toward edges of patch. At fully exposed reinforcing bars, force
patching mortar to fill space behind bars by compacting with trowel from sides of
bars.
3. For vertical patching, place material in lifts of not more than (50 mm) nor less than
(6 mm). Do not feather edge.
4. For overhead patching, place material in lifts of not more than (38 mm) nor less
than (6 mm). Do not feather edge.
5. After each lift is placed, consolidate material and screed surface.
6. Where multiple lifts are used, score surface of lifts to provide a rough surface for
application of subsequent lifts. Allow each lift to reach final set before placing
subsequent lifts.

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7. Allow surfaces of lifts that are to remain exposed to become firm and then finish to
a smooth surface.
8. Wet-cure cementitious patching materials, including polymer-modified,
cementitious patching materials, for not less than seven days by water-fog spray or
water-saturated absorptive cover.

G. Dry-Pack Mortar: Use for deep cavities and where indicated. Place according to
manufacturer's written instructions and as follows:

1. Provide forms where necessary to confine patch to required shape.

2. Wet substrate and forms thoroughly and then remove standing water.
3. Place dry-pack mortar into cavity by hand, and compact into place with a hardwood
drive stick and mallet or hammer. Do not place more material at a time than can
be properly compacted. Continue placing and compacting until patch is
approximately level with surrounding surface.
4. After cavity is filled and patch is compacted, trowel surface to match profile and
finish of surrounding concrete. A thin coat of patching mortar may be troweled into
the surface of patch to help obtain required finish.
5. Wet-cure patch for not less than seven days by water-fog spray or water-saturated
absorptive cover.

H. Concrete: Place as follows:

1. Apply epoxy bonding agent to reinforcing and concrete substrate.

2. Apply latex bonding agent to concrete substrate.
3. Use vibrators to consolidate concrete as it is placed.
4. At unformed surfaces, screed concrete to produce a surface that when finished
with patching mortar will match required profile and surrounding concrete.
5. Place concrete by form and pump method.
a. Design and construct forms to resist pumping pressure in addition to weight of
wet concrete. Seal joints and seams in forms and junctions of forms with
existing concrete.
b. Pump concrete into place, releasing air from forms as concrete is introduced.
When formed space is full, close air vents and pressurize to 14 psi (96 kPa).
6. Wet-cure concrete for not less than seven days by leaving forms in place or
keeping surfaces continuously wet by water-fog spray or water-saturated
absorptive cover.
7. Fill placement cavities with dry-pack mortar and repair voids with patching mortar.
Finish to match surrounding concrete.
1. Shotcrete: Place as follows:
2. Apply epoxy bonding agent to reinforcing and concrete substrate.
3. Apply Type I latex bonding agent to concrete substrate.
4. Screed and finish shotcrete to produce a surface matching required profile and
surrounding concrete.

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I. Shotcrete: Place as follows:

1. Apply epoxy bonding agent to reinforcing and concrete substrate.

2. Apply Type I latex bonding agent to concrete substrate

3. Screed and finish shotcrete to produce a surface matching required profile and
surrounding concrete.

J. Grouted Preplaced Aggregate Concrete: Use for column and wall repairs. Place as
follows:

1. Design and construct forms to resist pumping pressure in addition to weight of wet
grout. Seal joints and seams in forms and junctions of forms with existing
concrete.
2. Apply epoxy bonding agent to reinforcing and concrete substrate.
3. Place aggregate in forms, consolidating aggregate as it is placed. Pack aggregate
into upper areas of forms to achieve intimate contact with concrete surfaces.
4. Fill forms with water to thoroughly dampen aggregate and substrates. Drain water
from forms before placing grout.
5. Pump grout into place at bottom of preplaced aggregate, forcing grout upward.
Release air from forms at top as grout is introduced. When formed space is full
and grout flows from air vents, close vents and pressurize to 14 psi (96 kPa).
6. Wet-cure concrete for not less than seven days by leaving forms in place or
keeping surfaces continuously wet by water-fog spray or water-saturated
absorptive cover.
7. Repair voids with patching mortar and finish to match surrounding concrete.

K. Epoxy Joint Filler: Install in nonmoving floor joints where indicated.

1. Install filler to a depth of at least (25 mm). Use fine silica sand no more than (6
mm) deep to close base of joint. Do not use sealant backer rods or compressible
fillers below joint filler.
2. Install filler so that when cured, it is flush at top surface of adjacent concrete. If
necessary, overfill joint and remove excess when filler has cured.

