ACI RAP Bulletin 6

®
American Concrete Institute
Advancing concrete knowledge

Vertical and
FIELD GUIDE TO
Overhead Spall
CONCRETE REPAIR
APPLICATION PROCEDURES
Repair by Hand
Application

Vertical and Overhead Spall Repair by Hand Application (ACI RAP-6) 1

2 Repair Application Procedures Bulletin
 ACI RAP Bulletin 6

Field Guide to Concrete Repair Application Procedures

Vertical and Overhead Spall Repair by Hand Application

Reported by ACI Committee E706

David W. Whitmore
Chair

J. Christopher Ball* Fred R. Goodwin Kenneth M. Lozen Jay H. Paul

Peter H. Emmons Bob Joyce John S. Lund George I. Taylor
Timothy R. W. Gillespie Brian F. Keane Kelly M. Page Patrick M. Watson
H. Peter Golter

*
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 6.

Copyright © 2005, 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.

Vertical and Overhead Spall Repair by Hand Application (ACI RAP-6) 3

Introduction
One of the most common application methods for
repairing concrete is by hand troweling mortars. This
method can be used to repair spalled or deteriorated concrete
(Fig. 1) or to resurface vertical, overhead, and horizontal
concrete surfaces. Applying repair materials by hand does
not require significant equipment and is ideal for shallow
surface repairs, especially in areas with limited or difficult
access. While both portland cement-based and resin-based
repair mortars have been used for trowel-applied vertical and
overhead repairs, this field guide focuses on the application
of portland cement-based repair materials.
Before any concrete repair is initiated, the root cause of the
damage should be determined with a thorough condition
survey of the structure. Typical causes of concrete damage
can include corrosion of embedded metals from exposure to
chloride ions from deicing salts or sea spray in coastal areas; Fig. 1—Concrete delamination.
disintegration from freezing-and-thawing cycles when the
concrete is saturated with water; or deterioration from chem-
ical attack. Understanding the cause of the deterioration, the
owner’s repair objectives, and the in-service environment of
the concrete structure will help in the proper selection of
repair materials and application methods.
The technique of hand troweling repair mortars requires the
selection of a sag-resistant mortar and attention to detail
during application to achieve an adequately consolidated
repair that is well-bonded to the concrete substrate. The
successful installation is a function of good surface prepara-
tion, application techniques, curing procedures, and properties
of the repair material selected.

What is the purpose of this repair?

Hand-applied repair mortars replace damaged concrete
and are generally recommended for thin repairs that are
Fig. 2—Bulk concrete removal.
cosmetic in nature. Thin overlays of mortar can also be
applied to renovate deteriorated vertical and overhead
concrete surfaces. This technique, when properly executed,
1. Bulk concrete removal and edge conditioning— Loose,
improves the appearance of the deteriorated structure and
delaminated concrete should be removed until the substrate
provides additional protection to the concrete surface.
consists of sound concrete (Fig. 2). Where corrosion of the rein-
forcement exists, continue bulk removal along the reinforcing
When do I use this method? steel and adjacent areas with evidence of corrosion-induced
Structural repair projects generally require other repair damage that would inhibit bonding of repair materials. Bulk
methods such as form and cast-in-place, grouted pre-placed concrete removal should include undercutting the corroded
aggregate repair, or shotcrete. Experienced workers using reinforcing steel by approximately 3/4 in. (19 mm). The
wood floats, sponges, or steel trowels can achieve a variety of shape of the prepared cavity should be kept as simple as
finishes with trowel-applied mortars. Hand application has possible–generally square or rectangular in shape. The edges
been used to repair vertical and overhead surfaces including of the patches should be sawcut perpendicular to the surface
walls, columns, beams, soffits, and building facades. to a depth of 1/2 in. (13 mm) to avoid feather edging the
Placement thickness can vary depending on the type of repair material (Fig. 3).
materials selected and the size, depth, and orientation of the 2. Final surface cleaning— Use abrasive blasting (Fig. 4) to
repair cavity. Placement thickness can range from 1/8 to 2-3/4 in. remove residual dust, debris, fractured concrete, and contam-
(3 to 70 mm) on vertical surfaces, and 1/8 to 1 in. (3 to 25 mm) inants that prevent proper bonding. If abrasive blasting is not
on overhead surfaces in a single layer. Deeper placements may feasible, pressure washing using a minimum 3000 psi (250 MPa)
require repair material to be placed in additional layers. may be acceptable depending on the bond strength required.
Blowing with oil-free compressed air or alternately, the use of
How do I prepare the surface? a vacuum, may be appropriate if dust is still present after the
The recommended steps in properly preparing the surface blasting. The final surface texture should be rough, with
to receive a hand-applied mortar are as follows: approximately a 1/4 in. (6 mm) amplitude (Fig. 5);

