ON 


r in the West 
 

August 2015 

 

 

 

Guide to Concrete Repair
 
 

Second Edition 

Prepared by: 

Kurt F. von Fay, Civil Engineer 

Concrete, Geotechnical, and Structural Laboratory 

U.S. Department of the Interior 

Bureau of Reclamation 

Technical Service Center August 2015 
Mission Statements 

The U.S. Department of the Interior protects America’s natural 

resources and heritage, honors our cultures and tribal communities, 

and supplies the energy to power our future. 

The mission of the Bureau of Reclamation is to manage, develop, 

and protect water and related resources in an environmentally and 

economically sound manner in the interest of the American public. 
 

Acknowledgments
 

Acknowledgment is due the original author of this guide, W. Glenn Smoak, for all 

his efforts to prepare the first edition. 

For this edition, many people were involved in conducting research and field 

work, which provided valuable information for this update, and their contributions 

and hard work are greatly appreciated. They include Kurt D. Mitchell, Richard 

Pepin, Gregg Day, Jim Bowen, Dr. Alexander Vaysburd, Dr. Benoit Bissonnette, 

Maxim Morency, Brandon Poos, Westin Joy, David (Warren) Starbuck, Dr. 

Matthew Klein, and John (Bret) Robertson. Dr. William F. Kepler obtained much 

of the funding to prepare this updated guide. Nancy Arthur worked extensively 

on reviewing and editing the guide specifications sections and was a great help 

making sure they said what I meant to say. Teri Manross deserves recognition for 

the numerous hours she put into reviewing, editing and formatting this Guide. 

The assistance of these and numerous others is gratefully acknowledged. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

	 


 


 


 


 


 


 


 

	 


 


 


 


 


 


 


 


 


 


 


 


 


 

	 


 


 


 


 


 


 


 


 


 

Contents 

PART I: RECLAMATION'S METHODOLOGY FOR 

CONCRETE MAINTENANCE AND REPAIR 

Page 

A.	 Repair and Maintenance of Concrete 

1. Introduction ..........................................................................................I-1
 

a. Concrete Repair and Maintenance System ...................................I-2
 

2. Maintenance of Concrete......................................................................I-3
 

3. General Requirements for Quality Repair............................................I-8
 

a. Workmanship................................................................................I-9
 

b. Procedures.....................................................................................I-9
 

c. Materials .....................................................................................I-10
 

B.	 Using Reclamation's Concrete Maintenance and Repair 

System 

1. Determine the Cause(s) of Damage....................................................I-13
 

2. Evaluate the Extent of Damage ..........................................................I-16
 

3. Evaluate the Need to Repair...............................................................I-19
 

4. Select the Repair Method and Material..............................................I-25
 

5. Prepare the Existing Concrete for Repair...........................................I-26
 

a. Saw Cut Perimeters.....................................................................I-26
 

b. Concrete Removal.......................................................................I-29
 

c. Reinforcing Steel Preparation.....................................................I-34
 

d. Primary Cleaning ........................................................................I-36
 

e. Protecting the Prepared Area ......................................................I-37
 

f. Secondary Cleaning ....................................................................I-37
 

6. Apply the Repair Method ...................................................................I-39
 

7. Cure the Repair Properly....................................................................I-39
 

C.	 Causes of Damage to Concrete 

1. Excess Concrete Mix Water...............................................................I-41
 

2. Faulty Design .....................................................................................I-43
 

3. Construction Defects..........................................................................I-48
 

4. Sulfate Deterioration ..........................................................................I-51
 

5. Alkali-Aggregate Reaction.................................................................I-52
 

6. Deterioration Caused by Cyclic Freezing and Thawing Weather......I-56
 

7. Abrasion-Erosion Damage .................................................................I-60
 

8. Cavitation Damage .............................................................................I-65
 

9. Corrosion of Reinforcing Steel...........................................................I-68
 

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Contents (continued)
 

Page 

10. Acid Exposure ....................................................................................I-70
 

11. Cracking ............................................................................................I-72
 

12. Structural Overloads...........................................................................I-81
 

13. Multiple Causes of Damage ...............................................................I-83
 

D. Standard Methods of Concrete Repair 

1. Sealers and Coatings ..........................................................................I-88
 

a. High Molecular Weight Methacrylic Sealing Compounds.........I-90
 

(1) Preparation .........................................................................I-91
 

(2) Materials ............................................................................I-92
 

(3) Application.........................................................................I-92
 

(4) Curing and Protection ........................................................I-93
 

b. Low Viscosity Epoxy Sealing Compounds ................................I-93
 

(1) Preparation .........................................................................I-94
 

(2) Materials ...........................................................................I-95
 

(3) Application.........................................................................I-96
 

(4) Curing and Protection ........................................................I-96
 

c. Silane and Siloxane Sealing Compound .....................................I-96
 

(1) Preparation .........................................................................I-97
 

(2) Materials ............................................................................I-97
 

(3) Application.........................................................................I-98
 

(4) Curing ................................................................................I-99
 

d. Coating Compounds for Concrete ..............................................I-99
 

(1) Preparation ....................................................................... I-100
 

(2) Application....................................................................... I-102
 

(3) Curing ..............................................................................I-103
 

2. Thin Repairs .....................................................................................I-103
 

a. Surface Grinding.......................................................................I-104
 

b. Portland Cement Mortar ...........................................................I-105
 

(1) Preparation .......................................................................I-106
 

(2) Materials ..........................................................................I-107
 

(3) Application.......................................................................I-107
 

(4) Curing ..............................................................................I-108
 

c. Dry Pack and Bonded Dry Pack ...............................................I-108
 

(1) Preparation .......................................................................I-109
 

(a) Method 1.................................................................... I-110
 

(b) Method 2 ................................................................... I-110
 

(c) Method 3.................................................................... I-110
 

(2) Materials .......................................................................... I-111
 

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Contents (continued)
 

Page 

(3) Application....................................................................... I-111
 

(4) Curing and Protection ......................................................I-112
 

d. Polymer Concrete, Including Epoxy Mortar.............................I-112
 

(1) Preparation .......................................................................I-114
 

(2) Materials .........................................................................I-115
 

(3) Mixing and Handling ......................................................I-116
 

(4) Application.......................................................................I-118
 

(5) Curing ..............................................................................I-120
 

(6) Storage ............................................................................I-121
 

e. Epoxy-Bonded Replacement Concrete .....................................I-121
 

(1) Preparation .......................................................................I-122
 

(2) Materials ..........................................................................I-122
 

(3) Application.......................................................................I-123
 

(4) Curing ..............................................................................I-124
 

f. Packaged Cementitious and Chemical Repair Mortars ............I-124
 

(1) Preparation .......................................................................I-125
 

(2) Application.......................................................................I-125
 

(3) Curing ..............................................................................I-126
 

3. Thick Repairs ...................................................................................I-127
 

a. Replacement Concrete .............................................................. I-127
 

(1) Preparation .......................................................................I-127
 

(2) Materials ..........................................................................I-130
 

(3) Application.......................................................................I-131
 

(4) Curing and Protection ......................................................I-133
 

b. Preplaced Aggregate Concrete..................................................I-134
 

(1) Preparation .......................................................................I-135
 

(2) Materials ..........................................................................I-135
 

(3) Application.......................................................................I-136
 

(4) Curing ..............................................................................I-138
 

c. Shotcrete ...................................................................................I-138
 

(1) Preparation .......................................................................I-140
 

(2) Materials ..........................................................................I-140
 

(3) Application.......................................................................I-141
 

(4) Curing ..............................................................................I-141
 

d. Silica Fume Concrete................................................................I-141
 

(1) Preparation .......................................................................I-143
 

(2) Materials ..........................................................................I-143
 

(3) Application.......................................................................I-143
 

(4) Curing ..............................................................................I-144
 

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Contents (continued)
 

Page 

4. Crack and Water Leak Repairs.........................................................I-144
 

a. Resin Injection ..........................................................................I-146
 

(1) Epoxy Resins ...................................................................I-146
 

(2) Polyurethane and Methacrylic Acrylate Resins...............I-147
 

(3) Preparation .......................................................................I-149
 

(4). Materials ..........................................................................I-154
 

(5) Injection Equipment.........................................................I-155
 

(6) Application.......................................................................I-159
 

(a) Application of Epoxy Resin by Pressure
 

Injection................................................................. I-159
 

(b) Application of Polyurethane Resin by Pressure
 

Injection for Sealing Leaks....................................I-162
 

(7) Cleanup ............................................................................I-165
 

E. Nonstandard Methods of Repair 

1. Use of Nonstandard Repair Methods ...............................................I-167
 

a. Preparation ................................................................................ I-168
 

b. Materials ...................................................................................I-168
 

c. Application................................................................................ I-168
 

d. Curing .......................................................................................I-168
 

Bibliography .....................................................................................................I-169
 

Figures 

Figure	 Page 

1 Freeze-thaw damage that could have been prevented by proper 

maintenance .................................................................................................I-4
 

2 Removing the source of water properly would have resulted in
 

significantly less damage .............................................................................I-5
 

3 Freeze-thaw damage that could have been reduced by changing
 

operation of the structure .............................................................................I-7
 

4 Formwork used to maintain the existing joints in a spillway
 

floor repair .................................................................................................I-11
 

5 Poor quality aggregate used in concrete placed in the late 1960s
 

led to the need for expensive repairs in the 2000s.....................................I-15
 

6 Obtaining concrete samples is very important to properly assess
 

the cause and extent of damage .................................................................I-15
 

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Figures
 

Figure Page 

7 Inspecting a spillway floor using steel bars to sound the concrete ...............I-17
 

8 A drawing showing the original estimated limits of removal 

(black cross hatch) and the actual limits of removal (black 

and red cross hatch) ...................................................................................I-18
 

9 A structure experiencing freeze-thaw deterioration that will not
 

need repair for many years.........................................................................I-19
 

10 Freeze-thaw damage that should have been repaired before damage
 

became so extensive...................................................................................I-20
 

11 Damage from absorptive aggregates.............................................................I-20
 

12 Damage from absorptive aggregates deteriorating from freezing
 

and thawing weather that extends several inches into 

the concrete ................................................................................................I-21
 

13 Damage that appears serious, but because of the characteristics
 

of the spillway, repairs are not needed immediately..................................I-21
 

14 A spillway that appeared to be in good shape...............................................I-22
 

15 Abrasion erosion damage to the flip bucket and energy
 

dissipaters...................................................................................................I-24
 

16 After beginning concrete removal, the extent of damage was
 

much worse than originally believed .........................................................I-24
 

17 Coring through the temporary shotcrete repairs to obtain
 

samples of concrete for testing and examination.......................................I-25
 

18 Using a large, rail-mounted saw to cut completely through a
 

concrete slab...............................................................................................I-27
 

19 Saw cutting the perimeter after hydrodemolition removed most
 

of the concrete............................................................................................I-27
 

20 Examples of saw cut shapes..........................................................................I-28
 

21 Rounded corners are best..............................................................................I-29
 

22 Hydrodemolition using water pressure of 20,000 psi to remove
 

about 6 inches of concrete..........................................................................I-30
 

23 The first calibration test resulted in excessive concrete removal
 

and bent rebar.............................................................................................I-31
 

24 Using a small electric chipping hammer to remove damaged
 

concrete ......................................................................................................I-32
 

25 Shotblasting using a small unit prior to application of a
 

healer-sealer (Sealers and Coatings)..........................................................I-32
 

26 Sand blasting a concrete deck prior to application of a
 

healer-sealer (Sealers and Coatings)..........................................................I-33
 

27 A scabbler used to remove concrete .............................................................I-33
 

28 View of the bits in a scabbler used to remove concrete................................I-34
 

29 A schematic of the proper method for concrete preparation
 

for a concrete spall repair...........................................................................I-35
 

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Figures
 

Figure Page 

30 A schematic of the proper method for preparing a hole through a
 

concrete wall ..............................................................................................I-36
 

32 Using high-pressure water jetting for secondary cleaning
 

33 Using water spray to keep the substrate surface in an SSD
 

34 Durability improves with lower water content and the use of
 

36 Corrosion of reinforcing steel from deicing salts used on
 

38 Joint detail for joints that experience excessive expansion that
 

39 Large voids, rock pockets, and honeycombs resulting from
 

40 An example of inadequately consolidated concrete that needs
 

41 The addition of water or other substances during finishing
 

42 Surface damage appearing in new concrete caused by the
 

43 Salt scaling that resulted when water containing deicing
 

45 A cross section of backfill grout showing replacement of cement
 

46 Evidence of ASR provided by gel-filled cracks and reaction rim
 

49 Freeze-thaw deterioration in a spillway slab occurring below the
 

50 The top of a spillway wall suffering damage from cycles of
 

52 Example of D-cracking that resulted from freezing and thawing
 

53 Repairs that were not thick enough to prevent cycles of freezing
 

31 A properly prepared area for repair to a spillway approach apron ...............I-36
 

(4,000 psi) ..................................................................................................I-38
 

condition between placements...................................................................I-39
 

entrained air in the concrete.......................................................................I-42
 

35 Thermal cracking in a thick concrete wall....................................................I-44
 

the bridge ...................................................................................................I-45
 

37 Damage resulting from expansion at tight joints ..........................................I-46
 

results in damage........................................................................................I-47
 

inadequate concrete consolidation .............................................................I-48
 

repair ..........................................................................................................I-49
 

can lead to weakened and damaged concrete surfaces ..............................I-49
 

addition of water during finishing..............................................................I-50
 

salts froze on poor quality concrete surfaces.............................................I-50
 

44 Repairs that were damaged by sulfate attack................................................I-52
 

grout with thaumasite, a form of sulfate attack..........................................I-52
 

around some aggregate particles...............................................................I-54
 

47 Extensive cracking which can indicate ASR ................................................I-54
 

48 Examining concrete deterioration in a structure built in the 1970s ..............I-56
 

exposed surface, due to moisture and temperature gradients ....................I-57
 

freezing and thawing weather....................................................................I-57
 

51 Another example of freeze-thaw deterioration .............................................I-58
 

weather damage to absorptive aggregates..................................................I-59
 

and thawing weather from damaging the underlying concrete..................I-60
 

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Figures
 

Figure Page 

54 Top: Insulating panel and concrete debris on the pumping 

plant floor...................................................................................................I-61
 

55 Abrasion-erosion damage to concrete...........................................................I-62
 

56 Abrasion-erosion damage from flowing water with small
 

abrasive particles showing a polished surface ...........................................I-63
 

57 Placing silica fume concrete in a stilling basin in central 

Colorado to repair abrasion-erosion damage .............................................I-64
 

58 High-strength silica fume concrete materials were delivered in
 

3,000-pound sacks and mixed onsite with water and liquid 

admixtures..................................................................................................I-64
 

59 Typical pattern for cavitation damage in a spillway tunnel..........................I-65
 

60 Cavitation damage can be very extensive, as shown here, where
 

the damage extended deep into foundation material..................................I-66
 

61 The early stages of concrete erosion and possible cavitation .......................I-67
 

62 High chlorides in water, leading to corrosion of reinforcing steel ...............I-69
 

63 Examples of acid exposure on concrete........................................................I-71
 

64 There are many types of cracks that can affect concrete structures..............I-73
 

65 Plastic settlement cracking............................................................................I-74
 

66 Excessive drying shrinkage cracking due to loss of water from
 

the concrete after hardening.......................................................................I-74
 

67 Plastic shrinkage cracking in concrete placed in hot, dry weather ...............I-75
 

68 Foundation settlement in this water treatment plant caused
 

cracking in one of the water bays ..............................................................I-76
 

69 A dial gauge used to monitor crack movement ............................................I-76
 

70 Photogrammetric techniques can be used to measure movement
 

of cracks and joints by using data from digital photographs .....................I-77
 

71 An example of improper crack repair, resulting in an unsightly
 

appearance..................................................................................................I-79
 

72 Improperly repairing cracks often makes the repair very short lived ...........I-79
 

73 Reflective cracking from cracks below the concrete overlay .......................I-80
 

74 Classification system for drying shrinkage values........................................I-81
 

75 Structural damage from a collapsed roadway that impacted a
 

pier of a siphon...........................................................................................I-82
 

76 Core from concrete placed in the 1960s .......................................................I-83
 

77 An example of multiple causes of damage. In this case, ASR,
 

freeze-thaw, and conduits are too close to the surface of 

the concrete ................................................................................................I-84
 

78 A low viscosity epoxy resin was poured into plastic shrinkage
 

cracks .........................................................................................................I-90
 

79 Application of HMWM to the top of a concrete dam...................................I-91
 

80 Application of an epoxy sealer to a pumping plant deck..............................I-94
 

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Figures 

Figure Page 

81 Steel shotblasting a concrete deck prior to application of an 

epoxy sealer ...............................................................................................I-95
 

82 Application of a siloxane sealing compound ................................................I-98
 

83 Cracked concrete canal lining repaired with an elastomeric
 

polyurea....................................................................................................I-100
 

84 Insufficiently thick repairs on a spillway wall made with
 

concrete subject to freeze-thaw deterioration resulted in 

failure of the repair and additional damage to the 

surrounding concrete................................................................................I-104
 

85 Portland cement mortar is suitable for repairing voids resulting
 

from air and bleed water trapped under forms, as long as it is 

done in a timely manner...........................................................................I-105
 

86 Portland cement mortar repairs made to a shallow defect ..........................I-106
 

87 Using low-pressure spray equipment to apply Portland cement
 

mortar....................................................................................................... I-107
 

88 Cutting a slight key into the hole to help hold the repair material
 

in place .....................................................................................................I-109
 

89 Drying the surface of concrete using oil-free compressed air to
 

meet the surface moisture requirements of the manufacturer..................I-114
 

90 Using heaters in an enclosed area to increase the temperature
 

to meet application requirements.............................................................I-115
 

91 Using a simple bucket mixer to mix epoxy resin........................................I-117
 

92 Mixing epoxy mortar ingredients in buckets ..............................................I-117
 

93 Placing polymer concrete to repair shallow damage to a
 

stilling basin.............................................................................................I-119
 

94 Using drywall mud application tools to apply epoxy mortar......................I-119
 

95 Consolidating polymer concrete with a vibrator.........................................I-120
 

96 Protecting the polymer concrete until it gets hard ......................................I-120
 

97 Applying heat to speed curing of a polymer concrete repair......................I-121
 

98 Placing concrete on an epoxy bonding resin...............................................I-123
 

99 Extensive cracking in a packaged thin repair mortar applied to
 

a spillway crest.........................................................................................I-125
 

100 Applying a stiff repair mortar using hand packing ..................................I-126
 

101 An outlet works repair being prepared for replacement concrete............I-129
 

102 Form details for placing concrete in vertical repair holes........................I-129
 

103 The upstream face of Barker Dam was repaired with a
 

combination of precast panels and preplaced aggregate 

concrete ....................................................................................................I-135
 

104 Using shotcrete to repair a spillway floor. Shotcrete was used
 

here because of the remoteness of the site ...............................................I-138
 

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Figures
 

Figure Page 

105 Even though space was limited, due to the complicated 

geometry of this outlet works, shotcrete was used to 

make concrete repairs ..............................................................................I-139
 

106 Abrasion-erosion test results showing that the SFC mixture
 

withstood abrasion erosion much better than conventional 

concrete ....................................................................................................I-142
 

107 Adding additional reinforcement to the exterior of a 

large-diameter siphon...............................................................................I-145
 

108 Installing carbon fiber reinforced polymer to repair a large
 

concrete pipe ............................................................................................ I-146
 

109 High-volume water leaks can be repaired using polyurethane
 

resins ........................................................................................................I-148
 

110 Ground hydrophilic rubber deposited in front of a leaking contraction
 

joint ..........................................................................................................I-149
 

111 Cleaning the surface of a crack using a small grinder prior to
 

gluing on the port and sealing the face of the crack with 

epoxy resin...............................................................................................I-150
 

112 Using compressed air to clean dust and debris from the crack
 

opening.....................................................................................................I-150
 

113 Ports glued to the face of cracks prior to epoxy injection........................I-151
 

114 Sealing the crack opening for epoxy resin injection after
 

attaching the injection ports.....................................................................I-151
 

115 Drilling an injection hole to intercept the leak several inches
 

from the face for polyurethane resin injection.........................................I-152
 

116 Ports placed into holes for injecting polyurethane rein into
 

a leaking expansion joint in a powerplant deck .......................................I-153
 

117 Placing resin soaked jute or open cell backer rod into
 

large cracks or joints can help contain the polyurethane 

injection resin for large cracks and joints................................................I-153
 

118 Two-component cartridge system for injecting resin into cracks............I-156
 

119 A small pressure pot for injecting mixed epoxy resin into a crack..........I-156
 

120 A resin injection system specifically manufactured for injecting
 

epoxy resins .............................................................................................I-157
 

121 Hand-operated pump used to inject resin in difficult access
 

areas .........................................................................................................I-158
 

122 Airless paint sprayers can be used for some injection
 

applications ..............................................................................................I-158
 

123 A high-pressure resin injection pump capable of injecting two
 

components and water..............................................................................I-159
 

124 Simultaneous injection of multiple injection ports for epoxy
 

injection....................................................................................................I-161
 

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Figures 

Figure Page 

125 The exposed crack, after removing the injection port, is filled 

with cured epoxy......................................................................................I-161
 

126 There are a wide variety of ports available for resin injection,
 

including hammer-in ports, mechanical ports, and 

twist-in wall spears ..................................................................................I-162
 

127 Grouting is progressing from one end of the leaking expansion
 

joint to the other.......................................................................................I-163
 

128 A large packer for injecting resin through a drilled hole .........................I-164
 

Appendix IA: Historical Development of Durable Concrete for the
 

Bureau of Reclamation....................................................... IA-1
 

Appendix IB: Petrographic Analysis for Concrete ........................................ IB-1
 

Part II: Standard Specifications for Repair of 

Concrete, M-47
 

The Seven Steps of Concrete Repair and Maintenance .......................................II-2
 

1. Determine the cause(s) of damage...........................................................II-3
 

2. Evaluate the extent of damage .................................................................II-3
 

3. Evaluate the need to repair.......................................................................II-4
 

4. Select the repair method and material......................................................II-4
 

5. Prepare the existing concrete for repair ...................................................II-4
 

6. Apply the repair method ..........................................................................II-5
 

7. Cure the repair properly...........................................................................II-5
 

Appendix IIA: Guide Specifications............................................................... IIA-1
 

x 
Guide to Concrete Repair 

Part I: Reclamation's Methodology 

for Concrete Maintenance and Repair 

 

 

 

 

 

 

 

A. Repair and Maintenance of 

Concrete 

1. Introduction 

For decades, the Bureau of Reclamation (Reclamation) has published both the 

Concrete Manual and the Standard Specifications for Repair of Concrete, M-47.