L. Epoxy Crack Injection: Comply with manufacturer's written instructions and the
following:

1. Clean areas to receive capping adhesive of oil, dirt, and other substances that
would interfere with bond, and clean cracks with oil-free compressed air or low-
pressure water to remove loose particles.
2. Place injection ports as recommended by epoxy manufacturer, spacing no farther
apart than thickness of member being injected. Seal injection ports in place with
capping adhesive.

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3. Seal cracks at exposed surfaces with a ribbon of capping adhesive at least (6 mm)
thick by (25 mm) wider than crack.
4. Inject cracks wider than (0.075 mm) to a depth of (200 mm) or to a width of less
than (0.075 mm), whichever is less.
5. Inject epoxy adhesive, beginning at widest part of crack and working toward
narrower parts. Inject adhesive into ports to refusal, capping adjacent ports when
they extrude epoxy. Cap injected ports and inject through adjacent ports until crack
is filled.
6. After epoxy adhesive has set, remove injection ports and grind surfaces smooth.

M. Corrosion-Inhibiting Treatment: Apply by brush, roller, or airless spray in two coats at

manufacturer's recommended application rate. Remove film of excess treatment by
high-pressure washing before patching treated concrete or applying a sealer or overlay.

N. Polymer Overlay: Apply according to ACI 503.3.

1. Apply to traffic-bearing surfaces, including parking areas and walks.

O. Polymer Sealer: Apply by brush, roller, or airless spray at manufacturer's

recommended application rate.

1. Apply to traffic-bearing surfaces, including parking areas and walks.

P. Methylmethacrylate Sealer/Brighteners: Apply by brush, roller, or airless spray at

manufacturer's recommended application rate.

1. Apply to exterior concrete surfaces that are exposed to view, excluding traffic-
bearing surfaces.

Q. Composite Structural Reinforcement Using Preimpregnated Fiber Sheet: Unless

otherwise recommended by manufacturer, apply as follows:

1. Patch surface defects with epoxy mortar and allow to set before beginning
reinforcement application.
2. Apply epoxy adhesive with trowel or spatula to a thickness of (1.6 mm) to prepared
concrete surfaces in areas where composite structural reinforcement will be
applied.
3. Clean preimpregnated fiber sheet with acetone or other suitable solvent, and apply
epoxy adhesive with a roof-shaped spatula to a thickness of (1.6 mm).
4. Apply adhesive-coated fiber sheet to adhesive-coated concrete within open time of
epoxy adhesive, and roll with a hard rubber roller until fiber sheet is fully embedded
in adhesive and adhesive is forced out from beneath fiber sheet at edges.
5. Apply additional layers as indicated using same procedure.

R. Composite Structural Reinforcement Using Fiber Tow Sheet and Saturant: Unless
otherwise recommended by manufacturer, apply as follows:

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1. Apply epoxy primer using brush or short nap roller to prepared concrete surfaces in
areas where composite structural reinforcement will be applied.
2. After primer has set, patch surface defects with epoxy filler and allow to set before
beginning reinforcement application.
3. Apply epoxy saturant to fiber tow sheet with (10-mm-) nap roller to fully saturate
tow sheet. Apply fiber tow sheet to primed and patched surface while saturant is
still wet, using pressure roller to remove air pockets. Remove paper backing from
fiber tow sheet and apply additional epoxy as needed to fully saturate tow sheet.
4. Apply epoxy saturant to primed and patched surface with (10-mm-) nap roller.
Apply fiber tow sheet while saturant is still wet, using pressure roller to remove air
pockets. Remove paper backing from fiber tow sheet and apply additional epoxy to
fully saturate tow sheet.
5. Apply additional layers as indicated, fully saturating each with epoxy.
6. After saturant has cured, apply protective topcoat by brush or roller

3.4 FIELD QUALITY CONTROL

A. Testing Agency: Engage a qualified testing agency to sample materials and perform
tests as follows:

1. Patching Mortar, Packaged Mixes: 5 randomly selected samples tested according

to ASTM C 928.
2. Patching Mortar, Field Mixed: 5 randomly selected samples tested for compressive
strength according to ASTM C 109/C 109M.
3. Grouted Preplaced Aggregate: Tested for compressive strength of grout according
to ASTM C 942.
a. Testing Frequency: 1 sample for each (19 cu. m) of grout or fraction thereof,
but not less than 1 sample for each day's work.
4. Epoxy Joint Filler: Core drilled samples to verify proper installation.
a. Testing Frequency: One sample for each (30 m) of joint filled.
b. Where samples are taken, fill holes with epoxy joint filler.
5. Epoxy Crack Injection: Core drilled samples to verify proper installation.
a. Testing Frequency: 3 samples from mockup and 1 sample for each (30 m) of
crack injected.
b. Where samples are taken, fill holes with epoxy mortar.

END OF SECTION

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