4 Repair Application Procedures Bulletin

Fig. 3—Edge conditioning.
Fig. 4—Final surface cleaning.
3. Treatment of exposed reinforcement—Bond-inhibiting
corrosion should be removed from the reinforcing steel by an
abrasive blasting wire wheel or needle scaler. If the cross-
sectional area of the reinforcing steel has been significantly
reduced, a structural engineer should be consulted. If a rein-
forcing steel coating has been specified, apply the coating
after the reinforcing steel has been cleaned (Fig. 6).
4. Substrate saturation—Most portland cement-based
materials require the base concrete to be in a saturated,
surface dry (SSD) condition prior to application to prevent a
rapid loss of moisture from the repair material and into the
substrate. An SSD condition is achieved when the body of
the concrete is saturated and free surface water and puddles
have been removed from the surface of the concrete. An SSD
surface is not recommended if a polymer bonding agent is to
be used. When using polymer bonding agents, follow the
manufacturer’s recommended surface preparation require-
Fig. 5—Properly prepared surface.
ments. The general recommendations previously given may
be influenced by several factors, including:
• Desired roughness profile of the prepared surface (This may cement-based materials designed for hand application may
be specified by the manufacturer of the repair product); also include polymers, silica fume, shrinkage-compensating
• Method of surface preparation, including chipping materials, and other additives for enhanced physical properties
hammers, abrasive blasting, high-pressure water- and improved handling.
blasting, or hydrodemolition; Specifiers, applicators, and owners can consult ICRI Guide-
• Possible contamination of the surface by chemicals, line No. 03732, “Selecting and Specifying Materials for
oils, or grease; possible carbonation; and methods of Repair of Concrete Surfaces,” for a useful checklist for
removing contaminants or carbonated concrete; prioritizing desired material properties. Manufacturers’ tech-
• Repair material manufacturer’s recommendations (Ask nical data sheets should be consulted for material properties.
for technical data sheets and installation bulletins and The physical property requirements such as drying
read the printed instructions on the packaging.); and shrinkage, permeability, freezing-and-thawing resistance,
• Treatment of existing cracks and joints. and mechanical properties vary from project to project
For additional information, consult the recommendations of depending on the expected service conditions. The properties
the International Concrete Repair Institute (ICRI) Guidelines critical to the long-term success of the repair should be deter-
No. 03732, “Selecting and Specifying Concrete Surface mined during the evaluation phase and be specified.
Preparation for Sealers, Coatings, and Overlays,” or No. 03730, Other factors that may influence the selection of repair
“Guide for Surface Preparation for Repair of Deteriorated materials include desired application thickness, rate of
Concrete Resulting from Reinforcing Steel Corrosion.” strength gain, ease of application, color, and in-place cost.
For some hand-applied repairs, sealers or decorative or
How do I select the right material? protective coatings may be used to provide additional protec-
Hand- or trowel-applied repair materials are generally tion to the base concrete, to enhance aesthetics, or both.
proprietary, prepackaged, cementitious products. Portland When this is the case, confirm the required curing and drying

Vertical and Overhead Spall Repair by Hand Application (ACI RAP-6) 5

 Fig. 7—Typical equipment to mix materials.