1 

The subsequent revisions of these two documents (Bureau of Reclamation, 

1975 and 1996), particularly chapter 7 of the Concrete Manual, have formed the 

basis for much of the concrete repair performed on Reclamation projects. The 

first edition of Reclamation’s Guide to Concrete Repair (Smoak, 1996) presented 

a revised and updated M-47 and a narrative about the process that Reclamation 

recommends for obtaining successful repairs to concrete. 

This second edition of the Guide for Concrete Repair updates and revises the 

original Guide and M-47 to include much of the information gathered over the 

last 20 years through field work, international workshops, and collaborative 

research projects. The Guide is now in two parts: Part I consists of chapters A. 

through E., with appendices. Part II contains the M-47, which is updated with 

new information and formatted to follow current Reclamation specification 

standards. 

Reclamation operates and maintains hydroelectric and water resources 

structures in the Western United States. It serves as the fifth largest electric 

utility in the 17 Western States and the Nation's largest wholesale water supplier, 

administering 348 reservoirs with a total storage capacity of 245 million acre-feet 

(1 acre-foot, or 325,851 gallons of water, supplies enough water for a family of 

four for 1 year). Reclamation provides 1 out of 5 Western farmers (140,000) with 

irrigation water for 10 million farmland acres that produce 60 percent of the 

Nation's vegetables and 25 percent of its fruits and nuts. In addition, Reclamation 

operates 58 hydroelectric powerplants averaging 42 billion kilowatt-hours 

annually. Reclamation also delivers 10 trillion gallons of water to more than 

31 million people each year, and it manages in partnership 308 recreation sites 

visited by 90 million people per year. 

Concrete repair industry experts estimate that $18 billion to $21 billion 

(Vision 2020, 2006) (Emmons and Sordyl, 2006) are spent every year for concrete 

1 The first edition of the Concrete Manual was published in July 1938, and the first edition of 

the Standard Specifications for Repair of Concrete, M-47 was printed in November 1970. 

I-1 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

repairs in the U.S. alone. However, at least $1.2 billion (Vision 2020, 2006) of 

the approximately $20 billion total represent the estimated cost for annual repairs 

to water storage, hydroelectric, and management facilities and related structures. 

Clearly, there is a need for sound concrete repair and maintenance practices. The 

first edition of the Guide stated: “It has become apparent that there is need for

modernization and expansion of the information on the methods, materials, and 

procedures of concrete repair originally found in chapter 7 of the Concrete 

Manual (Bureau of Reclamation, 1975).” That still holds true, and the process of 

updating continues with this edition. Much of the information in the original 

Guide is still relevant. There are some significant changes in other areas. These 

changes are the result of several collaborative workshops and research efforts by 

Reclamation and others (NIST, 1995, 1999), (Naval Facilities Engineering 

Service Center, 2001), (Bureau of Reclamation, 2003), (Morency et al., 2005), 

(von Fay et al., 2009), (Bissonnette et al., 2012), as well as knowledge gained 

from project and field work. 

Part I of this Guide discusses Reclamation's methodology for concrete 

maintenance and repair and is designed to serve as a supplement for the “Standard 

Specifications for Repair of Concrete, M-47,” in Part II. Part I addresses the more 

common causes of damage to Reclamation concrete, including recommendations 

for the types of repair methods and materials most likely to be successful in 

repairing concrete damage resulting from those causes. Finally, the Guide 

contains a detailed description of the uses, limitations, materials, and procedures 

of each of the standard repair methods/materials included in the “Standard 

Specifications for Repair of Concrete, M-47.”

a. Concrete Repair and Maintenance System 

Concrete repairs have occurred on Reclamation projects since the first concrete 

was placed in 1903. Unfortunately, even though the best available knowledge and 

materials were used, many repair failures have occurred during the 112 years 

since that first concrete was placed. As a first step to increase the likelihood of a 

successful repair, it is paramount to use a consistent, systematic approach to 

concrete repair. 

Reclamation’s concrete repair and maintenance system consists of seven basic 

steps: 

1. Determine the cause(s) of damage 

2. Evaluate the extent of damage 

3. Evaluate the need to repair 

4. Select the repair method and material 

5. Prepare the existing concrete for repair 

I-2 
Chapter A: Repair and Maintenance of Concrete 

 

 

 

 

 

6. Apply the repair method 

7. Cure the repair properly 

There are several similar repair approaches or systems currently in use. The 

U.S. Army Corps of Engineers (USACE) lists an excellent system in the first 

chapter of its manual, Evaluation and Repair of Concrete Structures (U.S. Army 

Corps of Engineers, 1995). Other organizations, such as the American Concrete 

Institute (ACI), the Portland Cement Association, the International Concrete 

Repair Institute, and private authors (Emmons, 1994) have also published 

excellent methodologies for concrete repair. 

The above seven-step repair system has been developed, used, and evaluated by 

Reclamation over an extended period of time. This process is appropriate for 

repairing construction defects in newly placed concrete, as well as old concrete 

that has suffered damage. The repair system is designed to be followed in 

sequential order. Reclamation has found that, all too often, the first issues 

discussed are how to fix a problem (what material to use) and how much it will 

cost. Although these questions are relevant, for an effective repair, it is more 

useful to know the cause and extent of damage before selecting a repair method 

and material. 

When questions are asked in the right order, the necessary information can be 

obtained to design an effective repair. Of course, the information gathered must 

be viewed as part of a system of the existing structure, the deterioration or 

damage affecting the structure, and its service environment (Vaysburd et al., 

2014) for the repairs to be as durable and long lasting as possible. Whether a 

concrete maintenance or repair activity is being pursued, following the steps 

outlined above will result in a better, more cost effective outcome. 

2. Maintenance of Concrete 

Many times, concrete is viewed as a maintenance-free material. Modern concrete 

is a very durable construction material. If properly proportioned and placed, 

concrete will have a very long service life, usually without the need for any 

maintenance, at least for some time. 

Unfortunately, there are times when concrete does need maintenance to extend or 

prolong its service life. Many Reclamation concrete structures were constructed 

using early concrete technology, and they have already provided well over 

50 years of service under harsh conditions. Concrete in these circumstances 

should be inspected regularly to ensure that it is receiving the maintenance 

necessary to retain serviceability. 

I-3 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

In addition, new technology concrete can be placed in extremely aggressive 

environments. The life of that concrete can be extended by establishing and 

following a well planned maintenance program. 

Performing an effective maintenance program to prolong the life of a concrete 

structure is usually much more economical than taking no action. Failure to 

promptly provide the proper maintenance will usually result in expensive repairs 

or replacement. Figures 1 and 2 demonstrate the consequences of inadequate or 

inappropriate maintenance. These two structures now require replacement at a 

cost many times greater than the preventive maintenance that could have extended 

their serviceability. 

Figure 1. Freeze-thaw damage that could have been prevented by 

proper maintenance. 

During development of a maintenance program, or before specific maintenance 

activities are performed, it is good practice to review the seven steps, which are 

explained in Chapter B, “Using Reclamation's Concrete Repair and Maintenance

System.” The approach presented there will help ensure that the maintenance

plan and activities are well conceived and executed. 

A good maintenance program will involve regularly scheduled inspections. 

Suspect areas should be monitored. Photographs and notes should be 

collected and stored to establish a record that can be reviewed at a later date. 

Photogrammetric or other methods to generate three-dimensional (3D) point 

clouds of the condition of concrete structures can provide valuable information 

(Klein, 2014). The information can be used to relatively easily quantify the 

progression of damage, changes in cracking, or movement of slabs and walls, for 

example. 

I-4 
 

 

 

 

 

Chapter A: Repair and Maintenance of Concrete 

Figure 2. Removing the source of water properly would 

have resulted in significantly less damage. 

Many of Reclamation’s maintenance activities are focused on keeping aggressive

compounds out or off of concrete. They are designed to limit the intrusion of 

water into concrete, especially for older or poorer quality concrete that is not 

air-entrained. Chlorides, carbon dioxide, sulfates, and other contaminants can 

damage concrete, depending on concrete quality and service exposure. 

Reclamation experience has shown that there are certain portions of exposed 

concrete structures that are more vulnerable than others to deterioration from 

freezing climates. These include exposed surfaces of the top of walls, piers, 

posts, handrails, and parapets; all of curbs, sills, ledges, copings, cornices, and 

corners; and surfaces in contact with spray or water at frequently changing levels 

during freezing weather. The durability of these surfaces can be considerably 

improved, and serviceability can be greatly prolonged by protective 

maintenance such as weatherproofing treatment with concrete sealing compounds 

(see section D.1). 

Before the availability of more modern materials, linseed oil-turpentine-paint 

preparations were widely used by Reclamation to retard concrete deterioration 

caused by weathering. These preparations, when applied correctly, were 

I-5 
 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

effective. Modern concrete sealing compounds are much simpler to apply and 

provide superior protection of the concrete. The use of the linseed oil system is 

no longer recommended. 

Penetrating sealers, including silanes, siloxanes, and blended products, are a 

cost-effective means of protecting new and existing surfaces. When applied 

properly, penetrating sealers can serve as chloride screens and dampproofing to 

improve durability against destructive corrosion of embedded reinforcement and 

damage from freezing and thawing weather. Exposed concrete building exteriors, 

parking structures, and bridge decks are typical applications. Sealers can be 

applied at the time of original construction, as part of a maintenance program, and 

as protection for repairs. 

High molecular weight methacrylate (HMWM) and suitable low viscosity epoxies 

are Reclamation's choice for sealing concrete that has small cracks on its surface 

(von Fay and Pepin, 2013). Low viscosities are needed for these products to be 

effective, and viscosities should be below 200 centipoise (cps). Suitable epoxies 

are available that have viscosities below 100 cps, and many HMWMs have 

viscosities below 50 cps. Epoxies will tend to work better than HMWMs in damp 

cracks, but the mixture proportions must be closely followed. HWMWs can be 

mixed at somewhat different ratios, which can be used to adjust set time. These 

materials are very effective in “gluing” the small cracks together and keeping

water out of the concrete. 

Selecting the most satisfactory protective treatment depends, to a considerable 

extent, on correctly assessing the exposure conditions. Concrete sealing 

compounds and coatings that provide good protection from weathering in an 

essentially dry environment may perform poorly when exposed to wet conditions, 

such as on some bridge curbs and railings, stilling basin walls, and piers. 

Freezing and thawing tests of concrete specimens protected by a variety of 

concrete sealing compounds and coatings have been performed in Reclamation 

laboratories and include linseed oil, fluosilicates, epoxy and latex paints, 

chlorinated rubber, and waterproofing and penetrating sealers. These tests 

indicate that proprietary epoxy formulations, siloxane and silane formulations, 

and HMWM formulations clearly excel in resisting deterioration caused by 

repeated freezing and thawing in the presence of water. None of these 

formulations, however, will totally "waterproof" concrete (i.e., they will not 

prevent treated concrete from absorbing water and becoming saturated under 

conditions of complete or long-term submergence). 

For typical Reclamation exposure conditions, concrete sealing compounds are 

usually not applied on new concrete construction. The treatments are most 

commonly used on older surfaces when the earliest visible evidence of weathering 

appears. The treatment is best used before deterioration advances to a stage 

where it cannot be effectively slowed or halted. Such early evidence consists 

primarily of fine surface cracking that is close and parallel to edges and corners of 

I-6 
Chapter A: Repair and Maintenance of Concrete 

 

 

 

concrete structures. The need for protection may also be indicated by pattern 

cracking, surface scaling or spalling, and shrinkage cracking. By treating 

vulnerable surfaces in the early stages of deterioration, later repairs may be 

avoided or at least postponed. 

Other maintenance actions can include making changes to the operation of the 

facility to protect the concrete. For concrete that is subject to damage from 

freezing and thawing weather, reducing the number of cycles of freezing and 

thawing while the concrete is critically saturated can extend its service life. This 

can be done by insulating the concrete or by changing operating procedures to 

keep critical areas under water (that does not freeze) in cold weather, or by 

varying the depth of water over the years to avoid concentrating the damage at 

one elevation. For example, the concrete damage shown in figure 3 could have 

been reduced if the water level was varied during cycles of freezing and thawing 

weather. 

Figure 3. Freeze-thaw damage that could have been reduced by changing 

operation of the structure. 

Concrete in contact with high velocity flowing water has special needs. Small 

offsets at joints, or cracks or small holes in the concrete surface, can result in 

cavitation damage to concrete. The hole or offset causes the flowing water to 

separate from the concrete surface. This separation causes vapor bubbles to form 

in the flowing water. When these bubbles collapse downstream, they exert forces 

that destroy concrete and most other rigid materials including high strength 

stainless steel. 

I-7 
 

 

 

 

 

	 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Proper concrete maintenance in high velocity waterflow structures includes 

eliminating offsets and holes, and repairing observed cavitation damage before it 

can enlarge to cause more damage. No material will stand up to cavitation 

indefinitely; therefore, the long-term solution is to manage the flow to avoid 

conditions that will cause cavitation. 

Another form of damage resulting from flowing water is abrasion erosion. 

Flowing water, even at velocities too low for cavitation damage, can wear away 

or even destroy concrete structures by the impact and grinding action of silt, sand, 

and rock carried in the water. 

Proper maintenance means reducing the amount of debris in flowing water. 

Screens or settling areas at inlet structures can help. Retaining walls to protect 

flowing water from rock slides, and fences to keep people from throwing rocks 

into the water, are sometimes needed. In some stilling basins, rock and other 

debris are not swept out. A ball mill action is established with small to large 

aggregate and boulders beating on the concrete. Removing these materials from 

stilling basins should be a part of routine maintenance. A longer-term solution 

would be to change the stilling basin’s characteristics to prevent drawing

materials into or trapping them in the basin. 

3.	 General Requirements for Quality 

Repair 

The term “concrete repair” refers to any replacing, restoring, or renewing of 

concrete or concrete surfaces after initial placement. It can, in fact, be a part of 

some maintenance activities. 

Historically, the repair of concrete has been based at least as much on art as it has 

on science. Specific training related to concrete repair was limited or nonexistent, 

with most knowledge gained from years of experience, which can be a very 

expensive process. Many people in the concrete repair industry are working to 

change that by working to improve practices, knowledge, and training related to 

concrete repair (Vision 2020, 2006). 

While this document provides methods to greatly improve the success rate of 

concrete repairs, there are many times when repairs still fail prematurely. 

The failure rate for concrete repairs remains unacceptably high (Goodwin, 2008); 

therefore, before repairs are commenced, the method and materials proposed for 

use should be approved by someone knowledgeable and trained in the field of 

concrete repairs. Understanding all the issues related to material compatibility for 

the substrate concrete, exposure conditions, and service, as well as how they 

interact for the repaired structure is very important for achieving successful 

repairs (Vaysburd et al., 2014) (Vaysburd et al., 2015) 

I-8 
Chapter A: Repair and Maintenance of Concrete 

 

 

 

There has been a relative explosion of packaged cementitious repair materials as 

the size of the repair industry grows. Choosing which of these products to use can 

be a daunting task because very often the information needed to make such a 

decision is not readily available. Material suppliers do not always supply all the 

desired information, and the information can be generated differently among 

different manufacturers, making it impossible to compare products. For this 

reason, it is very important to select materials that have been tested according to 

either the ACI or International Concrete Repair Institute (ICRI) data sheet 

protocol (ACI 364.3R, 2009) (ICRI 320.3R, 2012). 

The need for repairs can vary from minor imperfections, such as she bolt holes, 

snap tie holes, or normal weathering, to major damage resulting from chemical 

or physical deterioration, water energy, or structural failure. Although the 

procedures described for repairs may initially appear to be unnecessarily detailed, 

experience has shown that no step in a repair operation can be omitted or 

carelessly performed without detriment to the serviceability of the entire repair. 

Inadequate workmanship, procedures, or materials will result in inferior repairs, 

which will likely fail prematurely. 

a. Workmanship 

Workmanship and skill of the craftsperson are of paramount importance for a 

successful concrete repair project, especially because most repair procedures 

involve predominantly manual operations. Repair personnel are responsible for 

making repairs that are durable, ideally crack-free, and, when appropriate, well 

bonded to existing surfaces. It is particularly important that key personnel be 

fully instructed concerning procedural details of repairing concrete and the 

reasons for the procedures. Some products may require that personnel are 

certified by the material manufacturer prior to a material’s use. Craftspeople 

should also be informed of the more critical aspects of repairing concrete. Proper 

inspection must be performed to ensure compliance with standards of 

workmanship. 

b. Procedures 

Serviceable concrete repairs result only if proper methods are chosen and 

techniques are carefully performed. Wrong or ineffective repair or construction 

procedures, coupled with poor workmanship, lead to poor quality repairs. Many 

proven procedures for making high quality repairs are detailed in this Guide; 

however, not all procedures used in repair or maintenance are discussed. 

Therefore, it is incumbent upon the personnel doing the work to use procedures 

I-9 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

that have been successful, that have a proven high reliability factor, or that are 

well formulated and planned if no established methods exist. 

Whenever possible, repairs made on new or old concrete should be made as soon 

as possible after the need for repair is realized. Especially for new concrete work, 

repairs that will develop the best bond and are most likely to be durable and 

permanent are repairs that are made immediately after stripping forms, while the 

concrete is still green. For this reason, repairs to newly constructed concrete 

should be completed within 24 hours after the forms have been removed and no 

more than 72 hours after the concrete is placed. For this type of repair, curing 

should be interrupted only in the area of repair operations and restarted as soon as 

possible. 

Long lasting repair of deteriorated or damaged portions of concrete structures 

cannot be ensured unless there is complete removal of all deteriorated and 

affected concrete (Bissonnette et al., 2012), proper preparation of the remaining 

concrete (Morency et al., 2007), careful replacement in strict accordance with a 

standard or approved procedure, and the anchorage is secure. Consequently, work 

of this type should not be undertaken unless or until ample time, personnel, and 

facilities are available. Only as much of this work should be undertaken as can be 

completed correctly; otherwise, the work should be postponed, but not so long as 

to allow further deterioration. When the need for repairs is recognized, repairs 

should always be made at the earliest possible date. 

Joints that are in damaged concrete should be maintained in the repair (figure 4). 

For partial depth repairs or overlays, cracks in the substrate concrete may reflect 

through the repair material. Almost always, joints also need to be preserved for a 

partial depth repair or overlay. If the repair material bonds on both sides of a 

joint, the repair material will crack. 

c. Materials 

Materials to be used in concrete repair must be of high quality, within their shelf 

life, and capable of meeting specifications requirements for the particular 

application or intended use. Mill reports or testing laboratory reports should be 

required of the supplier or manufacturer as an indication of quality and suitability. 

As an alternative, certifications should be required from the supplier to verify that 

the materials meet certain specification requirements. 

