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- “You want to remove all loose concrete, deteriorated concrete that’s lost its strength and other physical properties,” Fuller adds. “You want to make sure that you have that texture that creates a tooth for that repair to bond to. If you don’t do the right surface prep, that repair will loosen up.” - Source: Internet
- Kim Basham, Ph.D. PE FACI president of KB Engineering, LLC, shares a similar experience. “One of the most critical items for any repair is surface preparation - the key to a quality, long-lasting repair regardless of the repair material being used.” - Source: Internet
- Concrete mix manufacturers produce and label their products to match the situation and ease any confusion about which repair material to use for the project at hand. Consider the geometry and structural requirements. Ready-mix manufacturers like QUIKRETE, Sika, Master Builders, MAPEI, and more provide a range of repair products from waterproofing materials, vertical, overhead, repair motors, heavy-duty, rapid or fast setting, commercial-grade, sculptable products a contractor can form into place, and more. - Source: Internet
- Basham suggests a prebagged shrink-compensated material but to avoid feather edging: “It will always flake off,” he says. “Opt to undercut the repair area by saw cutting into the concrete by about five degrees to avoid a gap.” This undercut will mechanically lock the repair to the existing concrete where a cut straight down would likely result in a gap. - Source: Internet
- Consider the setting time of the repair material and when the owner needs the area accessible again. One of the most common questions QUIKRETE receives is “how quickly can I get back on this.” Repair materials can range from a fast cure allowing car traffic on them within three hours where others can be 24 or up to four days. However, many specialty restoration products are typically within the 24-hour timeframe. - Source: Internet
- Before anything happens, contractors need to ensure that the repair material will be able to be bonded to the structure and stay bonded for the lifecycle of the product. Conducting a scratch test to determine the hardness of the concrete can help make the right choice in which preparation technique/method to use. “Contractors shouldn’t solely rely on a consultant doing that because those are things that [a contractor] can do so they better know how to approach the project,” says Barlow. - Source: Internet
- Bagged concrete mix manufacturers design their repair products with safety regulations in mind such as removing silica out of their materials and making them easier to mix. Mixing is an important aspect of if a repair will last or not. Fuller and ICRI are seeing more pre-packaged materials with additives already inside. For thicker projects, reinforcement can help eliminate issues like crumbling or cracking, QUIKRETE provides products that include fibers, polymers, and/or admixtures to help resist cracking by giving the material some flexural strength and flexibility. - Source: Internet
- The challenge is to not damage any more concrete - or reinforcement if present - than necessary. For example, although designed for road and bridge renovation and repair, the figure-eight pattern of Aquajet’s Aqua Cutter 750V allows the highly pressurized water to reach the concrete below and to the side of reinforcement reducing the shadowing effect. However, one easy mistake contractors could make is not removing enough concrete or removing the corrosion off of the steel in the first place. Spend the time to adequately and sufficiently remove the concrete in the area of deterioration, says Barlow. - Source: Internet
- The ACI University made available a Repair Application Procedures (RAP) certificate program consisting of courses on the repair of cracking and spalling, reinforcement protection, as well as surface repair. Interested persons need to purchase the package or be ACI members. Clair Hiltz, director of professional development at ACI writes more about the program at “Concrete Repair Training & Online Certification.” - Source: Internet
- Whether it is a root system underneath the concrete driveway, natural settling causing a crack, or a sinkhole, Dave Fuller, Technical Director, International Concrete Repair Institute (ICRI) likens the issue causing the problem to a disease. “A lot of times we just address the symptoms instead of the disease,” he says. “And you’re not going to uncover the disease until you do some evaluation.” Often, this could include some destructive testing to reach the reinforcement to see if there is any indication of corrosion. Depending on the problem, this investigation can range from straightforward to difficult, timely, and costly. - Source: Internet
- Likewise, there are resources available through the ACI like training videos, technical documents, and repair application procedure (RAP) documents – many of which are free or at a minimal cost. Written and designed for the prep guys in the field, Barlow explains that they are an excellent source for training. Many are translated into Spanish. - Source: Internet
- “In some instances, you’ll have to cut the concrete and jackhammer it out, depending on the problem,” notes Russell. While each situation may be different, the prep work is key. If not done properly, the repair won’t hold and may fail in time. - Source: Internet
- Where surface prep was one of the most common reasons a repair would fail using the wrong material would likely follow not far behind. “Make sure that it’s the right material for the right project,” says Fuller. “There are some basic steps that [contractors] can do to ensure that the repair has the best chance of achieving the service life for what it was designed for.” He suggests connecting with the manufacturer for expert insight into the use of the product. ICRI has created a flowchart to help the process. - Source: Internet
- “You have to understand what is causing your issue first,” says Jeff Russell, regional vice president of sales for QUIKRETE. “Once you know what the cause is, you can then come up with your plan of how you’re going to remedy it.” Should you determine the repair be caused by a larger issue, specialized contractors or engineers might need to be contacted to review the situation. Remember, communication is key – especially with the owner. - Source: Internet
- One key can be to conduct a pull-off test or mock-up on-site to ensure the repair material will be able to bond to the existing concrete. This test includes gluing a metal dolly onto the surface of the repair, letting it cure, and using an instrument to pull and determine the failure psi point. A higher psi could indicate that the repair will last. - Source: Internet
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