Fig. 6—Treatment of exposed reinforcement.

• Hearing protection must reduce sound levels reaching
time (or maximum moisture content) with the sealer or the inner ear to limits that are specified by the United
coating manufacturer before application commences. For States Occupational Safety and Health Administration
more information, consult ACI 515.1R, “Guide to Use of (OSHA); and
Waterproofing, Dampproofing, Protective, and Decorative • Confirm that adequate ventilation is available in closed
Barrier Systems for Concrete.” spaces before operating equipment that emits dangerous
exhaust fumes.
What equipment do I need? It is the responsibility of the user of this document to
Typical equipment needed for hand-applied repair mortars establish health and safety practices appropriate to the
includes: specific circumstances involved with its use. ACI does not
• A suitable mixer unit such as a drill/paddle/pail combi- make any representations with regard to health and safety
nation for small repairs (Fig. 7), or paddle-type mortar issues and the use of this document. The user must determine
mixers for larger applications; the applicability of all regulatory limitations before applying
• Air compressor, sawcutting equipment, blades, abrasive the document and must comply with all applicable laws and
blast equipment; regulations, including but not limited to, United States Occu-
• Water-measuring device to ensure that proper amounts pational Safety and Health Administration (OSHA) health
of mixing water are used; and and safety standards.
• Finishing, handling, and testing tools required by the
specification or good concreting practices. Preconstruction meeting
Prior to proceeding with the repair, a preconstruction
Be sure that necessary equipment and tools are on site and
meeting is recommended. The meeting should include repre-
in proper working order. Have backup equipment or alter-
sentatives for the owner, engineer, contractor, materials manu-
nate methods planned and available.
facturer, and any other parties needed to explain the means,
methods, and materials necessary to achieve the repair objec-
What are the safety considerations?
Concrete repair mortars are hazardous materials and tives. See ICRI Guideline No. 03733, “Guide to Selecting and
should be treated as such. Job-site safety practices should Specifying Materials for Repair of Concrete Surfaces.”
include the following where applicable:
Repair procedure
• Applicable material safety data sheets (MSDS) should 1. Apply the repair material.
be on hand; • Mix the material following the manufacturers’ recom-
• Machinery and equipment used must have the correct mendations;
safety guards and warnings in place; • Scrub a thin bond coat of the repair mortar into the SSD
• Workers should wear protective gloves and other clothing substrate, thus filling pores to ensure intimate contact
needed to prevent skin contact with wet, highly alkaline and to help prevent sloughing or sagging of repair
cementitious materials; materials on vertical and overhead surfaces. Alterna-
• A face shield or safety glasses are needed to provide tively, apply a bonding agent if required by the manu-
eye protection; facturer or the repair specification;
• Eye wash facilities should be available on the job site. • Apply the material with adequate pressure before the
• Dust masks are needed for workers operating or working bond coat dries (Fig. 8). Thoroughly consolidate the
near the material mixer and forced-air respirators used repair material into the corners of the patch and around
for abrasive blasting; any exposed reinforcement in the repair zone. Full

6 Repair Application Procedures Bulletin

Fig. 8—Hand application of repair material. Fig. 9—Spray application of curing compound.