I-10 
 

 

 

 

Chapter A: Repair and Maintenance of Concrete 

Figure 4. Formwork used to maintain the existing joints in a spillway floor repair. 

The use of standardized methods and materials described in this Guide should 

always be the first choice when planning repairs. Due to the high cost associated 

with subsequent removal and replacement of new or unproven materials, if they 

prove unsuitable for the job, they should not be used in concrete repair unless 

both of these criteria are met: 

 The standard repair materials and methods have been determined 

unsuitable 

 The owners and all other parties to the repair have been informed of the 

need to use nonstandard materials and the associated risk 

There are numerous packaged, proprietary, thin repair products available for use 

for thin repairs. The data sheets for these products should be reviewed before 

selection. Many of them boast rapid strength gain; but for most Reclamation 

repair situations, rapid strength gain is not important. In most cases, rapid 

strength gain is not needed and can, in many cases, result in a less durable repair. 

When comparing different products, they should be evaluated using ICRI 320.3, 

“Guideline for Inorganic Repair Material Data Sheet Protocol” (ICRI 320.3R, 

2012) or ACI 364.3R-09, “Guide for Cementitious Repair Material Data Sheet” 

(ACI 364.3R, 2009). That way, users can be reasonably certain that products 

from different manufacturers are tested similarly. 

I-11 
 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Packaged and proprietary materials selected for repair application must be used in 

accordance with manufacturers' recommendations or other approved methods. 

Many times, the properties of these materials can be significantly impacted by 

small changes in mixing procedures and ingredients. Mixing, proportioning, and 

handling must be in accordance with the highest standards of workmanship. 

In addition, there are many products and technologies available to mitigate for 

the corrosion of reinforcing steel in concrete when the concrete is repaired. 

Products that are being considered for use to help control steel corrosion should 

be evaluated based on data generated using M-82, “Standard Protocol to Evaluate

the Performance of Corrosion Mitigation Technologies in Concrete Repairs”

(Bureau of Reclamation, 2014). 

I-12 
 

 

 

B. Using Reclamation’s 

Concrete Maintenance and 

Repair System 

As mentioned in chapter A, Reclamation developed the following seven-step 

process to help improve concrete repair practices and to ensure that repairs are 

conducted in a logical sequence: 

1. Determine the cause(s) of damage 

2. Evaluate the extent of damage 

3. Evaluate the need to repair 

4. Select the repair method and material 

5. Prepare the existing concrete for repair 

6. Apply the repair method 

7. Cure the repair properly 

The first three steps of the system comprise the functions necessary to perform a 

condition survey of the concrete structure and the guidelines here provide 

information for that process. Also, more information can be found in (ACI 201, 

2008) (ACI 364.1, 2007). Once a condition survey is completed, a suitable repair 

material can be selected. 

Generally, obtaining concrete cores will provide valuable information that will 

significantly add to the findings from the condition survey process. While the 

costs may seem high for obtaining and examining concrete cores, the results are 

almost always well worth the cost. 

1. Determine the Cause(s) of Damage 

The first and very important step of repairing damaged or deteriorated concrete is 

to correctly determine the cause of damage. Knowing what caused the damage, 

and reducing or eliminating that cause, will make the repair last longer. If no 

attempt is made to eliminate the original cause of damage, the repair may fail as 

the original concrete did, resulting in wasted effort and money. Freezing and 

thawing weather, structural overload, cavitation, abrasion-erosion, sulfate bearing 

waters or soils, acids, alkali-aggregate reaction, carbonation, and corrosion of 

I-13 
 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

reinforcing steel are some examples of causes of damage to concrete. Design and 

construction defects can result in concrete damage. Foundation movement, poor 

quality concrete, poor finishing, and poor curing can lead to concrete that suffers 

damage. 

All construction materials deteriorate eventually. Good design, construction, and 

maintenance will lengthen service life. Good concrete in the right environment 

can last hundreds or thousands of years. Some Roman concrete structures, 

including the Pantheon and some aqueducts, are still functional after 2,000 years. 

Since many Reclamation structure are quite old, having a historical perspective 

can help determine possible causes of damage. Refer to appendix IA for 

information about the development of durable concretes at Reclamation. 

If the original damage is the result of a one- time event, such as a flood that 

caused a roadway retaining wall to collapse on a siphon pier (structural overload), 

remediation of the cause of damage does not need to be addressed. It is unlikely 

that such an event will occur again. If, however, the cause of damage is 

continuing or recurring, remediation must be addressed. For example, the repair 

method and materials must, in some manner, be resistant to predictable future 

damage. The more common causes of damage to Reclamation concrete are 

discussed in chapter C. A quick review of these common causes of damage 

reveals that the majority of them are of a continuing or recurring nature. 

It is important to differentiate between causes of damage and symptoms of 

damage. In the above case of the retaining wall hitting the siphon pier, the cause 

of damage is the impact to the concrete. The resultant cracking is a symptom of 

that impact. In the event of deterioration to modern concrete, the cause of damage 

may well lie with the use of low quality or dirty aggregates in the concrete mix or 

an improperly batched load of concrete (figure 5). The resultant damage is a 

symptom of low durability concrete. The application of high cost repairs to low 

quality concrete may be necessary, but the life of the repairs will likely be shorter 

than desired. 

With Reclamation’s older concrete structures, it is common to find multiple

causes of damage (see section C.13). Older design standards, low quality 

materials, and poor construction practices reduced the durability of concrete and 

increased its susceptibility to deterioration (appendix IA). Similarly, sulfate or 

alkali-silica deterioration cause cracks in the exterior surfaces of concrete. Those 

cracks can allow accelerated deterioration from cycles of freezing and thawing 

weather, or the reverse can occur (freeze-thaw deterioration can occur, allowing 

alkali-silica reaction or sulfate attack). 

I-14 
 

 

Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 5. Poor quality aggregate used in concrete placed in the late 

1960s led to the need for expensive repairs in the 2000s. 

Unfortunately, it is often difficult or impossible to confirm a cause of damage by 

visual examination alone. Evaluating several samples of concrete by obtaining 

concrete cores provides very valuable information (figure 6). The information is 

very important to support any decisions to make or to postpone repairs. The 

concrete cores can be tested for physical properties. In addition, a petrographic 

exam of representative concrete cores helps to determine the cause and extent of 

damage. Refer to Appendix IB, “Petrographic Analysis for Concrete,” and 

section B.2. for more information about the uses of petrographic exams of 

concrete. 

Figure 6. Obtaining concrete samples is very important to properly 

assess the cause and extent of damage. In this case, the concrete 

apron was a few inches below the water surface. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Finally, it is important to fully understand the original design intent of a damaged 

structure before attempting repair. A classic example of misunderstanding the 

intent of design occurred several years ago on a project in Nebraska. A concrete 

sluiceway that would experience great quantities of waterborne abrasive sand was 

designed with an abrasion-resistant protective overlay of silica fume concrete. 

This overlay was intentionally designed so that it would be easy to replace when 

required by the anticipated abrasion-erosion damage, so bond to the parent 

concrete was not required, nor was any reinforcing steel specified. This design 

concept, however, was not communicated to construction personnel. They 

became deeply concerned when the silica fume overlay was observed to have 

cracks in it and was found to be “disbonded" shortly after placement and curing 

was completed. Some difficulty was experienced in preventing field personnel 

from requiring the construction contractor to repair a perfectly serviceable overlay 

that was performing exactly as intended. 

2. Evaluate the Extent of Damage 

The next step of the repair process is to evaluate the extent and severity of 

damage. The intent of this step is to determine how much concrete has been 

damaged, and how this damage will affect serviceability of the structure (how 

long, how wide, how deep, and how much of the structure is involved). This 

activity can include predicting how quickly the damage may increase and how the 

damage may progress. 

Damage resulting from cyclic freeze-thaw, sulfate exposure, and alkali-aggregate 

reaction can appear to be similar. The damage caused by alkali-aggregate 

reaction and sulfates can be far more severe than damage caused by freeze-thaw, 

although all three of these causes can result in destruction of the concrete and loss 

of the affected structure. The main difference in severity is based on the fact that 

freezing and thawing is limited to portions of the concrete that are at least 

90-percent saturated and then freeze, so the damage tends to manifest itself on 

outdoor surfaces. When alkali-aggregate reaction and sulfate attack occur, much 

more of the structure can be affected. 

One of the easiest and most common techniques used to quickly estimate the 

extent of damage is sounding the damaged and surrounding undamaged concrete 

with a hammer or other large metal object to listen for a hollow or drummy sound 

(figure 7). If performed by experienced personnel, this simple technique can 

provide needed information on the extent of damage in many instances. In 

sounding suspected delaminated or disbonded concrete, it should be remembered 

that deep delaminations, or delaminations that contain only minute separation, 

will not always sound drummy or hollow. An indication of the relative strength 

of concrete can also be determined by hammer blows. Good quality concrete 

develops a distinct ring from a hammer blow, and the hammer rebounds smartly. 

Low quality concrete resounds with a dull thud and little rebound of the hammer. 

I-16 
Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

There are a number of nondestructive testing (NDT) methods that can be used to 

evaluate the extent of damage (Giannini et al., 2012) (ICRI 210.4, 2009). The 

Schmidt Rebound Hammer is perhaps the cheapest and simplest tool to use. 

Rebound hammer data provides relative quality information, which might be 

useful when comparing similar concretes in different areas of a structure. 

However, rebound data, particularly on older concrete, should not be relied on too 

heavily to provide meaningful information. It is usually more effective for newer 

concrete structures that have not experienced much weathering or deterioration. 

Figure 7. Inspecting a spillway floor using steel bars to sound the 

concrete. The soundings indicated delaminations in the spillway floor. 

Ultrasonic pulse velocity and acoustic pulse echo devices measure the time 

required for a sound wave to either travel through a concrete section or to travel to 

the far side of a concrete section and rebound. Damaged or low quality concrete 

deflects or attenuates such sound waves and can be detected by comparison of the 

resulting travel time with that of sound concrete. Acoustic emission devices 

detect the elastic waves that are generated when materials are stressed or strained 

beyond their elastic limits. With such devices, it is possible to “hear” the

impulses from development of microcracks in overly stressed concrete. One of 

the main advantages of this type of technology is the ability to evaluate large 

areas of concrete relatively quickly. 

However, the technology is not suitable for making stand-alone conclusions. 

Results from these technologies need to be correlated to actual core strength test 

results (ACI 228.1R, 2003). Without confirmation from coring, results can be 

I-17 
 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

misleading. For a complete description of the uses of various NDT methods used 

for evaluating concrete, refer to (ACI 228.2R, 2013). 

Cores taken from the damaged areas can be used to detect subsurface 

deterioration, to determine strength properties through laboratory testing, and to 

perform petrographic exams. Petrographic examination of concrete (appendix IB) 

obtained by coring is also the best method for determining the specific causes of 

deterioration. It is also very effective for finding microcracks in the concrete, 

which can indicate areas where deterioration has occurred or is starting to occur, 

but cannot be detected by sounding or other methods. 

The areas of deteriorated or damaged concrete discovered by these methods 

should be mapped or marked on drawings of the affected structure. This will 

provide information for subsequent calculations of the area and volume of 

concrete to be repaired, as well as for preparation of repair specifications. Even 

though care is taken in these investigations, it is common during preparation of 

the concrete for repair to find that the actual area and volume of deteriorated 

concrete exceeds the original estimate. 

For example, sometimes removal of existing constraining damaged concrete 

allows previously undetected damaged concrete to strain and crack. For this 

reason, it is usually a good idea to increase the computed quantity estimates by 

15 to 25 percent to cover overruns (figure 8). 

Figure 8. A drawing showing the original estimated limits of removal (black 

cross hatch) and the actual limits of removal (black and red cross hatch). 

I-18 
Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

 

 

 

3. Evaluate the Need to Repair
 
 

Not all damaged concrete requires immediate repair. Many factors need to be 

considered before the decision to perform repairs can be made. Obviously, repair 

is required if the damage affects safety or safe operation of the structure (von Fay 

et al., 2004). Similarly, repairs should be performed if the deterioration has 

reached a state, or is progressing at a rate, such that future serviceability of the 

structure will be reduced. Most concrete damage, however, progresses slowly, 

and several options are usually available if the deterioration is detected early. 

With early detection, it may be possible to arrest the rate of deterioration using 

maintenance procedures. Even if repair is required, early detection of damage 

will allow orderly budgeting of funds to pay the costs of repair. 

Some types of concrete deterioration can simply be ignored. Thermal cracking or 

cracking due to drying shrinkage and freeze-thaw deterioration is common on the 

downstream face of many older Western dams. These types of damage are 

unsightly, but repair can seldom be justified for only cosmetic purposes. 

Conversely, structural cracks due to foundation settlement and freeze-thaw 

deterioration to the walls or floor of a spillway will usually require repair, if not 

immediately, at some point in the future. Figure 9 shows freeze-thaw damage to 

the face of a dam that does not require repair for safe operation of the structure. 

Figure 10 shows similar damage that should have been repaired long ago. 

Figure 9. A structure experiencing freeze-thaw deterioration that will not need 

repair for many years. 

I-19 
 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 10. Freeze-thaw damage that should have been repaired before 

damage became so extensive. 

Damage caused by absorptive aggregate popouts can be common on some 

concrete surfaces (figure 11). As long as the damage is only surficial and the 

concrete is not exposed to high velocity waterflows, where the offsets caused by 

popouts can result in cavitation damage, repairs are probably not necessary. 

Absorptive aggregates can, in some cases, lead to extensive damage of concrete 

structures when the aggregates stay wet and undergo repeated cycles of freezing 

and thawing weather. Figure 12 shows damage from absorptive aggregates that 

extends deep into the structure, requiring extensive repairs. Several structures in 

Kansas and Nebraska have been affected by this form of deterioration. 

Figure 11. Damage from absorptive aggregates. 

I-20 
Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 12. Damage from absorptive aggregates deteriorating from 

freezing and thawing weather that extends several inches into the 

concrete. 

Figure 13 shows damage to a spillway that appears quite serious, and repair seems 

to be required. This spillway, however, is constructed with a very thick slab and 

does not experience high velocity waterflow. The repairs can be scheduled at 

some future date to allow an orderly process of budgeting to obtain the required 

funding. It should be noted, however, that proper maintenance might have 

eliminated the need to repair this spillway. 

Figure 13. Damage that appears serious, but because of the characteristics 

of the spillway, repairs are not needed immediately. 

I-21 
 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 14 shows a spillway that appeared to be in overall good condition; 

however, a void at the top of the spillway wall could not be kept full (it was 

initially assumed to be an animal burrow). After the void was filled, the fill 

material would subside. Closer examination revealed that spillway foundation 

material had been removed from a very large area beneath the spillway floor slab 

and that immediate repair was needed. Without repair, this spillway may have 

experienced extensive additional damage if operated during periods of high flows. 

Figure 14. A spillway that appeared to be in good shape. Subsequent investigations 

discovered large voids under large sections of the spillway. 
Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

 

 

 

 

Selecting or scheduling the most optimum time to perform needed concrete repair 

should be part of the process of determining the need to repair. Except in 

emergencies, many irrigation structures cannot be removed from service during 

times of water delivery. The expense or loss of income involved with taking a 

structure out of service to perform repairs may exceed the costs of the repairs by 

many times. 

In many cases, the cost of access to the areas needing repair (for example, 

dewatering costs) can be quite high. In these cases, timing the outages and 

adjusting the scope of the repair work may make sense. For example, if the cost 

of dewatering a stilling basin is higher than repair costs, it can make sense to 

expand the scope of the repairs to include more of the structure and to use more 

expensive repair materials that will last longer. 

As noted earlier, these first three steps of the seven-step process (determining the 

cause of damage, evaluating the extent of damage, and evaluating the need to 

repair) form the basis of what is known as a “condition survey.” If the damage is 

not extensive, or if only a small part of a structure is involved, the condition 

survey could be simply a mental exercise. If major repair or rehabilitation is 

required, a detailed condition survey should be performed and documented. Such 

a survey can consist of a review of the plans, specifications, and operating 

parameters for the structure; determination of concrete properties; and any 

additional field surveys, engineering studies, or structural analysis required to 

fully evaluate the present and desired conditions of the structure. The final 

feature of a condition survey, completed only after the above items have been 

completed, is a list of the recommended repair methods and materials. 

A recent repair program demonstrated the importance of conducting a condition 

survey. There was abrasion erosion damage to a spillway for a small water 

diversion structure in southern Colorado (figure 15). Obtaining cores to verify the 

cause of the abrasion erosion damage (i.e., was the damage from abrasive 

materials or some form of deterioration resulting in poor quality concrete that 

abraded easily) was recommended. However, to save money, the decision was 

made to forego obtaining cores and evaluating the concrete. A repair 

specification was developed using hydrodemolition to remove damaged concrete. 

It soon became apparent that the damage was much more widespread and serious 

than originally thought (figure 16). Concrete was easily removed to significant 

depth over most of the spillway. Because the end of the construction season was 

fast approaching, and there was insufficient budget or design detail for a large 

repair, the decision was made to cap the structure with shotcrete to protect the 

remaining concrete over the winter and spring. A thorough investigation was 

conducted the next spring and summer by obtaining and examining cores from 

several areas (figure 17). The underlying cause of damage was determined to be 

from alkali-silica reaction, and a majority of the structure is affected by this. With 

this new information, proper designs can be developed and budgets prepared 

before beginning repairs. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 15. Abrasion erosion damage to the flip bucket and energy 

dissipaters. The underlying cause of the damage was not 

determined prior to starting repairs. 

Figure 16. After beginning concrete removal, the extent of damage 

was much worse than originally believed. Concrete was easily 

removed due to extensive deterioration. 

There is a tendency to start thinking about repair material options early in the 

repair process. Repair professionals should try to avoid this. Without enough 

information, making proper, economical, and successful decisions is almost 

impossible. 

I-24 
 

 

 

	 

Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 17. Coring through the temporary shotcrete repairs to obtain 

samples of concrete for testing and examination. 

4.	 Select the Repair Method and 

Material 

Once the first three steps of the repair process have been completed, the selection 

of proper repair methods and materials usually becomes more straightforward. 

These steps define the types of conditions the repair must resist, the available 

repair construction timeframe, and when repairs must be accomplished. This 

information, in combination with data on the volume and area of concrete to be 

repaired, will usually determine which of the standard repair materials should be 

used. Also, this information will determine when the standard repair materials 

cannot be expected to perform well and when nonstandard materials should be 

considered (see chapter E). Chapter D contains a detailed discussion of each of 

the standard repair materials. In addition, when selecting the repair method and 

material, it is important to consider compatibility issues (Vaysburd et al., 2014). 

Selecting a repair material and method that may lead to subsequent damage or 

accelerate damage to the existing concrete or reinforcing steel must be avoided. 

In addition to the information presented here, ICRI 320.2R, “Guide for Selecting

and Specifying Materials for Repair of Concrete Surfaces” (ICRI 320.2R, 2009),

and ACI 546.3R, “Guide for the Selection of Materials for the Repair of 

Concrete” (ACI 543.3R, 2006), offer guidance for the selection of repair 

materials. 

I-25 
 

 

 

	 

	 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

5. Prepare the Existing Concrete for 

Repair 

Preparing the existing concrete for repair is very important for accomplishing 

durable repairs. This step involves removing all the deteriorated and damaged 

concrete and leaving a sound surface for the repair material to bond to. If this 

step is not done properly, then regardless of how well the other steps are 

performed, the repair will likely fail prematurely. It is essential that all of the 

unsound or deteriorated concrete be removed before repair materials are applied. 

Because this phase of a repair project is so important, final acceptance of a 

proposed concrete removal and cleaning plan should be based on actual results. 

The proposed methods should be evaluated by testing the methods on the concrete 

to be repaired. Results should be examined to ensure that the proposed removal 

and cleanup will meet specification requirements, including surface roughness 

and bond strength requirements. It is typically not difficult to test bond strength; 

refer to (ACI 503R, 1993) (ICRI 210.3, 2004). 

a.	 Saw Cut Perimeters 

Usually, the first step in preparing the old concrete for repair is to saw cut the 

perimeter of the repair area to a minimum depth of 1 inch, or more if possible 

(figure 18). For thinner repairs, grinders can be used to prepare edges to a 

minimum depth of 1⁄4 inch. The exceptions are when removing concrete by 

hydrodemolition (figure 19) and when removing concrete damaged from 

reinforcing steel corrosion. In the case of hydrodemolition, the concrete removal 

process leaves rough edges, so saw cutting after removal saves time and money. 

For concrete removal around corroded reinforcing steel, it is important to continue 

to remove concrete beyond the areas of corrosion. That area is not precisely 

known until the concrete is removed, at which time the saw cuts can be made. 

During saw cutting, it is important to ensure that any embedded items, including 

reinforcing steel, are not damaged. 

The purpose of the square perimeter edges is to provide a retaining boundary 

against which the repair material can be compacted and consolidated. Without 

square edges, poor compaction and feather (very thin) edges of repair material 

will result at the repair perimeters. Experience shows that these repair areas will 

usually fail quickly; thus, feather edge perimeters to repair areas are not allowed. 

Cutting to the full depth of the repair is not usually necessary, although doing so 

is advisable whenever possible. The saw cuts should be perpendicular to the 

concrete surface, or tilted inward between 5 and 10 degrees, to provide a retaining 

keyway that can mechanically hold the repair material into the area. Tilting the 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

saw inward more than 10 degrees may result in a repair with weak top corners and 

hard to fill areas in the lower corners of the repair cavity. The saw cut edges 

should never be beveled outward. 

Figure 18. Using a large, rail-mounted saw to cut 

completely through a concrete slab. 

Figure 19. Saw cutting the perimeter after 

hydrodemolition removed most of the concrete. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Closely following the shape of the repair area with multiple short saw cuts, as 

seen at the bottom of figure 20, is usually counterproductive. The cost of sawing 

such a shape most likely will exceed the cost of increased concrete removal, and 

the resulting repair may be less attractive than repairs with simple rectangular 

shapes. In addition, many corners and angles will increase the likelihood of 

cracking in the repair material. Finally, saw cuts should not meet in acute angles, 

as shown at the top of figure 20. It is difficult to properly compact repair material 

into such sharp corners. 

Figure 20. Examples of saw cut shapes. 

Saw kerfs should not cross. Doing so results in grooves in the existing concrete 

that are difficult to fill and that can serve as a site for further deterioration or 

cracking, due to trapped water and other debris. The saw cut perimeters should 

have rounded corners, as shown in figure 21, whenever reasonable. Rounded 

corners cannot be cut with a circular concrete saw, but the cuts can be stopped 

short of the intersection and rounded using a chipping hammer carefully held in a 

vertical orientation. Another option is to take short cores at the corners. 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 21. Rounded corners are best. 

b. Concrete Removal 

All deteriorated or damaged concrete must be removed from the repair area to 

provide sound concrete for bonding of the repair material. No repair material will 

be effective long term when placed on damaged or deteriorated concrete. In most 

cases, it is good practice to remove at least 1-1⁄2 inches of concrete. Experience 

shows that repairs thinner than 1-1⁄2 inches may not be as durable. However, this 

is a very rough rule of thumb, and the focus should be on using a repair thickness 

that is suitable for the situation and that will be long lasting. There are many 

cases where 1-1⁄2 inches will not be thick enough and some cases where it may not 

be advisable to remove concrete to that depth. 

The first choice of concrete removal techniques should be high pressure (8,000 

to 40,000 pounds per square inch [psi]) hydroblasting or hydrodemolition 

(figure 22). These methods can be very effective for large jobs. They have the 

advantage of removing the unsound concrete, while leaving high quality concrete 

I-29 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

in place. A further advantage is that they do not leave microfractured surfaces on 

the old concrete. To use hydrodemolition equipment, typically one or more 

calibration tests are conducted to determine the operating parameters of the 

equipment to achieve the desired depth of removal (figure 23). Additional 

calibration tests may be needed if concrete conditions change, or if a different 

depth of removal is needed for different areas of the repair. When using 

hydrodemolition or other high water pressure concrete removal and preparation 

methods in areas with unbonded prestressing steel reinforcement, care must be 

exercised to prevent water from entering into the sheathing surrounding the steel. 

Further damage may result, or the long-term durability of the steel could be 

compromised. A disadvantage of high pressure water blasting techniques is that 

the waste water and debris must be handled in an environmentally acceptable 

manner as prescribed by regulations. Concrete debris left in hydrodemolition 

cavities can be difficult to remove if they are allowed to dry. 

Figure 22. Hydrodemolition using water pressure of 20,000 psi to remove about 

6 inches of concrete. 

Impact concrete removal techniques for partial depth repairs, such as 

jackhammering for large jobs and bush hammering and scabblers for smaller 

areas, have been used for many years. These removal procedures are quick and 

economical, but the costs of subsequent removal of the microfractured surfaces 

resulting from these techniques must be included when comparing the costs of 

these techniques to the costs of high-pressure water blasting. For partial depth 

repairs with reinforcing steel, the maximum size of jackhammers should usually 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

be limited to 15 or 30 pounds (figure 24). Larger jackhammers remove concrete 

at a high rate but are more likely to damage surrounding sound concrete. The 

larger hammers can also impact and loosen the bond of concrete to reinforcing 

steel for a significant distance away from the point of impact. Pointed hammer 

bits, which are more likely to break the concrete cleanly, rather than to pulverize 

it, should be used to reduce the occurrence of surface microfracturing. Bits 

should be kept sharp throughout the removal process. Using spade shaped bits is 

appropriate near saw cut perimeters. 

Figure 23. The first calibration test resulted in excessive 

concrete removal and bent rebar. 

Shallow surface deterioration (usually less than 1⁄2-inch deep) is best removed 

with shot blasting (figure 25) or dry or wet sand-blasting (figure 26). Shot 

blasting equipment is very efficient and usually includes some type of vacuum 

cleanup for resulting dust and debris. The use of such equipment is much more 

environmentally acceptable than dry sand blasting. The need for removal of 

deteriorated concrete to shallow depths is seldom encountered in Reclamation 

repairs, except for removal of microfractured surfaces, for cosmetic surface 

cleaning, or for application of a surface treatment. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 24. Using a small electric chipping hammer to remove 

damaged concrete. 

Figure 25. Shotblasting using a small unit 

prior to application of a healer-sealer 

(Sealers and Coatings). Even though this 

unit is small, it is capable of preparing a 

large area fairly quickly. 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 26. Sand blasting a concrete deck prior to application of a 

healer-sealer (Sealers and Coatings). 

Shallow deterioration to concrete surfaces can also be removed with tools known 

as scabblers (figure 27) and bush hammers, but their use is discouraged. These 

tools usually have multiple bits (figure 28) or heads with points that pound and 

pulverize the concrete surfaces in the removal process. Their use greatly 

increases the occurrence of microfractures in the remaining concrete surfaces. 

Extensive high-pressure water, sand, or shot blasting efforts are then needed to 

remove the resulting microfractured surfaces. Such efforts are seldom achieved 

under field conditions. For this reason, Reclamation's specifications prohibit the 

use of scabblers and bush hammers for concrete removal. 

Figure 27. A scabbler used to remove concrete. 

I-33 
 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 28. View of the bits in a scabbler used to remove concrete. 

Similar bits can be used in bush hammers. 

c. Reinforcing Steel Preparation 

Reinforcing steel exposed during concrete removal requires special treatment. In 

general, if more than one-third of the circumference of the steel is exposed, the 

concrete should be completely excavated from around the steel. In other cases, it 

is best to completely expose the reinforcing steel if any of it is exposed during 

concrete removal. For concrete repairs that may be subjected to unusual loads, it 

may be appropriate to excavate around reinforcing steel, even if the damage is 

shallow. The depth of excavation under reinforcing steel should be at least equal 

to the nominal maximum size aggregate of the repair material plus 1⁄4 inch, or at 

least 1 inch deep, whichever is greater. 

If the steel is corroded, it should be completely exposed, and all surrounding 

concrete should be removed. The bars should be exposed to the point where the 

concrete is well bonded to the steel, and the steel is not affected by corrosion. 

The cause of the corrosion should be determined. If the corrosion is a result of 

chloride contamination, all concrete with water soluble chloride content higher 

than about 0.15 percent to 1.00 percent, by mass, of cementitious materials should 

be removed, depending on service conditions. However, this limit varies among 

national and international standards, and it can be affected by a number of factors. 

A corrosion specialist should be consulted if repairs to concrete damaged by 

reinforcing steel corrosion are planned. If contaminated concrete is not removed, 

there is a good chance that corrosion of the steel near the intersection of the new 

and old concrete will accelerate, which is commonly called the “halo” or “ring”

effect. 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

 

When the reinforcing steel is exposed, all loose scale, rust, and concrete must be 

removed by wire brushing or high-pressure water or sand blasting. It is not 

necessary to clean the steel to white metal condition; just remove all the loose or 

poorly bonded debris that would affect bond between the repair material and the 

reinforcing steel. 

If corrosion has reduced the cross section of the steel to less than 80 percent of its 

original diameter, a structural analysis may be needed to determine if the steel is 

still adequate. Guidelines for performing this analysis for buildings are found in 

ACI 562 (ACI 562, 2013). If the remaining steel is deemed inadequate, the 

affected bars should be removed and replaced using reinforcing steel in 

accordance the latest guidance from ACI Committee 318 (ACI 318, 2013). 

Figure 29 shows a schematic of the correct concrete removal and preparation 

process for repairing a delamination occurring at the top mat of reinforcing steel 

of a concrete slab. Figure 30 shows correct preparation of a concrete defect that 

extends entirely through a wall. Figure 31 shows a properly prepared repair area 

on a spillway approach apron. 

Figure 29. A schematic of the proper method for concrete 

preparation for a concrete spall repair. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 30. A schematic of the proper method for preparing a hole through a 

concrete wall. 

Figure 31. A properly prepared area for repair to a spillway 

approach apron. 

d. Primary Cleaning 

After concrete removal and preparation of the reinforcing steel are completed, 

primary cleaning must be performed. Some steps for this have already been 

described and include contained shotblasting, sandblasting, or water blasting to 

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Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

 

 

 

 

 

 

remove any weakened or microfractured surfaces resulting from the initial 

concrete removal. Essentially all mechanical concrete removal techniques 

leave behind some microfractured concrete that should be removed by cleaning 

(Bissonnette et al., 2012) (Morency et al., 2007). If water blasting is used, use 

pressure that is sufficiently high to prepare the surface. Pressures up to 15,000 psi 

may be necessary, depending on the condition of the concrete surface, although 

4,000 to 5,000 psi may also work. 

Remove any other materials that will weaken the bond between the remaining 

concrete and the repair material. Include saw cut or ground faces in this step. 

e. Protecting the Prepared Area 

After the repair area has been prepared, it must be kept clean and protected from 

damage until the repair materials can be placed and cured. In hot climates, this 

might involve providing shade to keep the concrete cool, thereby reducing rapid 

hydration or hardening. If cold weather conditions exist, steps must be taken to 

provide sufficient insulation and/or heat to prevent the repair area from being 

covered with snow or ice. 

Repair activities can contaminate or damage a nearby properly prepared site. 

Workers placing repair materials in one area of a repair can track debris into an 

adjacent repair area. Once deposited on a prepared surface, this material will 

serve as a bond breaker if it is not cleaned up before the new repair material is 

placed. Additional preparation will be needed if a repair area is allowed to 

become damaged or contaminated. 

f. Secondary Cleaning 

Within 48 hours prior to placement of repair material, use low-pressure water 

jetting to remove any materials that will impair bond (figure 32). Wash all 

surfaces thoroughly. Pressures up to 5,000 psi may be required for this step. 

Ensure that surface moisture conditions meet the repair material requirements. 

Surfaces should be kept wet or dry, depending on the repair material to be used. 

Surfaces that will receive polymer concrete or epoxy-bonded materials should be 

kept as dry as possible. Some epoxies will bond to damp concrete, but they 

always bond better to dry concrete. 

Surfaces that will be repaired with a cementitious repair material should be in a 

saturated surface dry (SSD) condition immediately prior to material application. 

This condition is achieved by soaking the surfaces with water for 2 to 24 hours 

just before repair material application. Immediately before material application, 

the repair surfaces should be allowed to start drying, using natural means or by 

using oil-free compressed air. The surface should appear slightly damp, with no 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

standing water (figure 33). In many cases, a slightly dry condition is much better 

than a wet condition. The SSD condition prevents the existing concrete from 

absorbing excess mix water from the repair material and promotes development 

of adequate bond strength between the repair material and the substrate concrete. 

The presence of free water on the repair surfaces during application of the repair 

material must be avoided. Excess water at the repair surfaces creates a higher 

water content at the interface of the new and old concrete, resulting in decreased 

bond strength and durability. 

Figure 32. Using water jetting for secondary cleaning (4,000 psi). 

The influence of surface moisture on the bond between old concrete and repair is 

an issue of significant importance. As described above, SSD conditioning of 

the substrate prior to application of cementitious repair materials is usually 

recommended and used. However, there is no clear physical meaning that 

defines the SSD condition, and there exists no strict definition of what actually 

constitutes SSD: saturation to what degree, to what depth, how to measure it, etc. 

Investigation is currently taking place to better determine what is needed for 

optimal moisture content to achieve the best bond (Bissonnette et al., 2013). 

For noncementitious repairs or surface treatments, different surface moisture 

conditions from those discussed above are usually required. Some materials 

require that the surfaces be dry, while others can tolerate some surface moisture. 

When using these types of materials, be sure to follow the manufacturer’s surface

moisture requirements. 

I-38 
 

 

 

Chapter B: Using Reclamation’s Concrete Maintenance and Repair System 

Figure 33. Using water spray to keep the substrate surface in an SSD condition 

between placements. 

6. Apply the Repair Method 

There are 14 different standard concrete repair methods/materials described in 

chapter D, and guide specifications are provided in Reclamation's M-47 

specification (Part II of the Guide). Each of these materials has unique 

requirements for successful application. Whenever a repair is planned, the 

information provided in chapter D and the guide specifications in Part II should 

be reviewed. 

7. Cure the Repair Properly 

All of the standard repair materials require proper curing procedures. Some 

systems require extensive water curing, others require water curing followed by 

drying, and some systems require protection with no water exposure until they are 

hardened. Curing is usually the final step of the repair process, followed only by 

cleanup and demobilization. It is common to find that the curing step has been 

shortened, performed haphazardly, or eliminated entirely as a result of workers 

eager to leave the job site. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Proper curing is critical to long-term repair material performance. Money and 

effort to adequately cure the repair represent a sound investment to ensuring 

long-term performance. Inadequate or improper curing can result in significant 

loss of repair material performance and, ultimately, a loss of money. At best, 

improper curing will reduce the service life of the repairs. More likely, 

inadequate or improper curing will result in the need to remove and replace the 

repairs. The costs of the original repair are completely lost, and the costs of the 

replacement repair will be greater because the replacement repairs will be larger 

and must include the cost of removing the failed repair material. 

I-40 
 

 

 

 

 

	 

	 

	 

	 

	 

C. Causes of Damage to 

Concrete 

This chapter discusses the common causes of damage to Reclamation concrete. 

The discussion for each cause of damage consists of the following: 

1.	 A description of the cause and how it damages concrete 

2.	 A discussion and/or listing of appropriate methods and materials to repair 

that particular type of concrete damage 

This sequence for discussion was chosen to highlight the importance of first 

determining the cause(s) of damage to concrete before trying to select a repair 

material or method. Before a repair is attempted, the full description of the 

selected repair method, found in chapter D, should be reviewed. 

In general, if there is damage to concrete, then it was not durable for its service or 

exposure condition(s). Thus, the causes of damage can be broadly divided into 

three categories: 

	 An inability to withstand its intended design loadings, such as normal 

structural loads, or unusual loadings caused by flooding or earthquakes 

	 An inability to withstand the physical environment, such as abrasionerosion, cavitation, and freezing and thawing 

	 An inability to withstand the chemical environment, such as sulfate attack, 

alkali-aggregate reaction, or chloride intrusion (leading to corrosion of 

embedded reinforcing steel) 

Factors that can lead to damage resulting from these conditions are described 

below. Many of these factors are also described in Appendix IA, “Historical

Development of Durable Concrete for the Bureau of Reclamation.”

1. Excess Concrete Mix Water 

The use of excessive mix water was common practice in many Reclamation 

structures built before about 1920 (appendix IA). The excessive mix water 

certainly made placing concrete easier in many cases, but it resulted in a low 

quality material that would likely not have a service life as long as was anticipated 

and desired. Unfortunately, the use of excessive mix water still occasionally 

occurs today. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Excessive water reduces strength, increases drying shrinkage, increases porosity, 

increases creep, and reduces the abrasion resistance of concrete. All these factors 

mean that the concrete will not be durable in many exposure conditions. 

Figure 34 shows the effect of water-cement ratio on the durability of concrete. In 

this figure, high durability is associated with low water-cement ratio and the use 

of entrained air. 

Figure 34. Durability improves with lower 

water content and the use of entrained air in 

the concrete. 

Damage resulting from the use of excessive mix water can be difficult to diagnose 

because it can be masked by damage from other causes. Freeze-thaw cracking, 

abrasion erosion damage, or drying shrinkage cracking, for example, are often 

blamed for damage to concrete when, in reality, excessive mix water caused the 

low durability that allowed these other mechanisms to damage the concrete. 

I-42 
Chapter C: Causes of Damage to Concrete 

 

 

 

 

To help identify if excessive mix water is the cause of damage, it is usually 

necessary to obtain samples of similar but undamaged concrete. During a 

petrographic examination, excessive mix water in hardened concrete can be 

detected by the presence of bleed water channels and pockets under aggregate 

particles caused by bleed water. If available, examination of the batch sheets, 

mixture records, and field inspection reports may provide confirmation of the use 

of excessive mix water in damaged concrete. However, water added to transit 

truck mixers at the construction site, or applied to concrete surfaces during 

finishing operations, often goes undocumented. For that reason, Reclamation’s 

concrete guide specification requires that all water added to the concrete mixture 

be documented. 

Repairs bonded to this type of concrete will likely have a short service life. The 

only permanent repair for concrete made with excessive mix water is removal and 

replacement of much or all of the original concrete. 

However, depending on the extent and nature of damage, a number of 

maintenance or repair methods can be useful in extending the service life of 

such concrete. If the damage is detected early, application of concrete sealing 

compounds such as the high solids content (greater than 20 percent) siloxane or 

silane systems (section D.1.c.), HMWM systems, or low viscosity epoxies 

(sections D.1.a. or D.1.b.) will reduce water penetration and improve resistance to 

freeze-thaw damage and other deterioration mechanisms. In addition, coatings 

may provide protection to the concrete (section D.1.d.). Such treatments are not 

permanent and will require reapplication at 5- to 20-year intervals. 

For repairs less than 1-1⁄2 inches thick, the guidance given in section D.2 can be 

used, depending on the specific nature of the repair. In many cases, holes in 

concrete can be repaired using the information provided in section D.2.c. Epoxy 

bonded replacement concrete (section D.2.e.) can be used under special 

circumstances for thinner repairs. In general, however, bonding agents are not 

recommended. Instead, proper practices and procedures for concrete removal, 

cleaning, and adequate curing are required. For repairs that are about 1-1⁄2 inches 

thick and thicker into the concrete, information from sections D.2.f. through 

D.3.d. can be used, again depending on the specific needs of the repair. 

2. Faulty Design 

Design faults can create many types of concrete damage. The simplest case of 

damage occurs when the concrete is not sufficient for the actual loading, which 

rarely occurs in Reclamation structures. However, one type of design fault that is 

somewhat common is positioning embedded items, such as electrical conduits or 

I-43 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

outlet boxes, too near the exterior surfaces of concrete structures. Cracks can 

form in the concrete over and around such embedded metal features and allow 

moisture into the concrete. This can lead to accelerated deterioration to concrete 

susceptible to freeze-thaw deterioration or alkali-silica reaction (ASR). Bases of 

handrails or guardrails are sometimes placed too close to the exterior corners of 

walls, walkways, and parapets with similar results. These bases or intrusions into 

the concrete expand and contract with temperature changes at a rate different from 

the concrete. Tensile stresses, created in the concrete by expanding metal, lead to 

cracking and allow for additional moisture penetration, which can lead to 

freeze-thaw or ASR damage. Long guardrails or handrails can create a different 

problem. The pipe used for such rails also undergoes thermal expansion and 

contraction. If sufficient slip joints are not provided in the rails, the expansion 

and contraction causes cracking at the points where the rail attachment bases enter 

the concrete. This cracking also allows accelerated damage to the concrete, 

similar to the description above. In other cases, the holes in the concrete for the 

rail posts can fill with water and freeze, causing cracking. 

Another case of faulty design involves using inappropriate concrete mixture 

proportions for a concrete component of a structure. For example, using a 

structural concrete mixture for thick, large placements may cause thermal 

cracking (section C.11) as a result of the heat that is generated while the concrete 

cures (figure 35). 

Figure 35. Thermal cracking in a thick concrete wall. The concrete got fairly 

hot during curing and then cooled too quickly. The picture shows epoxy resin 

injection repairs underway. 

I-44 
Chapter C: Causes of Damage to Concrete 

 

 

 

Insufficient concrete cover over reinforcing steel is a common cause of damage to 

concrete structures. Insufficient cover allows for easier corrosion of the 

reinforcing steel. The iron oxide byproducts of this corrosion occupy more space 

in the concrete than the reinforcing steel originally occupied, which results in 

cracking and delaminating in the concrete (figure 36). 