encapsulation of the reinforcement is important for • Sounding the cured repair for delaminations;
long-term durability; and • In-place direct tensile bond testing of the hardened,
• If a second lift is required, thoroughly roughen the cured repair to the base concrete using methods similar
surface of the first lift by scoring the soft mortar to to those described in ICRI Technical Guideline No.
achieve an aggressive finish, similar in profile to the 03739, “Guide to Using In-Situ Tensile Pull-Off Tests
prepared concrete substrate. This process will promote to Evaluate Bond of Concrete Surface Materials,”
additional mechanical bond between lifts. If the second published by the International Concrete Repair Insti-
lift will not be immediately applied, keep the first lift tute. Important observations include maximum stress,
moist until application of the second lift. After the first expressed in psi or MPa, and failure mode (base
lift has reached final set, moisten the surface of the first concrete, bond line, or cohesive failure of the mortar).
lift, scrub in a thin layer of fresh mortar, and apply the
second lift of material. Once the desired thickness has References
been achieved, strike off level with the adjacent concrete. ACI Committee 201, 1992, “Guide for Making a Condition Survey of
Concrete in Service (ACI 201.R-92), American Concrete Institute, Farm-
2. Finish and cure the repair. ington Hills, Mich., 16 pp.
• Finish the repair material to produce a final finished ACI Committee 308, 2001, “Guide to Curing Concrete (ACI 308R-01),”
appearance as required by the project specifications. American Concrete Institute, Farmington Hills, Mich., 31 pp.
ACI Committee 364, 1994, “Guide for Evaluation of Concrete Struc-
Because of the nonbleeding, “sticky” nature of many of
tures Prior to Evaluation (ACI 364.1R-94),” American Concrete Institute,
these materials, the use of an evaporation control film Farmington Hills, Mich., 22 pp.
may be helpful; and ACI Committee 515, 1985, “A Guide to the Use of Waterproofing, Damp-
• As with all portland cement-based materials, proper roofing, Protective, and Decorative Barriers for Concrete (ACI 515.1R-79
(Revised 1985)),” American Concrete Institute, Farmington Hills, Mich., 44 pp.
curing will provide enhanced physical properties. Good ACI Committee 546, 2004, “Concrete Repair Guide (ACI 546R-04),”
curing procedures prevent rapid moisture loss at early American Concrete Institute, Farmington Hills, Mich., 53 pp.
ages. Consult the product manufacturer for curing instruc- ASTM C 309, 1998, “Standard Specification for Liquid Membrane-
tions. Curing will generally be conducted in accordance Forming Compounds for Curing Concrete,” ASTM International, West
Conshohocken, Pa., 3 pp.
with ACI 308R, “Guide to Curing Concrete.” The use of
Dorsch, D. F., 1995, “A Guide to Placement Methods for Repair Materials,”
curing compounds (Fig. 9) that comply with the moisture Concrete Repair Digest, Dec., pp. 320-325.
retention requirements of ASTM C 309, or moist curing Emmons, P., 1993, Concrete Repair and Maintenance Illustrated, RS
are common curing methods. Means.
International Concrete Repair Institute, 1995, “Guide for Surface Prepa-
ration for the Repair of Deteriorated Concrete Resulting from Reinforcing
How do I check the repair? Steel Corrosion,” Technical Guideline No. 03730, 8 pp.
Requirements may include: International Concrete Repair Institute, 1997, “Selecting and Specifying
• Before and after photos; Concrete Surface Preparation for Sealers, Coatings, and Polymer Over-
lays,” Technical Guideline No. 03732., 41 pp.
• Confirmation of acceptable surface preparation. This International Concrete Repair Institute, 1997, “Guide for Selecting and Con-
may include observing the surface amplitude profile. crete Repair Materials,” Technical Guideline No. 03733, 34 pp.
Alternatively, direct tension testing of the prepared International Concrete Repair Institute, 1997, “Guide for Using In-Situ
surface will provide quantitative data regarding the Tensile Pull-Off Tests to Evaluate Bond of Concrete Surface Materials,”
Technical Guideline No. 03739, 16 pp.
level of surface preparation achieved; Smoak, W. G., 1997, Guide to Concrete Repair, U.S. Department of the
• Material testing performed by a qualified testing agency; Interior, Bureau of Reclamation Technical Service Center, Apr.

Vertical and Overhead Spall Repair by Hand Application (ACI RAP-6) 7