Figure 36. Corrosion of reinforcing steel from deicing salts used on 

the bridge. 

Reclamation usually requires a minimum of 2 inches of concrete cover over 

reinforcing steel, or, 3 inches of cover if the concrete is in contact with the 

ground. However, for concrete exposed to aggressive or corrosive environments, 

this may be insufficient. Additional coverage in these exposure conditions should 

be considered. Design experts should be consulted in this case, to consider the 

potential for larger drying shrinkage cracks in the surface of the concrete as a 

result of having the reinforcement at a greater depth. 

Failure to provide adequate joints, or failure to make expansion joints wide 

enough to accommodate temperature expansion in concrete slabs, can result in 

damage. The concrete will crack wherever a joint was needed but not provided. 

Unfortunately, such cracks will not be as visually attractive as a formed, tooled, or 

sawed joint. Formation of cracks relieves tensile stresses and, though unsightly, 

may not require repair. If repairs are needed, many times the best option is to 

treat the crack as a joint and repair it using techniques appropriate for a joint. 

Inadequate joints (too few or too narrow) can cause serious damage to bridge 

deck surfaces, dam roadways, and the floors of spillways. Such concrete can 

experience large daily and seasonal temperature changes, resulting in relatively 

I-45 
Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

large expansions and contractions. The resulting concrete expansion is greater in 

the top surfaces of the slabs, where the concrete temperatures are higher, and the 

expansion is lesser in the cooler, bottom areas. Such expansion can cause the 

upper portions of concrete in adjacent slabs to butt against one another at the 

joints between the slabs. The only possible direction of relief movement in such 

slabs is upward. Either by expansion on its own or, in some cases, when these 

forces are combined with effects of deterioration, cracking and delaminations can 

form in the concrete, starting at the joints and extending 1 or 2 inches back into 

the slab. These delaminations are commonly located at the top mat of reinforcing 

steel. In cold climates, water can enter the cracks and delaminations, where it 

undergoes cycles of freezing and thawing. This action causes the delaminations 

to grow and extend to as much as 3 to 5 feet away from the joint. 

Figure 37 is an exaggerated example of such damage. 

Figure 37. Damage resulting from expansion at tight joints. 

For exposure conditions where this might occur, a modified joint detail was 

developed and has been used recently during the repairs of several spillways 

(figure 38) (von Fay K., 2007). For this detail, it is important to realize that the 

joint sealant is not intended to seal the joint from water intrusion (there is a 

waterstop for that); rather, it is intended to keep debris out of the expansion slot. 

Further, a thick layer of sealant will help ensure that the material stays in place 

during spilling. 

Repair of damage caused by faulty design may be very difficult if the design 

feature cannot be easily adjusted. Embedded metal features can be removed, 

handrails can be provided with slip joints, and guardrail attachment bases can be 

changed to bolt-on bases. Mitigation of insufficient concrete cover over 

reinforcing steel can be difficult because additional cover needs to be added, 

I-46 
Chapter C: Causes of Damage to Concrete 

I-47 

 

 

which can lead to other required changes. In some cases, repairs can be made 

with concrete sealing compounds or coatings (section D.1.d.) to reduce water or 

chloride penetration. 

Figure 38. Joint detail for joints that experience excessive expansion that results in damage. 

This detail shows an example for placing a new slab next to an existing slab. 

Damage caused by design faults can most likely be repaired using replacement 

concrete (section D.3.a.), polymer concrete (section D.2.d.), a suitable packaged 

repair material (section D.2.f.), or resin injection (section D.4.a.). 
 

 

 


 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

3. Construction Defects

Some of the more common types of damage to concrete that are caused by 

construction defects are rock pockets and honeycombs, form failures, dimensional 

errors, and finishing defects. 

Honeycombs and rock pockets are areas of concrete where voids are left, due to 

failure of the paste or concrete to completely fill the spaces around coarse 

aggregate particles and reinforcing steel (figures 39 and 40). These defects, if 

minor, can be repaired with Portland cement mortar (section D.2.b.) if less than 

24 hours have passed since form removal and not more than 72 hours has passed 

since concrete placement. If repair is delayed longer than this, or if the rock 

pocket is extensive, the defective concrete must be removed and replaced with dry 

pack mortar (section D.2.c.), a packaged repair material (section D.2.f.), or a thick 

repair method (replacement concrete [section D.3.a.], preplaced aggregate 

concrete [section D.3.b.], shotcrete [section D.3.c.], or silica fume concrete 

[section D.3.d.]). 

Figure 39. Large 

voids, rock 

pockets, and 

honeycombs 

resulting from 

inadequate 

concrete 

consolidation. 

Some minor defects resulting from form movement or failure can be repaired with 

surface grinding (section D.2.a.). More likely, the resulting defect is either simply 

accepted by the owner, or the contractor is required to remove the defective 

concrete and reconstruct that portion of the structure. 

Dimensional errors can occur in concrete construction. Whenever possible, it is 

usually best to accept the resulting defect, rather than attempt to repair it. If the 

I-48 
Chapter C: Causes of Damage to Concrete 

I-49 

 

 

deficiency cannot be accepted, complete removal and replacement is probably the 

best option. Occasionally, dimensional errors can be corrected by removing the 

defective concrete and replacing it with a thick concrete repair. 

Finishing defects usually involve overfinishing or adding water, cement, or other 

substances to the concrete surface during finishing procedures (figure 41). In 

each instance, the resulting surface can be porous, permeable, or have low 

durability 

Figure 40. An 

example of 

inadequately 

consolidated 

concrete that needs 

repair. 

Figure 41. The 

addition of water or 

other substances 

during finishing can 

lead to weakened 

and damaged 

concrete surfaces. 

Poorly finished surfaces can exhibit surface spalling early in their service life 

(figure 42). Repair of surface spalling involves removal of the weakened concrete 

and replacement using a packaged repair material (section D.2.f.) or replacement 
 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

concrete (section D.3.a.). If the deterioration is detected early, the service life 

of the surface may be extended by using concrete sealing compounds 

(sections D.1.a. through D.1.c.). The service life of sealing compounds for low 

quality concrete surfaces will likely be short. 

Finally, surface defects do not always indicate improper finishing. Other forms of 

deterioration can cause surface defects, including aggregate popouts, salt scaling 

(figure 43) and freeze-thaw damage. 

Figure 42. Surface 

damage appearing in new 

concrete caused by the 

addition of water during 

finishing. 

Figure 43. Salt scaling that resulted when water containing 

deicing salts froze on poor quality concrete surfaces. 

I-50 
Chapter C: Causes of Damage to Concrete 

 

 

 

 

4. Sulfate Deterioration
 

Sodium, magnesium, and calcium sulfates are salts commonly found in the alkali 

soils and groundwater in the Western United States. These sulfates react with the 

hydrated lime and hydrated aluminate in cement paste and form calcium sulfate 

and calcium sulfoaluminate. The volume of these reaction byproducts is greater 

than the volume of the cement paste from which they are formed, causing 

cracking of the hardened concrete. Once the cause of damage is confirmed, 

repairs must be performed using sulfate resisting materials, including using low 

permeable concrete (low water/cement and higher cement and fly ash contents), 

and incorporating a sulfate resisting cement (Type II and Type V), which have a 

low calcium aluminate content. Reclamation’s concrete guide specifications and 

ACI 318 provide guidance on selecting cement types and mixture proportions 

based on sulfate contents in the soil or groundwater. 

Concrete that is undergoing active deterioration and damage due to sulfate 

exposure can sometimes be maintained by applying a coating (section D.1.d.) or 

concrete sealing compounds (sections D.1.a. through D.1.c.). Alternate wetting 

and drying cycles can accelerate sulfate deterioration. Some slowing of the rate 

of deterioration can be accomplished by interrupting the cyclic wetting and 

drying. Procedures for eliminating or removing waterborne sulfates are also 

helpful if this is the source of the sulfates. Otherwise, the deteriorating concrete 

should be monitored and considered for removal and replacement with concrete 

proportioned using Type II or Type V cement, perhaps including a Class F 

fly ash, as appropriate. 

Sulfate attack can also manifest itself in different ways. An interesting example 

of sulfate attack occurred recently in a spillway in central Kansas. Concrete 

below the gallery drains was damaged and then repaired (figure 44). However, 

the repairs soon began to fail. Evaluation of cores taken from the site revealed 

that the damage was confined to the areas that were wet from the gallery drains, 

and it did not extend more than about 1 inch into the concrete. Subsequent water 

tests revealed that during hot summer months, the water exiting from the galleries, 

and then evaporating, had high sulfate contents, which resulted in sulfate attack. 

Once the cause of damage was determined, repairs could be made with concrete 

that contained sulfate resistant cement; in this case, a Type V cement. 

A rare form of sulfate attack occurred recently at a west-central Montana dam. 

Quality issues led to installation of poor quality backfill grout to support new 

stoplog guides. Due to the unique exposure conditions (circulation of water near 

the guides to prevent water freezing near the gates, the presence of calcium 

carbonate constituents in the reservoir water, and very cold water), the thaumasite 

form of sulfate attack occurred, leading to significant weakening of the backfill 

grout (figure 45) (Hurcomb, 2006). The deterioration occurred relatively quickly, 

over just a few years. With the cause of deterioration determined, proper repairs 

were made during replacement of the grout. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 44. Repairs that were damaged by sulfate attack. New repairs were 

performed using materials that are durable when exposed to sulfates. 

Figure 45. A 

cross section of 

backfill grout 

showing 

replacement of 

cement grout with 

thaumasite, a 

form of sulfate 

attack. 

5. Alkali-Aggregate Reaction 

Alkali aggregate reaction (AAR) is typically not a problem for concrete placed 

after about the early 1940s. For ASR (one form of AAR), alkalies in cement react 

with certain glassy, siliceous aggregates such as opals, chalcedony, cherts, 

andesites, basalts, and some quartz. The reaction products, in the presence of 

I-52 
Chapter C: Causes of Damage to Concrete 

 

 

water, have a swelling nature, leading to tensile stresses that cause cracking 

within the concrete. The cracking may allow moisture to be more readily 

absorbed by the silica gel, which further increases the swelling or allows or 

accelerates freeze-thaw damage. The problem was first observed early in 

Reclamation’s history, but it was not fully studied until the late 1930s, after the 

construction of Parker Dam. At that time, the steps identified to prevent 

ASR were to use petrographic techniques to identify those aggregates with the 

potential for reaction and to specify a 0.6-percent limit of sodium and potassium 

hydroxide alkalies in the cement. Reclamation instituted the low-alkali limit for 

concrete with potentially reactive aggregates in the early 1940s (Bureau of 

Reclamation, 1942). Unfortunately, there are still occasions when reactive 

aggregates are used in concrete construction, leading to ASR damage in concrete 

placed well after the 1940s. 

These reactions, although observed and studied for many years, still require 

additional research work to fully understand. Some concrete that contains alkali 

reactive aggregate shows immediate evidence of destructive expansion and 

deterioration. Other concrete might remain undisturbed for many years. 

Undoubtedly, both the exposure conditions and the type of aggregate involved 

play a role. There are no widely accepted methods to stop the reaction in existing 

concrete, although treatment with lithium compounds may help in some 

situations. In addition, although several methods have been evaluated to measure 

how much expansion may be left in a concrete structure, none have proven 

entirely satisfactory. 

Petrographic examination of reactive concrete shows that a gel is formed around 

the reactive aggregate. This gel undergoes extensive expansion in the presence of 

water or water vapor (a relative humidity of 80 to 85 percent is all the water 

required), creating tension cracks around the aggregate and expansion of the 

concrete (figure 46). If unconfined, the expansion within the concrete is first 

apparent by pattern cracking on the surface. Usually, some type of whitish 

deposit will be evident in and around the cracked concrete, although that can 

occur for other reasons as well. In extreme instances, these cracks can become 

very large (figure 47). It is common for such expansion to cause significant 

offsets in the concrete, as well as binding or seizure of control gates on dams. In 

large concrete structures, ASR may occur only in certain areas of the structure, 

usually because multiple aggregate or cement sources were commonly used to 

construct large concrete structures (Stark and DePuy, 1995). Only portions of the 

structure constructed with concrete containing alkali reactive sand and/or course 

aggregate will exhibit expansion due to ASR. In addition, alkalies may migrate 

through concrete due to moisture gradients. This can increase the concentration 

of alkalies near surfaces that are exposed to wetting and drying conditions. 

In new construction, low-alkali Portland cement and fly ash (pozzolan) can be 

used to mitigate ASR. In some cases, however, these methods may not be 

sufficient to stop it. If so, lithium-based admixtures may be used because they 

I-53 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

have proven to prevent expansion due to ASR. In addition, there are American 

Society for Testing and Materials (ASTM) procedures for detecting potentially 

reactive aggregates. Reclamation has developed language for its concrete 

specifications to help determine if aggregates are reactive and how to mitigate for 

reactive aggregates and/or high alkali cement if they must be used in concrete. 

Figure 46. Evidence of ASR provided by gel-filled cracks and 

reaction rims around some aggregate particles. 

Figure 47. Extensive cracking which can indicate ASR. 

I-54 
Chapter C: Causes of Damage to Concrete 

 

 

Although there are no widely applicable methods of eliminating the deterioration 

of alkali-aggregate reaction, the rate of expansion can sometimes be reduced by 

taking steps to maintain the concrete in a condition that is as dry as possible. Low 

viscosity epoxies and HMWM, when applied as a “healer-sealer,” can sometimes 

slow the rate of deterioration by lowering the moisture content of the concrete. 

Repairs to concrete undergoing ASR will likely be short lived. The continuing 

expansion within the concrete will simply disrupt and destroy the repair material. 

However, in some cases, making repairs that will likely be short lived may still be 

the best alternative. 

Structures undergoing active deterioration should be monitored for rate of 

expansion and movement, and the only repairs that should be made are those 

necessary to maintain safe operation of the facility. The binding gates of several 

dams have been relieved and returned to operation by using wire saws to make 

expansion relief cuts in the concrete on either side of the binding gates. The cuts 

were subsequently sealed to water leakage using polyurethane resin injection 

techniques (section D.4.a.). With continuing expansion of the concrete, relief cuts 

may have to be repeated several times. 

In some structures, the expansion and movement associated with ASR slow down 

and cease when all the alkali components are consumed. Once the expansion 

ceases, repairs can be performed to rehabilitate and restore the structure to full 

operation and serviceability. However, it should be anticipated that, ultimately, it 

may be necessary to replace structures that are undergoing alkali-aggregate 

deterioration. This was the case with the 1975 replacement of Reclamation's 

American Falls Dam in Idaho. It was constructed in 1927 and replaced after 

extensive studies conducted by Reclamation’s Denver concrete laboratories 

revealed that it had been severely damaged by ASR. 

Finally, even though ASR is typically associated with older structures, it can still 

occur in newer construction when improper concrete materials are used. For 

example, in the early 1970s, a new dam was constructed in Idaho. A review of 

construction documents indicated that some studies to determine the reactivity of 

the aggregates used standards that were available at the time. However, those 

studies either failed to show reactivity of the aggregates, or they were not done 

properly. When field crews began doing spall repairs in the early 2000s, they 

observed significant areas of deterioration (figure 48), which was determined to 

be from ASR. 

I-55 
 

 

	 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 48. Examining concrete deterioration in a structure built in the 1970s. It 

was later determined that the deterioration was caused by ASR. 

6.	 Deterioration Caused by Cyclic 

Freezing and Thawing Weather 

Freeze-thaw deterioration is a common cause of damage to concrete that was 

constructed in colder climates prior to the 1940s. All three of the following 

factors must be present for freeze-thaw damage to occur: 

 Cycles of freezing and thawing temperatures 

 Concrete that is saturated or nearly saturated with water 

 Concrete without an adequate air void system 

When all three factors are present, water in the concrete freezes and expands 

about 9 percent as it becomes ice. The expansion causes cracking and forces the 

concrete apart. During thawing, more water enters and fills the enlarged cracks 

and voids. In the next freezing cycle, the concrete is further damaged by water 

expanding into ice. 

For concrete that is not properly air entrained, if the pores and capillaries in 

concrete are saturated or nearly saturated during freezing, the expansion exerts 

tensile forces that fracture the cement mortar matrix. This deterioration usually 

occurs from the outer surfaces inward in almost a layering manner. However, the 

damage can also occur below the exposed concrete surface if the moisture 

I-56 
Chapter C: Causes of Damage to Concrete 

gradient and temperatures are such that the saturated zone of concrete is below 

the surface and freezes (figure 49). 

Figure 49. Freeze-thaw deterioration in a spillway slab 

occurring below the exposed surface, due to moisture and 

temperature gradients. 

The rate of progression of freeze-thaw deterioration depends on the number of 

cycles of freezing and thawing, the degree of saturation during freezing, the 

porosity of the concrete, and the exposure conditions. The tops of walls 

(figure 50) exposed to snowmelt or water spray, horizontal slabs exposed to 

water, and vertical walls at the water line are the locations most commonly 

damaged by freeze-thaw deterioration. If such concrete has a southern exposure, 

it may experience freezing during the night and thawing during the day, leading to 

many freezing and thawing cycles throughout the year. Conversely, concrete with 

a northern exposure may only experience one cycle of freezing and thawing each 

winter, a far less damaging condition. Figure 51 shows a typical example of 

freeze-thaw deterioration. 

Figure 50. The top of a 

spillway wall suffering 

damage from cycles of 

freezing and thawing 

weather. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 51. Another example of freeze-thaw deterioration. It is common for the 

damage to be more pronounced at joints because they will likely stay saturated 

longer. 

As discussed earlier in section B.1, another type of deterioration caused by cycles 

of freezing and thawing is damage to low quality, absorptive aggregates. If poor 

quality aggregates are used, they can absorb water, and then crack and deteriorate 

during freezing conditions. The damage typically becomes apparent at slab joints 

and joint corners, and the cracking pattern is typically referred to as D-cracking. 

A series of roughly parallel cracks exuding calcite usually cuts across the corners 

of such damage (figure 52). In some structures, the damage can be quite severe 

and require extensive repairs (section B.3; figures 10 and 12). 

In 1948, Reclamation began to widely specify the use of air entraining admixtures 

(AEA) to protect concrete from freeze-thaw damage. Concrete structures built 

prior to that date did not contain AEA. Angostura Dam, begun in 1946, was the 

first Reclamation dam constructed with specifications that required the use of 

AEA (Price, 1981). This type of admixture produces small air bubbles in the 

concrete matrix that provide space for water expansion during freezing. If the 

proper AEA, used at the correct concentration, is properly mixed into high quality 

concrete, there should be very little damage resulting from cyclic freezing and 

thawing, except in very severe climates or if poor quality absorptive aggregates 

were used. If freeze-thaw damage is suspected in modern concrete, investigations 

should be performed to determine if an AEA was used, or if it was not effective. 

Except in cases of extremely cold and wet exposure, modern concrete that 

exhibits freeze-thaw damage has most likely suffered low durability from some 

other cause (section C.13), or the AEA did not function properly. 

I-58 
 

 

 

 

I-59 

Chapter C: Causes of Damage to Concrete 

Figure 52. Example of D-cracking that resulted from freezing and thawing weather damage to 

absorptive aggregates. 

For concrete susceptible to damage from freezing and thawing weather, 

successful mitigation of deterioration involves either reducing or eliminating the 

cycles of freezing and thawing, or reducing the moisture content of the concrete. 

It usually is not practical to protect or insulate concrete from cycles of freezing 

and thawing temperatures, but concrete sealing compounds (sections D.1.a. 

through D.1.c.) can be applied to exposed concrete surfaces to prevent or reduce 

water absorption. The sealing compounds are not effective in protecting 

inundated concrete, but they can provide protection to concrete exposed to rain, 

windblown spray, or snowmelt. 

Repair of concrete damaged by freeze-thaw deterioration is most often 

accomplished with replacement concrete (section D.3.a.). The replacement 

concrete must contain an AEA. Making shallow repairs to concrete that has been 

damaged by freeze-thaw deterioration is usually not successful (figure 53). It is 

important that the repair be sufficiently thick to reduce or eliminate freezing and 

thawing cycles of the underlying concrete, or thick enough to reduce the water 

content of the remaining concrete. Otherwise, there is a possibility that the 

deterioration will continue in the remaining concrete, and the repair will debond 

in a relatively short time. In some cases, insufficiently thick repairs may 

accelerate the deterioration of the existing concrete. 
Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 53. Repairs that were not thick enough to prevent cycles 

of freezing and thawing weather from damaging the underlying 

concrete. 

Concrete that is exposed to moisture and cycles of freezing and thawing weather, 

including concrete that is air entrained, should not be encapsulated. 

Encapsulating or sealing all surfaces in such conditions can lead to rapid 

deterioration of the concrete (Emmons and Vaysburd, 1993). This situation 

occurred at a pumping plant in North Dakota, where the concrete parking deck 

had a geomembrane between concrete layers and watertight insulating panels that 

were glued to the underside of the deck. Significant freeze-thaw damage occurred 

in the layer of concrete between the geomembrane and the insulating panels 

(figure 54). 

7. Abrasion-Erosion Damage 

Concrete structures that transport water containing silt, sand, gravel, or rock, or 

water at high velocities, are subject to abrasion damage. Abrasion-erosion 

damage results from the grinding action of silt, sand, and rock. Some stilling 

basins experience abrasion damage when the flows do not sweep debris from the 

basin, and some can have turbulent flow patterns that cause downstream sand, 

gravel, and rock to be pulled upstream into the basins. This material can be 

retained in the basin, where it produces significant damage during periods of high 

flow (figure 55). With larger particles, the damage can be extensive. 

I-60 
Chapter C: Causes of Damage to Concrete 

Figure 54. Top: Insulating panel and concrete debris 

on the pumping plant floor. Bottom: Original location 

of the panel in the ceiling below the parking deck. 

Concrete surfaces damaged by smaller particles usually have a polished 

appearance (figure 56). The coarse aggregate is often exposed and somewhat 

polished due to the action of the silt and sand on the cement mortar matrix. The 

extent of abrasion-erosion damage is a function of many variables—duration of 

exposure, shape of the concrete surfaces, flow velocity and pattern, flow 

direction, and aggregate loading— so it is difficult to develop general theories to 

predict concrete performance under these conditions. Consequently, hydraulic 

model studies are often required to define the flow conditions and patterns that 

exist in damaged basins and to evaluate required modifications. If the conditions 

that caused abrasion-erosion damage are not addressed, repairs will also be 

damaged. Using high-strength repair materials will lessen the damage. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 55. Abrasion-erosion damage to concrete. 

It is generally understood that high quality concrete is far more resistant to 

abrasion damage than low quality concrete, and a number of studies (Smoak, 

1991) clearly indicate that the resistance of concrete increases as the compressive 

strength of the concrete increases. 

I-62 
 

Chapter C: Causes of Damage to Concrete 

Figure 56. Abrasion-erosion damage from flowing 

water with small abrasive particles showing a polished 

surface. 

Abrasion-erosion damage is best repaired with silica fume concrete 

(section D.3.d.) or polymer concrete (section D.2.d.). These materials have 

shown the highest resistance to abrasion damage in laboratory and field tests. 

Figure 57 shows the placement of silica fume concrete to repair an area of 

abrasion-erosion damage to a spillway located in central Colorado. For this 

repair, concrete was removed using hydrodemolition. 

Using silica fume concrete repairs for abrasion erosion damage at remote sites can 

be problematic, due to the specialized materials and long haul times. Two recent 

jobs (Bureau of Reclamation, 2006) (Bureau of Reclamation, 2009), overcame 

this issue by using shotcrete-type mixtures supplied in super sacks. All the dry 

ingredients were delivered to the jobsite in super sacks. A transit mixer was used 

to mix the dry ingredients from the super sacks with water and additional 

admixtures (figure 58). Using this method resulted in high-strength concrete that 

worked well for these jobs. 

I-63 
Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 57. Placing silica fume concrete in a stilling basin in central 

Colorado to repair abrasion-erosion damage. 

Figure 58. High-strength silica fume concrete materials were delivered in 

3,000-pound sacks and mixed onsite with water and liquid admixtures. 

I-64 
Chapter C: Causes of Damage to Concrete 

8. Cavitation Damage
 

Cavitation damage occurs when high velocity waterflows encounter rough areas 

on the flow surface. A standard rule of thumb is that cavitation damage will not 

occur at flow velocities less than about 40 feet per second (ft/s) at ambient 

pressures. 

At higher velocities, roughness in the flow path may cause the water to lift off of 

the flow surface and create negative pressure zones that result in bubbles of water 

vapor. These bubbles travel downstream and collapse. If the bubbles collapse 

against a concrete surface, a zone of very high-pressure impact occurs over a 

small area of the surface. Such high impacts can remove particles of concrete, 

forming more rough areas, which then can create more extensive cavitation 

damage. Figure 59 shows the classic “Christmas tree” pattern of cavitation 

damage that occurred in a large concrete-lined tunnel at Glen Canyon Dam during 

flood releases in 1983. In that instance, cavitation damage extended entirely 

through the concrete tunnel lining and 40 feet into foundation rock (figure 60). 

Figure 59. 

Typical pattern 

for cavitation 

damage in a 

spillway tunnel. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 60. Cavitation damage can be very extensive, as 

shown here, where the damage extended deep into 

foundation material. 

Figure 61 shows an early stage of erosion from abrasion damage to a stilling basin 

wall. Due to the turbulence over the step at certain flow conditions, flow 

velocities can be high enough to lead to cavitation. Cavitation damage is also 

common on and around water control gates and gate frames. Very high velocity 

flows occur when control gates are first being opened, or as they close, and at 

small gate openings. These flows can cause cavitation damage just downstream 

from the gates or gate frames. 

Laboratories of Reclamation, the USACE, and others have tested the cavitation 

resistance of many different repair materials; however, to date, no material, 

including stainless steel and cast iron, has been found capable of withstanding 

fully developed instances of cavitation. Successful repairs must first include 

mediation of the causes of cavitation. 

I-66 
 

 

 

 

 

 

Chapter C: Causes of Damage to Concrete 

Figure 61. The 

early stages of 

concrete erosion 

from ebrasion and 

possible 

cavitation. 

Subsequent 

damage may lead 

to further 

cavitation 

damage. 

As flow velocities approach the 40-ft/s threshold, it becomes necessary to ensure 

that there are no offsets or discontinuities on the surfaces in the flow path. Actual 

acceptable roughness and offsets will depend on actual flow conditions, and 

specialists may need to be consulted. Reclamation's specifications require very 

tight tolerances for finishing surfaces of concrete structures that will experience 

high velocity flows. Repairs to newly constructed concrete that fail to meet these 

requirements can sometimes be accomplished by surface grinding 

(section D.2.a.). More likely, however, concrete that does not meet surface 

specifications must be removed and replaced with replacement concrete 

(section D.3.a.). 

In many cases, cavitation damage at, or adjacent to, control gates can be repaired 

with polymer concrete or epoxy mortar (section D.2.d.) depending on exposure 

conditions, packaged cementitious and chemical repair mortars (section D.2.f.), or 

replacement concrete (section D.3.a.). Fortunately, such damage is usually not 

very extensive in nature. 

However, depending on the nature of the damage, great consideration must be 

given to how to perform the repairs. For example, in cases of shallow damage 

(less than 1-1⁄2 inches deep), and where polymer concrete (section D.2.d.) may not 

be effective, it may not be advisable to remove sound concrete material to achieve 

a minimum repair thickness of 1-1⁄2 inches. For these cases, using a thin, 

packaged cementitious or chemical repair mortar (section D.2.f.) may be 

warranted. Reclamation has not had consistent performance with these types of 

materials, so they must be carefully considered. A program to evaluate thin repair 

materials for use at Yellowtail Dam Spillway Tunnel was conducted to select a 

repair material that would have the best chance of being successful, given the 

difficult placement and harsh exposure conditions (von Fay K., 2009). 

Fortunately, cavitation damage is usually discovered before major repairs become 

necessary. Repairs in areas of this type should be monitored because the damage 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

mechanism can occur frequently if the underlying cause of damage is not 

addressed. If epoxy mortar or polymer concrete is used for repairs, the repairs 

should be inspected frequently, because these types of materials may become 

unbonded over time due to thermal property incompatibilities with the underlying 

concrete. After performing such repairs, it may help to apply a 100-percent solids 

epoxy coating (section D.1.d.) to the concrete around the repair to make the 

surface very smooth. The glass-like surfaces of epoxy coatings may help prevent 

cavitation damage to the concrete. It should be understood, however, that epoxy 

coatings will not resist fully developed instances of cavitation damage. In 

addition, these coatings have a limited service life, so they should be routinely 

inspected. 

Successful repair of cavitation damage to spillway, outlet works, or stilling basin 

concrete almost always requires making major modifications to the damaged 

structure to prevent recurrence of damage. Changes in operating procedures can 

also have a significant impact on the occurrence of cavitation. Consideration 

should be given to conducting hydraulic model studies to ensure the correctness 

of the design of such repairs and facility modification and/or changes in operating 

procedures. One modification technique, the installation of air slots in spillways 

and tunnels, has been very successful in eliminating or significantly reducing 

cavitation damage. Replacement concrete is usually used for construction of such 

features and the repair of the cavitation damaged concrete. 

9. Corrosion of Reinforcing Steel 

Corrosion of reinforcing steel can be either a cause, or a symptom, of damaged 

concrete. In other words, the concrete could be cracked from some other damage 

mechanism, which then allows steel corrosion to occur. 

The alkalinity of Portland cement (pH of about 12) used in concrete normally 

creates a passivation layer around the reinforcing steel, which protects it from 

corrosion. When that layer is lost or destroyed, or when the concrete is cracked or 

delaminated sufficiently to allow free entrance of water and air, corrosion can 

occur. The passivation can be lost by intrusion of chloride ions from deicing salts 

or carbonation of the concrete. Carbonation is a natural process where 

atmospheric carbon dioxide reacts with compounds in the concrete to form 

calcium carbonate. The process lowers the pH of the concrete, and once it gets 

down to a pH of about 9, the protective passivation can be lost, allowing for 

corrosion. The iron oxides formed during steel corrosion require more space in 

the concrete than the original reinforcing steel. This creates tensile stresses within 

the concrete and results in additional cracking and/or delamination, which can 

accelerate the corrosion process. 

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Chapter C: Causes of Damage to Concrete 

 

 

For Reclamation, some of the more common forms of deterioration that can lead 

to corrosion of reinforcing steel are cracking associated with freeze-thaw 

deterioration, sulfate exposure, alkali-silica reaction, acid exposure, and loss of 

alkalinity due to carbonation (usually from insufficient cover, as discussed 

above). 

In addition, exposure to chlorides can lead to corrosion. Chlorides change the 

passivation layer and greatly accelerate the rate of corrosion. Exposure to 

chlorides can occur from a number of sources and in several ways. The 

application of deicing salts (sodium or magnesium chloride) to concrete to 

accelerate thawing of snow and ice is a common source of chlorides. Chlorides 

can also be present in the sand, aggregate, and mixing water used to prepare 

concrete mixtures. Some irrigation structures located in the Western States 

transport waters that have high chloride content (figure 62). Concrete structures 

located in marine environments experience chloride exposure from the sea water 

or from windblown spray. Finally, it was once a somewhat common practice to 

use concrete admixtures containing chlorides to accelerate the hydration of 

cement in concrete placed during cold weather conditions. 

Figure 62. High chlorides in water, leading to corrosion of reinforcing steel. 

The occurrence of corroding reinforcing steel can usually, but not always, be 

detected by the presence of rust stains on the exterior surfaces and by the hollow 

or drummy sounds from tapping the affected concrete with a hammer. It can also 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

be detected by measuring the half cell potentials of the affected concrete using 

special electronic devices manufactured specifically for this purpose. When the 

presence of corroding steel has been confirmed, it is important to define what 

actually caused the corrosion because the cause(s) of corrosion will usually 

determine which repair procedure should be used. Further discussion of such 

repair procedures can be found elsewhere in this Guide. Once the cause of 

corrosion damage has been defined and mitigated, proper preparation of the 

corroded steel exposed during removal of the deteriorated concrete becomes 

important. See the discussion under Reinforcing Steel Preparation for guidelines. 

Corroded reinforcing steel may extend from areas of obviously deteriorated 

concrete well into areas of apparently sound concrete. Care must be taken to 

remove sufficient concrete to include all the corroded steel. 

10. Acid Exposure 

The more common sources of acidic exposure involving concrete structures occur 

in the vicinity of underground mines. Drainage waters exiting from such mines 

can contain acids of sometimes surprisingly low pH value. A pH value of 7 is 

defined as neutral. Values higher than 7 are defined as basic, while pH values 

lower than 7 are acidic. A 15- to 20-percent solution of sulfuric acid will have a 

pH value of about 1. Such a solution will damage concrete very rapidly. Acidic 

waters having pH values of 5 to 6 will also damage concrete, but only after long 

exposure. 

It is very easy to detect concrete that has been damaged by acids. The acid 

reacts with the Portland cement mortar matrix of concrete and converts the 

cement into calcium salts that slough off or are washed away by flowing waters. 

The coarse aggregate is usually undamaged but left exposed. The appearance of 

acid-damaged concrete is somewhat like that of abrasion damage, but the 

exposure of the coarse aggregate is more pronounced and does not appear 

polished. Figure 63 shows the typical appearance of concrete that has been 

damaged by acid exposure. Acid damage begins, and is most pronounced, on the 

exposed surface of concrete, but it can extend into the concrete past the surface. 

The acid is most concentrated at the surface. As it sits on the concrete surface or 

penetrates into it, the acid is neutralized by reaction with the paste. If the acid is 

in flowing water, the damage can progress quickly as the damaged materials are 

washed away and fresh acid is exposed to the concrete. Preparation of aciddamaged concrete, therefore, may involve removal of more concrete than would 

otherwise be expected. Failure to remove all the concrete affected and weakened 

by the acid will result in bond failure of the repair material. 

As with all causes of damage to concrete, it is generally necessary to remove the 

source of damage prior to repair. The most common technique used with acid 

damage is to dilute the acid with water. Low pH acid solutions can be converted 

to higher pH solutions having far less potential for damage in this manner. 

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Chapter C: Causes of Damage to Concrete 

 

Alternately, if the pH of the acid solution is relatively high, coatings can be 

applied over repair materials to prevent the acid from redamaging the surfaces. 

Laboratory tests have revealed very few economical coatings that are capable of 

protecting repair materials from low pH solutions. 

Figure 63. Examples of acid exposure on concrete. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Repairs to acid-damaged concrete can be made using replacement concrete 

(section D.3.a.), and polymer concrete (section D.2.d.). Polymer concrete and 

epoxy mortar, which do not contain Portland cement, offer the most resistance to 

acid exposure conditions. In addition, there are non-Portland cement based repair 

mortars (section D.2.f.) that can be proportioned to make them acid resistant. 

Acid washes were once permitted as a method of cleaning concrete surfaces in 

preparation for repairs. Reclamation has learned, however, that bond failures 

would occur unless extensive efforts were made to remove all traces of acid from 

the concrete. Reclamation specifications no longer permit the use of acid washes 

to prepare concrete for repair or to clean cracks subject to resin injection repairs. 

Finally, it should be mentioned that damage from pure water can look like acid 

attack. This type of damage usually occurs at higher elevations where the water is 

very pure. The pure water has a high affinity for minerals in the concrete and can 

dissolve concrete surfaces with which it comes in contact. 

11. Cracking 

There are many types of cracks in concrete. Figure 64 (Concrete Society, 1992) 

shows many of them. While cracking is sometimes a cause of damage, it is 

usually a result of some type of deterioration mechanism or damage. Many times, 

once the concrete has cracked, other forms of deterioration can occur or 

accelerate. 

As discussed earlier, ASR, freeze-thaw, and sulfate attack can cause cracking. 

Improperly proportioned or placed concrete can settle around the reinforcing steel 

as it cures, resulting in plastic settlement cracks (figure 65). 

All Portland cement concrete undergoes some degree of shrinkage during 

hydration and curing. This shrinkage can be comprised of several components, 

including thermal shrinkage, plastic shrinkage, drying shrinkage, and autogenous 

shrinkage. Many concrete practitioners believe that reinforcing steel will prevent 

shrinkage and thermal cracking. However, the steel will not entirely prevent 

cracking, although it will certainly influence cracking size and location. Drying 

shrinkage is best known because of its prevalence and negative effects on 

durability as a result of the numerous cracks it can produce (figure 66). In the 

case of drying shrinkage, water is usually lost by evaporation after the concrete 

hardens. The loss can also occur when underlying dry concrete or soil dries the 

concrete. In some cases, depending on exposure conditions, drying shrinkage 

cracks can be small (crazing) and may not need repair. 

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Chapter C: Causes of Damage to Concrete 

I-73
 

Figure 64. There are many types of cracks that can affect concrete structures. 
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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 65. Plastic settlement cracking. 

Plastic shrinkage cracking occurs 

when the fresh concrete is 

exposed to conditions that result 

in high rates of evaporation from 

the concrete surface (wind, 

moderate to high temperatures, 

and low humidity). The resultant 

shrinkage, due to the water loss, 

causes cracking while the concrete 

is still plastic (figure 67). Plastic 

shrinkage cracks can be deeper 

than drying shrinkage cracks. 

They typically exhibit numerous 

short cracks that are parallel to 

each other and can lead to 

accelerated deterioration. In some 

conditions, plastic shrinkage 

cracking can be repaired during 

finishing operations by working 

the fresh concrete until the cracks 

close. This should be done 

without adding water to the 

concrete surface. 

Thermal cracking can result 

from excessive concrete heating 

during curing and subsequent 

rapid cooling, or by the normal 

expansion and contraction of 

concrete during changes in 

ambient temperature if joints are 

not properly placed. Concrete 

has a linear coefficient of 

thermal expansion of about 

5.5 millionths inch per inch per 

degree Fahrenheit (°F). This 

can cause concrete to undergo 

length changes of about 0.5 inch 

per 100 linear feet for an 80 °F 

temperature change. If joints to 

accommodate this length change 

are not provided in the design, 

the concrete will simply crack 

 cracking will normally extend 

ce of leakage in water retaining 

rom heat generation during curing 

Figure 66. Excessive drying 

shrinkage cracking due to loss of 

water from the concrete after 

hardening. 

and provide joints where needed. This type of

entirely through the member and create a sour

structures. Thermal cracking can also result f
Chapter C: Causes of Damage to Concrete 

 

 

 

and subsequent cooling. During curing, the cement hydrates and generates heat. 

The concrete can harden while at elevated temperatures, and subsequent 

contraction of exposed surfaces upon rapid cooling can lead to internal tensile 

stresses and cracking. 

Figure 67. Plastic 

shrinkage cracking 

in concrete placed in 

hot, dry weather. 

Inadequate foundation support is another common cause of cracking in concrete 

structures. The tensile strength of concrete is usually only about 200 to 400 psi. 

Foundation settlement can easily create displacement conditions where the tensile 

strength of concrete is exceeded, leading to cracking (figure 68). 

Because of the challenges related to repairing cracks, monitoring crack movement 

prior to attempting repair (figure 69) is usually justified. Traditional methods to 

monitor movements involved the use of manual or electronic gauges. Newer 

technology can capture very accurate movement data using digital images from 

cameras or smart phones (figure 70), as well as special photogrammetric software. 

To use this method, digital images of the joint or crack need to be captured 

periodically (Klein, 2014). 

Movement should be monitored for extended periods of time to determine if the 

cracks are simply opening and closing as a result of daily or seasonal temperature 

changes, or if there is a continued or progressive widening of the cracks resulting 

from foundation or load conditions. Repairs should be attempted only after the 

cause and behavior of the cracking are understood. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 68. Foundation settlement in this water treatment plant caused 

cracking in one of the water bays. 

Figure 69. A dial gauge used to monitor crack movement. 

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I-77Figure 70. Photogrammetric techniques can be used to measure movement of cracks and joints by using dat

photographs. 
 

 

 

 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

The role of concrete cracking related to corrosion of rebar is not always 

clear. Studies have shown that cracks less than approximately 0.3 millimeter 

(0.012 inch) wide have little influence on the corrosion of reinforcing steel 

(Atimay and Ferguson, 1974). However, other research (Darwin et al., 1985) 

(Oesterle, 1997) has shown that corrosion is not clearly correlated with surface 

crack widths, perhaps because there is poor correlation between surface crack 

openings and crack widths near rebar. ACI 222R-01 (ACI 222R-01, 2010) states, 

“Cracks that follow the line of a reinforcing bar (as might be the case with a

settlement crack) are much more damaging because the corroded length of the bar 

is greater and the resistance of the concrete to spalling is reduced.” ACI 318 

(ACI 318, 2013) states that although a number of studies have been conducted, 

clear experimental evidence is not available to show how wide a crack can 

become before corrosion danger exists. Exposure tests indicate that concrete 

quality, adequate consolidation, and proper concrete cover may be of greater 

importance for corrosion protection than crack width at the concrete surface. 

Other investigations show no relationship between crack width and corrosion 

(Beeby, 1978a) (Tremper, 1947) (Martin and Schiessel, 1969) (Raphael and 

Shalon, 1971). One study (Beeby, 1978b) showed that closely spaced cracks can 

actually cause greater corrosion rates than with more widely spaced, wider cracks. 

A detailed discussion relating to cracking is available in ACI 224 (ACI 224, 

2013). 

It is often very difficult to attain successful repair of cracks. The type of repair 

that is required depends, to a great extent, on the type and nature of the cracks. 

For many crack repairs, it is necessary to determine if the cracks are “live” or

“static.” If the cracks are cyclically opening and closing, or progressively

widening, structural repair becomes very complicated and may require adding 

reinforcement to correct. If the cracks are moving or changing, there are several 

nonstructural repair options. It is better to leave most types of concrete cracking 

unrepaired than to perform inadequate or improper repairs (figures 71 and 72). 

The selection of methods for repairing cracked concrete depends on the cause of 

the cracking. If improper methods are used, cracks will usually reoccur in the 

repair material or adjacent concrete, and it may make the initial damage worse. 

For some cracks, epoxy or polyurethane resin injection (section D.4.a.) can be 

used. Epoxy resin would typically be used to structurally rebond the concrete. If 

the objective of the repair is to seal water leakage, rather than to accomplish 

structural rebonding, the cracks or joints can be injected with polyurethane or 

similar resins. Epoxy resin injection can sometimes be used to seal low volume 

water leakage, while structurally rebonding cracked concrete members. Epoxy 

resins cure to form hard, brittle materials that will not withstand movement of the 

injected cracks. Polyurethane resins cure to a flexible, low tensile strength, closed 

cell foam that is effective in sealing water leakage; however, it cannot normally 

be used for structural rebonding. These flexible foams can experience 300- to 

400-percent elongation, due to crack movement. Some two component 

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Chapter C: Causes of Damage to Concrete 

 

polyurethane resin systems cure to form flexible solids that may be useful for 

structural rebonding. For more detailed information, see MERL 2013-58, Guide 

to Chemical Grouting of Joints and Cracks in Concrete (Joy, 2013). 

Figure 71. An example of improper crack repair, resulting in an unsightly 

appearance. 

Figure 72. Improperly repairing cracks often makes the repair very short lived. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

For other cracks, surface sealing and coatings may be appropriate (section D.1). 

These methods are typically used when numerous smaller cracks exist that would 

be difficult to repair using injection methods. 

Many times, damaged concrete can contain cracks that are not related to the 

primary cause of damage (section C.13). If the depth of removal of the damaged 

or deteriorated concrete does not extend below the depth and extent of the 

existing cracks, then the existing crack will likely reflect into and through the new 

repair materials. Reflective cracking is common in bonded overlay repairs to 

bridge decks, spillways, and canal linings (figure 73). If reflective cracking is 

intolerable, special steps must be taken, which may include preventing bond in 

the area of the crack, adding additional reinforcement in the repair material over 

the crack, or creating additional joints in the repair material to match the existing 

cracks. As a last resort, it may be appropriate to let the reflective cracking occur, 

then repair the cracks. 

Figure 73. Reflective 

cracking from cracks 

below the concrete 

overlay. 

Finally, restrained shrinkage cracking of concrete repair materials is a common 

problem with overlays and patches. The term restrained shrinkage comes from 

the fact that the repair material is restrained from shrinking by the bond to the 

underlying concrete. Restraint from bond development can occur faster than the 

increase in tensile strength of the repair material. As a result, as the repair 

material cures and shrinks, it is likely to crack much more than if it was 

unrestrained. Many times, these cracks are small and may not significantly 

impact the life of the repair. In other cases, the cracks can potentially shorten the 

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Chapter C: Causes of Damage to Concrete 

 

 

repair service life. In almost all cases, they are unsightly and may raise concern 

about the durability of the repairs. The only way to reduce or prevent them is to 

use low shrinkage repair materials, usually proportioned with shrinkage reducing 

additives (von Fay K., 2011). A USACE study to develop performance criteria 

for concrete repair materials proposed the classification listed below for drying 

shrinkage (figure 74) (Emmons and Vaysburd, 1995). Using low to very low 

magnitude shrinkage materials should always be a high priority. 

Magnitude 

(%) Classification 

< 0.025 Very low 

0.025 to 0.05 Low 

0.05 to 0.10 Moderate 

> 0.10 High 

Figure 74. Classification system for drying 

shrinkage values. 

12. Structural Overloads 

Concrete damage caused by structural overloading is usually very obvious and 

easy to detect. Frequently, the event causing the overload is known and is a 

matter of record (figure 75). The stresses created by overloads result in 

distinctive patterns of cracking that indicate the source and cause of excessive 

loading and the point(s) of loading. Normally, structural overloads are one-time 

events and, once defined, the resulting damage can be repaired with the 

expectation that the cause of the damage will not reoccur to create damage in the 

repaired concrete. 

Usually, the assistance of a knowledgeable structural engineer will be required to 

perform the analysis needed to fully define and evaluate the full consequences of 

most structural overloads, as well as to assist in determining the extent of repair 

required. This analysis should include determination of the loads the structure 

was designed to carry and the extent to which the overload exceeded design 

capacity. A thorough inspection of the damaged concrete should be performed to 

determine the entire effect of the overload on the structure. The inspection should 

also look for any secondary damage that might have occurred. Care should be 

taken to ensure that some other cause of damage did not first weaken the concrete 

and make it incapable of carrying the design loads. If the overload caused 

yielding of the reinforcing steel, the steel will most likely need to be replaced. 

Thus, the need for repair and/or replacement of damaged reinforcing steel should 

be anticipated and included in the repair procedures. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

I-82 

Figure 75. Structural damage from a collapsed roadway that impacted a pier of a 

siphon. The road was undercut by flooding and then collapsed against the pier. 

Structural analysis indicated that the reinforcing steel was not yielded, so epoxy 

injection was used to repair the pier. 
Chapter C: Causes of Damage to Concrete 

13. Multiple Causes of Damage
 

Multiple causes of damage should be suspected whenever damage or deterioration 

is discovered. It is fairly common to see multiple damage mechanisms with 

Reclamation’s older structures.

Modern concrete (concrete constructed since about 1950) has the benefit of 

various admixtures and advanced concrete materials technology, and it should not 

be damaged by many of the causes listed in this section. If deterioration or 

damage has occurred, it is likely that modern practices were not followed during 

material selection, mixture proportioning, placement, or curing (figure 76). 

Figure 76. Core from concrete placed in the 1960s. It has been damaged by 

alkali-silica reaction and freezing and thawing weather. Reactive aggregates were 

used in the concrete mixture. 

Failure to recognize and mitigate all of the causes of damage will most likely 

result in poor repair serviceability. Figure 77 shows the results of multiple causes 

of damage (note the repair overlay that is also cracking). This concrete is 

suffering from AAR cracking that has also accelerated freeze-thaw deterioration 

of the surface. It is also being damaged by faulty design or construction 

techniques that located the electrical conduits too close to the exterior surface of 

the concrete and a walkway post spanning a joint. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 77. An example 

of multiple causes of 

damage. In this case, 

ASR, freeze-thaw, and 

conduits are too close to 

the surface of the 

concrete. 

The proper use of air-entraining admixtures in modern concrete has greatly 

increased the resistance of concrete to freeze-thaw deterioration. However, 

freeze-thaw deterioration is often still blamed as the cause of damage to 

modern concrete. There are many factors that can interfere with the ability of 

air-entraining admixtures to properly protect the concrete. Mix records and 

aggregate quality test results may indicate that the concrete was poorly 

proportioned or that the available aggregate was of low quality. Construction 

inspection records may indicate that placing and finishing techniques were 

inadequate. Petrographic examination of the affected concrete may reveal that 

alkali-silica reaction, sulfate exposure, or steel corrosion have weakened the 

concrete and allowed freeze-thaw damage to occur. These findings might indicate 

that the problem is far more extensive than first thought, and that it requires more 

extensive preventative or corrective action than simple replacement of the 

deteriorated concrete. The use of excessive mix water, improper cement type, 

poor construction practices, improper mixture proportioning, dirty or low quality 

aggregate, and inadequate curing all contribute to low durability concrete. 

I-84 
Chapter C: Causes of Damage to Concrete 

 

Selection of the proper methods and materials for repair of concrete damaged by 

multiple causes depends on determining the primary and secondary (and perhaps 

other) deterioration mechanisms. Once the primary cause is fully understood, it is 

usually necessary to take preventative measures to protect the remaining original 

concrete from additional damage. The application of concrete sealing and coating 

compounds (section D.1) may prove useful. If no preventative measures are 

judged useable, repair of the damaged concrete can be made as discussed in 

previous sections; however, a short repair service life and the need for additional 

future repairs should be anticipated. 

I-85 

 

 

 

	 

	 


 

	 

	 

	 

	 

	 

	 

	 

D. Standard Methods of 

Concrete Repair 

This chapter describes standard methods of repairing and maintaining concrete. 

Generally, repairs can be thought of in four broad categories: 

	 Sealers and coatings, which can be used to protect concrete and to repair 

surface damage and small cracks (used frequently for maintenance) 

	 Thin repairs, which are less than about 2 inches thick and do not 

encompass any reinforcing steel
 

	 Thick repairs, which typically extend behind at least one mat of 

reinforcing steel or are at least 6 inches thick 

	 Crack and water leak repairs 

Thinking of repairs this way can be advantageous because it helps with the 

selection of an appropriate repair material and method. There will also be cases 

when there is an overlap between what would be considered a thin or thick repair 

in some applications (for example, when a polymer concrete [PC] repair, 

generally considered a thin repair, is made that encompasses rebar). In some 

repair applications, a combination of methods will be needed. For example, if 

there are cracks leaking water into a repair cavity, the cracks may need to be 

sealed using one of the crack sealing methods before the cavity is repaired. 

Lastly, shrinkage of repair mortars and concrete can be a significant issue for 

these materials (Vaysburd et al., 2014). Shrinkage can lead to cracking, which 

may reduce durability and weaken bond strength. As stated earlier, steps should 

be taken to select and/or proportion repair mortars that are as low shrinkage as 

possible (figure 74). 

This chapter contains detailed discussions of each of the standard repair methods. 

Detailed guide specifications are contained in the latest revision of Reclamation's 

Guide to Concrete Repair, Part II - Standard Specifications for Repair and 

Maintenance of Concrete, M-47 for: 

	 Concrete removal, including hydrodemolition 

	 Concrete repair, including small and large repairs 

	 Concrete surface repair using polymer concrete (including epoxy mortar) 

	 Crack repair using epoxy injection 

	 Chemical grout to seal leaks 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

 Concrete crack healer and penetrating sealer 

 Coating concrete 

Specifications for concrete used for replacement concrete, shotcrete, silica fume 

concrete, and other forms of concrete that might be used for repair (for example, 

self-consolidating concrete) are covered in Reclamation’s concrete and shotcrete 

guide specifications, which are also included in Part II. In addition, while 

preplaced aggregate concrete is a very effective repair method, it has rarely been 

used by Reclamation, especially over the last 20 years. If a repair using preplaced 

aggregate concrete is being considered, please contact staff in the Concrete, 

Geotechnical, and Structural Laboratory (CGSL) for assistance. 

The provisions contained in this Guide should be closely followed during repair 

of Reclamation concrete. However, these “standard” methods and specifications 

may not apply to unusual concrete repair jobs. Assistance with unusual repair 

problems can be obtained by contacting CGSL personnel. In addition, all of the 

methods and materials discussed here have specific safety requirements for proper 

use. The user should always ensure that all appropriate safety protocols are 

followed. 

1. Sealers and Coatings 

Concrete sealing and coating compounds are applied to cured, dry concrete as a 

maintenance and repair procedure to reduce or prevent penetration of water, 

aggressive solutions, or gaseous media. They help to reduce or prevent associated 

deterioration such as corrosion of rebar, freeze-thaw, carbonation, or sulfate 

damage. These materials are not suitable for repairing badly damaged or 

deteriorated concrete, but they are suitable for sealing concrete surfaces and 

cracks in concrete that is in overall good condition. In many cases, small areas of 

damaged and deteriorated concrete can be repaired prior to application of one of 

these products. Linseed oil based treatment, which was generally misunderstood 

and often misused, is no longer recommended for use on Reclamation concrete. 

Cracks in concrete are widely regarded as a long-term durability and maintenance 

problem because they increase the permeability of the concrete. Cracks can allow 

ingress of moisture and other compounds into concrete, leading to further 

deterioration. Cracking is a problem that occurs in most geographical locations 

and climates, and in many types of concrete structures. Reclamation has a large 

inventory of aging concrete that is experiencing deterioration resulting in cracking 

or exacerbated by cracking. Effective sealing and coating compounds for smaller 

cracks could slow or halt deterioration in some cases. 

A variety of different membrane forming (paints or coatings) and surface 

penetrating chemicals are manufactured and sold as sealing compounds for 

concrete surfaces. Some of these materials provide very good protection to the 

I-88 
Chapter D: Standard Methods of Concrete Repair 

 

 

concrete for discrete periods of time (ACI 515, 2013). Other commercially 

available sealing materials, however, may consist of little more than mineral 

spirits and linseed oil. Such systems will, at best, do little harm to the concrete. 

Their application may, however, prevent subsequent treatment with sealing 

compounds that have proven more effective. For this reason, only products that 

have been proven effective in standardized laboratory evaluations should be used 

on Reclamation concrete. 

There are three basic categories of protective surface treatment that can be 

performed on concrete. These treatment methods include: 

(1) The concrete surface can be treated with a coating that essentially covers 

the surface. These surface treatments are typically polymeric materials 

such as epoxy, polyurethane or polyurea. 

(2) The concrete surface can be protected by low viscosity crack sealers, 

which can fill surface voids and cracks. They can be applied by flooding 

the surface, spraying onto surfaces, or placing into cracks (figure 78). 

These surface treatments are typically low viscosity epoxies, high 

molecular weight methacrylates (HMWM), and urethanes. These products 

have been successfully used on cracks as small as 0.002 inch, by gravity 

feed, and as large as about 0.5 inch wide, as long as they are clean and dry. 

For large cracks, it may be possible to prefill the cracks with a gap-graded, 

clean, high quality sand. Best results are obtained when cracks are treated 

as soon as possible after they form. These products can also glue fine 

cracks together. If crack penetration is the primary goal, cracks will be 

more open during cooler seasons or during cooler parts of the day. Of 

course, this has to be balanced against the ambient and surface 

temperature requirements of the product being used. The viscosity of 

these products can change significantly with changing temperatures, 

becoming much thicker (higher viscosity) at lower temperatures. 

(3) The concrete surface can be treated with surface sealers. Surface sealers 

saturate the concrete surface with a penetrating water repellant compound 

that leaves the pores and cracks open, but repels water on the treated 

concrete surface. These products do not rebond cracks. For small cracks, 

about 0.002 inch or smaller, these materials can seal cracks, if they are 

clean and dry. Two types of surface sealing treatments are frequently used 

in the concrete industry. One type is a silane or siloxane based water 

repellant (both are based on silicon technology). The other type is a 

sodium silicate solution. Both types of sealing treatments penetrate 

concrete pores and cracks, and react with hydrated cement particles. 

Silanes or siloxanes react to form a hydrophobic lining of the pores. The 

sodium silicates react to fill the pores and cracks with reactant products, 

and they function more as pore blockers. The effectiveness of these 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

silicates has been hard to quantify and, in some cases, the reaction may be 

damaging to concrete (Al-Otoom et al., 2007). 

Figure 78. A low viscosity epoxy resin was poured into plastic shrinkage 

cracks. Although unsightly, the resin was effective in filling and sealing the 

cracks. 

There are several concrete sealing technologies that would be effective for 

reducing water infiltration on Reclamation’s structures. Depending on exposure

conditions and anticipated use, silanes, siloxanes, HMWM, and low viscosity 

epoxies can be effective. For applications using silanes, the newer formulations 

of gels and creams seem to be the most effective at achieving deeper penetration 

(Jian-Guo Dai, 2010). 

a.	 High Molecular Weight Methacrylic Sealing 

Compounds 

One type of sealing compound that has proven effective in Reclamation 

laboratory tests and field applications is known as a high molecular weight 

methacrylic healer-sealer. This sealing compound is composed of a methacrylic 

monomer and appropriate polymerization “catalysts” that are very similar to some 

of the monomer systems used in polymer concrete (section D.2.d.). It is a very 

thin, amber colored liquid that is easily spread over horizontal concrete surfaces 

with brooms or squeegees. The liquid can penetrate the concrete surface to a 

depth of about 1/16 inch or less, but it is most effective in penetrating and sealing 

fine cracks in the concrete surface. This sealer will act like a membrane-forming 

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system if a thick coat is applied, or if two or more applications are made. The 

appearance of the concrete following application will be somewhat like a 

varnished or wet surface and may be splotchy in areas of high and low absorption. 

Cured sealer left on the surface of the concrete will be deteriorated by solar 

radiation within 1 to 2 years and will disappear. If the purpose of the application 

is to seal cracks, the loss of this surface material is immaterial because the sealer 

in the cracks is protected from solar radiation. The expected service life of 

properly applied methacrylic sealing compound under typical Western State 

climatic conditions is about 10 to 20 years. Reapplication is then necessary. 

Figure 79 shows application of HMWM sealing compound to the crest of a dam 

in central Wyoming. 

Figure 79. Application of HMWM to the top of a concrete dam. 

(1) Preparation 

Concrete to receive methacrylic sealing compound must be dry, clean, and sound. 

The cracks and pores of wet or damp concrete will be completely or partially 

filled with water, which will prevent the desired penetration of the sealing 

compound. In most cases, the concrete is suitably dry if no moisture appears 

under a sheet of transparent polyethylene taped to the concrete surface during a 

2-hour exposure to full sunlight. 

Proper surface preparation usually includes light sandblasting or steel shot 

blasting, power sweeping or hand brooming, and then blowing with oil-free, 

high-pressure air to remove all debris from the surface and within cracks. Dirt 

and debris in cracks will greatly limit penetration of the product. Very small 

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areas of paint, asphalt, rubber, or similar types of coatings can usually be ignored. 

It should be expected, however, that the methacrylic monomer system will attack 

and deteriorate most markings or coatings intentionally placed on the concrete. 

Deteriorated or unsound concrete should be removed by following the methods 

described in section B.5 and then be repaired (typically sections D.2.c. through 

D.2.f.) prior to applying the sealing compound. After proper preparation, the 

concrete must be protected from construction traffic and wetting. 

(2) Materials 

The HMWM sealing compound is usually obtained from the manufacturer as a 

three component system: 

1. A thin liquid methacrylic monomer 

2. Cuemene hydroperoxide initiator (or catalyst) 

3. Cobalt napthenate promoter 

Each manufacturer will specify the proper proportions for mixing these materials, 

and these instructions must be closely followed. As a general rule, it can be 

expected that the initiator will be added to the monomer at about 4 to 6 percent, 

by weight, and the promoter at about 1 to 3 percent, by weight. The initiator and 

promoter must never be directly mixed with each other because an extremely 

violent and explosive chemical reaction could result. Instead, the initiator should 

first be thoroughly mixed with the monomer, and then the promoter should be 

added and mixed with the monomer-initiator mixture. 

Some manufacturers supply a two-part monomer system that already contains the 

proper proportion of promoter. With these systems, it is necessary to add only the 

proper quantity of initiator. Once all the components are mixed, the sealing 

compound system will have a definite and short pot life that cannot be extended 

under normal conditions. 

(3) Application 

The following information provides general guidelines, but specific products 

might have somewhat different requirements. With these systems, it is very 

important to closely follow manufacturer’s instructions. Surface and ambient 

temperature requirements must be met. Surfaces need to be clean and dry. The 

mixed system has a short pot life at normal ambient temperatures, so applicators 

should not mix more material than can be easily applied before the system 

becomes too thick (usually about 15 to 20 minutes). If the material is being 

applied by two workers, and the application path is clear and easily attained, 

mixing up to 5-gallon quantities of material is typical, unless the ambient 

temperature is high. The sealant should be applied immediately after mixing. 

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Applying the sealant to concrete in direct sunlight may cause rapid curing. 

Squeegees, industrial size paint rollers, push brooms, brushes, and airless spray 

systems can be used to apply the sealant. If a specific thickness of resin is desired 

for later application of sand, tined squeegees can be used. The goal is to flood the 

concrete with a heavy, uniform coverage without leaving puddles of excess 

material. It may be appropriate to push puddles of the material back and forth 

over the surface to help it penetrate into areas of higher permeability. Vertical 

surfaces should receive two or more brushed, sprayed, or rolled applications. 

Repeat applications should be made immediately without waiting for the sealant 

to cure. 

If a skid-resistant surface is required for foot or vehicular traffic, or if protection 

from solar radiation is desired, sand must be broadcast over the liquid sealant 

system within 15 to 20 minutes of application. The sand is usually broadcast to 

refusal (which means that the sand layer is thick enough so that the top of the sand 

layer is not in contact with the resin), then excess sand is removed after curing. In 

some cases, this can be done two or more times to build up the thickness. 

(4) Curing and Protection 

After application, the treated surfaces should be protected for a minimum of 

24 hours. Protection should be provided for 48 to 72 hours if ambient 

temperatures are lower than 50 °F to allow the sealant to fully cure. Sealant 

applied at night will be quickly cured by solar radiation heating the following 

morning. Night applications allow for maximum penetration into cracked 

surfaces and should be pursued whenever feasible. 

b. Low Viscosity Epoxy Sealing Compounds 

Another type of sealing compound that is being used more and has proven 

effective in Reclamation laboratory tests and field applications is low viscosity 

epoxy sealing compounds. They can be somewhat easier and safer to use than 

HMWM, with more flexibility in cure times. However, they tend to have a higher 

viscosity than HMWM, so they may not penetrate fine cracks as effectively. 

This sealing compound is composed of an epoxy resin and an appropriate catalyst 

or hardener. These types of epoxies are specifically formulated to be very low 

viscosity to penetrate fine cracks in concrete. They are easily spread over 

horizontal concrete surfaces with brooms or squeegees. The use and performance 

of this sealer is very similar to an HMWM. It can penetrate the concrete surface 

to a depth of about 1/16 inch or less, but it is most effective in penetrating and 

sealing cracks in the surface. It will also act like a membrane-forming system if 

two or more applications are made. The appearance of the concrete following 

application will be somewhat like a varnished or wet surface and may be splotchy 

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in areas of high and low absorption. Cured sealer left on the surface of the 

concrete will be deteriorated by solar radiation within 1 to 2 years. If the purpose 

of the application is to seal cracks, the loss of the surface material is of no 

consequence because the sealer in the cracks is protected from solar radiation. 

The expected service life of properly applied epoxy sealing compound under 

typical Western State climatic conditions is about 10 to 20 years. Reapplication is 

necessary thereafter. Figure 80 shows application of an epoxy sealing compound 

to the concrete deck of a southern Colorado pumping plant. 

Figure 80. Application of an epoxy sealer to a pumping plant deck. 

(1) Preparation 

Concrete that will receive an epoxy sealing compound must be dry, clean, and 

sound. The cracks and pores of wet or damp concrete will be completely or 

partially filled with water that will prevent the desired penetration of the sealing 

compound. The concrete is suitably dry if no moisture appears under a sheet of 

transparent polyethylene taped to the concrete surface during a 2-hour 

exposure to full sunlight. 

Proper surface preparation usually includes light sandblasting or steel shot 

blasting (figure 81), power sweeping, or hand brooming, which is followed by 

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blowing with oil-free, high-pressure compressed air to remove all debris from the 

surface. Removing dirt and debris from cracks will improve penetration of the 

resin. Very small areas of paint, asphalt, rubber, or similar type coatings can 

usually be ignored. Deteriorated or unsound concrete should be removed 

following the methods described in section B.5 and repaired (typically 

sections D.2.c. through D\.2.f) prior to sealing. After proper preparation, the 

concrete must be protected from construction traffic and moisture. 

Figure 81. Steel shotblasting a concrete deck prior to application of an epoxy 

sealer. 

(2) Materials 

The epoxy sealing compound is a two-component epoxy system: the epoxy resin 

and a hardener. When selecting epoxy products for sealing concrete, ensure they 

are expressly manufactured for that purpose. Select low viscosity products that 

are made for the expected service conditions. For assistance selecting products, 

contact CGSL staff. 

Each manufacturer will specify the proper methods and proportions for mixing 

these materials, and those recommendations must be closely followed. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(3) Application 

Prior to mixing, the components must be conditioned to the proper temperatures. 

Ambient and surface temperatures must meet the manufacturer’s requirements. It 

is important to avoid mixing more material than can be easily applied before the 

system becomes too thick— normally within 15 minutes to 1 hour. The epoxy 

should be applied immediately after mixing. Applicators can use squeegees, 

industrial-sized paint rollers, push brooms, brushes, and airless spray systems to 

apply the epoxy. The area being sealed should be flooded with a heavy, uniform 

coverage without leaving puddles of excess material. If a specific thickness of 

resin is desired for later application of sand, tined squeegees can be used. 

Prefilling larger cracks may be necessary. It may be appropriate to push puddles 

of the material back and forth over the surface to help it penetrate into cracks and 

areas of higher permeability. Vertical surfaces should receive two or more 

brushed, sprayed, or rolled applications. Back brushing after spraying may help 

the material soak into vertical surfaces. 

If a thicker overlay, a skid-resistant surface, or protection from solar radiation is 

desired, sand should be broadcast over the epoxy system while it is still tacky. 

The sand is usually broadcast to refusal (which means that the thickness prevents 

the top layer from contacting the resin), and then excess sand is removed after 

curing. In some cases, this can be done two or more times to build up the 

thickness. 

(4) Curing and Protection 

After application, protect the treated surfaces until cured. Protection times will 

vary depending on the specific product and exposure conditions. 

c. Silane and Siloxane Sealing Compound 

Silanes and related products have been receiving attention because of their 

effectiveness and ease of use. They have been used to seal concrete surfaces 

and cracks smaller than about 0.002 inch wide. They are effective in 

reducing water penetration into treated concrete (Aitken and Litvin, 1989) 

(Attanayaka et al., 2002), provided that the sealing compound contains a 

minimum of 20-percent solids and as long as the cracks are not too large (greater 

than about 0.01 inch). For larger cracks, application of a silane/siloxane and an 

epoxy or HMWM sealer has worked well. 

The silane and siloxane solids are suspended in a carrier such as water, alcohol, 

or mineral spirits that evaporates from the concrete following application. 

Solvent-based sealers seem to work better than water-based sealers, and, as 

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mentioned earlier, the newer gel and cream formulations have been shown to 

work very well. Since the molecules are slightly larger for siloxanes than for 

silanes, they can work well in older, more porous concrete. Silanes will generally 

penetrate to a deeper level. Silanes need a high pH to cure properly, while 

siloxanes do not. 

Use of these sealing compounds does not significantly change in the appearance 

of the treated concrete, except that the darkening normally associated with wetting 

of concrete does not occur. When the surfaces get wet, the water usually forms 

beads. These sealing compounds will not provide protection to concrete that is 

completely inundated in water, except for short periods. They should not be used 

under conditions that involve prolonged inundation, which occurs with stilling 

basins, canal floors, or spillway floors, unless there are significantly long dry 

periods between inundations, and it is acceptable to reapply the sealing compound 

following inundation. They are best used to protect concrete from rain, snowmelt, 

and water splash. 

These materials have a relatively limited service life, and reapplication should be 

scheduled about every 5 to 7 years for optimum protection. Application of these 

materials, however, proceeds very quickly on horizontal and vertical concrete 

surfaces. Two workers can be expected to treat 10,000 to 15,000 square feet of 

horizontal surface in 1 day. 

(1) Preparation 

Concrete surfaces to be treated with a silane or siloxane sealing compound should 

be dry, clean, and sound. Any material that will block absorption of the sealing 

compound in the concrete should be removed. For new concrete that will be 

treated, planning is needed to ensure that proper curing occurs without using 

difficult to remove curing compounds. All deteriorated concrete should be 

removed (section B.5), and all needed repairs should be accomplished prior to 

application. As a general rule, power sweeping and, in some instances, 

high-pressure (less than 8,000 psi) water washing or shot blasting of surfaces 

will be sufficient. The concrete should be allowed to dry for 24 to 48 hours 

following wetting. Cracks in the concrete should be cleaned and blown out with 

compressed air to remove any debris. Once preparation (including drying if 

needed) is completed, the sealing compound should be applied within 24 hours. 

(2) Materials 

These sealing compounds should be one-part, ready to apply, and contain no 

less than 20-percent active solids. Sealing compounds that contain less than 

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20-percent active solids do not provide sufficient protection to the concrete and 

are not recommended. The material should be supplied in 5-gallon pails or 

55-gallon drums. No additional mixing or blending should be necessary prior to 

application. No additional solvents or diluents should be added to the supplied 

sealing compound. 

(3) Application 

Manufacturer’s application guidelines should always be followed. The following

are general guidelines that may not always correspond exactly to a specific 

manufacturer’s recommendations. The sealing compound should be applied 

to the concrete using squeegees, push brooms, paint rollers (figure 82), or 

low-pressure airless spray equipment. Adjacent glass, metal, and painted surfaces 

must be protected from the sealing compound. Overspray protection must be 

provided if spray application equipment is used. Fine spray mists can travel 

extensively and damage downwind structures, equipment, and automobiles. 

Figure 82. Application of a siloxane sealing compound. 

Follow the manufacturer’s recommendations for application rate and allowable 

time between coats. Two coats of 20-percent solids material provide about the 

same protection as one coat of 40-percent solids. Excess sealant should be 

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broomed or rolled out until it is absorbed by the concrete. Low density areas of 

the concrete surface need the most protection, and these areas are the most 

absorptive. 

(4) Curing 

Treated concrete must be protected from foot and vehicular traffic, and water 

wetting, for 24 hours following application. Should the concrete experience rain 

or heavy water splashing during this period, repeat drying and apply additional 

material. 

d. Coating Compounds for Concrete 

The reasons for coating concrete typically fall into one of four categories. 

1.	 Waterproofing is typically used to prevent the flow of water into or out of 

concrete. Positive side (the side exposed to water) waterproofing is 

recommended to produce a dry surface for the application of coatings on 

the opposite side of a structure. However, waterproofing systems can be 

designed for either negative or positive side installation. Waterproofing 

coatings are generally thicker film asphalts, urethanes, or epoxies, and 

they can be spray applied or installed in layup sheets. 

2.	 Dampproofing is used to seal the porosity of concrete and prevent 

absorption of water. Dampproofing systems are generally thin film 

asphaltic emulsions and are not usually effective against hydrostatic 

pressure. A common use of dampproofing is to seal concrete and masonry 

structures to prevent water absorption and prevent freeze-thaw damage. 

3.	 Decorative coatings change the appearance of concrete and masonry to 

enhance aesthetics. Decorative coatings and sealers can be used to obtain 

a specific color or texture, to increase stain resistance, and to make it 

easier to clean and maintain an acceptable appearance. 

4.	 Barrier coatings are installed over concrete and masonry when conditions 

require the concrete and masonry to be isolated from its service 

environment. This is usually necessary to either protect the concrete and 

masonry from exposure to chemicals or to protect a product from being 

contaminated by direct contact with the concrete or masonry. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

While the success of any coating applied to a concrete surface is largely 

dependent upon the thoroughness of the surface preparation, coating material 

selection and application are equally critical. Some examples of coating materials 

that are compatible with concrete are epoxies, acrylics, polyurethanes, polyureas 

(figure 83), vinyl esters, chlorinated rubbers, and elastomeric coatings. Many 

concrete coatings are not able to properly bridge cracks in concrete, so careful 

selection of surface coatings should be made when coating concrete that contains 

cracks. 

For more information about coating concrete, refer to Reclamation’s Guide to 

Coating Concrete (Pepin, 2015). 

Figure 83. Cracked concrete canal lining repaired with an elastomeric polyurea. 

(1) Preparation 

Proper surface preparation includes the following: 

 Inspection of the concrete substrate 

 Removal and replacement of nondurable concrete 

 Decontamination of concrete and masonry surfaces 

 Creation of a surface profile 

 Repair of surface irregularities 
Chapter D: Standard Methods of Concrete Repair 

 

 

 

Inspection of the concrete substrate is critical to determine its general condition 

and soundness, whether contaminants or moisture vapor emissions are present, 

and to determine the best methods for preparing the surface to meet the job 

requirements. A proper evaluation will result in selection of the proper tools and 

equipment to accomplish the objective. 

Removal and replacement of nondurable concrete must be accomplished prior to 

installation of the coatings. Localized weak or deteriorated concrete must be 

removed from sound concrete and replaced. Repair of surface damage, including 

spalls, cracks, deteriorated joints, and other damage, should be performed prior to 

the placement of the coatings, according the appropriate sections of this Guide. 

Only specialized coatings in certain conditions can bridge large or moving cracks, 

so most coatings should not be expected to repair cracks. 

Decontamination and cleaning of the concrete surface requires the removal of 

oils, grease, wax, fatty acids, and other contaminants. This may be accomplished 

by using detergent scrubbing with a cleaner and degreaser, low-pressure water 

cleaning (less than 5,000 psi), steam cleaning, or chemical cleaning. The success 

of these methods depends on how deeply the contaminant has penetrated. In areas 

where the contaminants cannot be removed, the contaminated concrete must be 

removed and replaced. 

For many coating compounds, a surface profile in the concrete needs to be created 

to provide for adhesion of the coating. The surface profile is the measure of the 

average distance from the peaks of the surface to the valleys, as seen through a 

cross-sectional view of the surface of the concrete. This dimension is defined 

pictorially and through physical samples in ICRI 310.2R (ICRI 310.2R, 2014) and 

is expressed as a Concrete Surface Profile (CSP) number (CSP 1-10). The 

creation of a surface profile can be accomplished by a number of methods, each 

using a selection of tools, equipment, and materials to accomplish the intended 

purpose. 

The preferred methods for creating a surface profile, including the removal of dirt, 

dust, laitance, and curing compounds, is steel shot blasting (figures 25 and 81), 

abrasive (sand) blasting (figure 26), and scarifying. Chemical (acid) etching is 

generally not allowed to create a surface profile and is only allowed for concrete 

coatings when required by the coating manufacturer. If acid etching is used, extra 

care is needed to ensure all acid is removed before applying the coating. Vertical 

and overhead surfaces should be prepared using methods of grinding, scarifying, 

abrasive (sand) blasting, needle scaling, high-pressure water jetting (5,000 to 

45,000 psi), or vertical steel shot blasting. 

Surfaces to receive coatings must be inspected after the surface is prepared to 

ensure that the substrate is sound and structurally durable. Areas found to be 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

unsound or nondurable must be removed and replaced. Dust or other deleterious 

substances not removed after the initial surface preparation must be vacuumed, 

leaving the surface clean and free of dust. 

Surface preparation selection is dependent on the type of surface to be prepared 

and the type of system to be installed. In addition, floors, walls, ceilings, 

trenches, tanks, and sumps each have their own particular requirements. The type 

and thickness of the selected coating also play an important role in the selection 

process. Regardless of the method selected or tools employed, a surface that will 

accept the application of polymer-based products and allow the mechanical bond 

of the polymer securely to the concrete must be provided. The type of service to 

which the structure will be subjected will also help to define the degree of profile 

required. 

	 Thin film linings up to 20 mils dry film thickness (dft) need a surface 

profile of CSP 2 to 3, typically accomplished through decontamination 

and cleaning of the concrete surface, followed by grinding or light shot 

blast. 

	 Medium film linings and flexible coatings up to 40 mils dft need a surface 

profile of CSP 3 to 5, typically accomplished through decontamination of 

the concrete surface, followed by light shot blasting, light scarification, or 

medium shot blasting. 

	 Laminate linings and self-leveling mortar coatings need a surface profile 

of CSP 4 to 6, typically accomplished through decontamination and 

cleaning of the concrete, followed by light scarification, medium shot 

blasting, or medium scarification. 

	 Mortar coatings and mortar laminates need a surface profile of CSP 5 to 9, 

typically accomplished through decontamination and cleaning of the 

concrete, followed by medium shot blasting, medium scarification, heavy 

abrasive blasting, or heavy scarification. 

(2) Application 

Manufacturer application guidelines should always be followed. The following 

are general guidelines that may not always correspond exactly to a specific 

manufacturer’s recommendations. The coating compound can be applied to the 

concrete using squeegees, push brooms, paint rollers, or airless spray equipment. 

Some coatings will require specialized equipment and certified personnel. 

Adjacent glass, metal, and painted surfaces must be protected from the coating 

compound. Overspray protection must be provided if spray application 

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equipment is used. Fine spray mists can travel extensively and damage 

downwind structures, equipment, and automobiles. 

(3) Curing 

Manufacturer’s curing requirements should be followed. Different materials will

have different curing requirements, and exposure conditions will impact curing 

time. 

2. Thin Repairs 

Thin repairs are generally from about 1⁄4- to about 2 inches deep and do not 

encompass any existing reinforcing steel. Typical examples of thin repairs 

include surface grinding, Portland cement mortar, some coatings and surface 

sealers, dry pack mortar, packaged cementitious and chemical repair mortars, and 

polymer mortars (including epoxy mortars). 

Unfortunately, insufficiently thick repairs to some concretes should not be 

considered permanent. In some circumstances, thin repairs my lead to 

accelerating deterioration behind or adjacent to the repair. A few examples that 

show where this can occur are: 

	 New concrete placed over old concrete subject to freeze-thaw 

deterioration. Because of the lower porosity of the new concrete, moisture 

can be trapped behind the repair material, increasing the moisture content 

beneath the repair, and accelerating freeze-thaw deterioration in the 

original concrete. This can lead to debonding of the repair material 

(figure 84). 

	 New concrete placed over concrete susceptible to alkali-silica reaction. 

The new concrete may contribute some alkalies to the existing concrete at 

the interface between the new and old concrete, and increase the moisture 

content in the existing concrete, which could accelerate deterioration due 

to ASR in the original concrete near the repair. 

	 New concrete covering rebar that extends into old concrete. In some 

cases, corrosion of the rebar occurs around the perimeter of the repair due 

to the ring or halo effect, which is caused by a conductor (the rebar) 

connecting concrete that has different electrical potentials (typically 

resulting from different pH, permeability, and/or different chloride ion 

contents). 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 84. Insufficiently thick repairs on a spillway wall made 

with concrete subject to freeze-thaw deterioration resulted in 

failure of the repair and additional damage to the surrounding 

concrete. 

a. Surface Grinding 

Surface grinding can be used to repair some bulges, offsets, and other 

irregularities that exceed desired surface tolerances. Excessive surface grinding, 

however, may result in weakening of the concrete surface, exposure of easily 

removed aggregate particles, or an unsightly appearance. For these reasons, 

surface grinding should be performed subject to the following limitations: 

	 Grinding of surfaces subject to cavitation erosion (hydraulic surfaces 

subject to flow velocities exceeding 40 ft/s) should be limited in depth, so 

that no aggregate particles more than 1⁄4 inch in cross section are exposed 

at the finished surface. 

	 Grinding of surfaces exposed to public view should be limited in depth, so 

that no aggregate particles more than 1⁄2 inch in cross section are exposed 

at the finished surface. 

	 In no event should surface grinding result in exposure of aggregate of 

more than one-half of the diameter of the maximum size aggregate. 

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Where surface grinding has caused, or will cause, exposure of aggregate particles 

greater than the limits described above, the concrete must be repaired by 

removing and replacing the concrete in accordance with sections D.2.d. through 

D.3.a. 

b. Portland Cement Mortar 

Portland cement mortar may be used for repairing defects on new or green 

concrete. This method may be used provided that the repairs are performed 

within 24 hours of removing the concrete forms and not more than 72 hours after 

concrete placement (figure 85), and that repairs meet the following requirements: 

	 Any single defect less than about 6 inches across 

	 Where the defects are too shallow for concrete filling and no deeper than 

the bottom of the nearest reinforcement 

	 Surfaces are not prominently exposed 

	 Where the defects are too wide for dry pack filling 

. 

Figure 85. Portland cement mortar is suitable for repairing voids resulting from air 

and bleed water trapped under forms, as long as it is done in a timely manner. 

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Repairs may be made either by low-pressure spray application or by hand 

application methods 

Portland cement mortar was used in the past to repair old or deteriorated concrete 

on Reclamation projects. However, we now know that making Portland cement 

mortar repairs to older concrete is rarely successful. Evaporative loss of water 

from the surface of the repair mortar, combined with capillary water loss into the 

old concrete, results in unhydrated or poorly hydrated cement in the mortar. 

Additionally, there can be relatively large amounts of shrinkage that can cause 

cracking of the mortar and poor bond to the substrate. 

A Portland cement mortar patch is usually darker than the surrounding concrete 

unless precautions are taken to match colors (figure 86). A leaner mix will 

usually produce a lighter color patch. Also, white cement can be used to produce 

a patch that will blend with the surrounding concrete. The quantity of white 

cement to use must be determined by trial. 

Figure 86. Portland cement mortar repairs made to a shallow defect. Note 

how it differs in color from the parent concrete. 

(1) Preparation 

Concrete to be repaired with Portland cement mortar should be prepared in 

accordance with the provisions of section B.5. After preparation, the areas should 

be cleaned, roughened if necessary (preferably by water jetting or wet 

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sandblasting), and surface dried to a SSD condition. The mortar should be 

applied immediately after preparation. 

(2) Materials 

Portland cement mortar contains water, Portland cement, and sand. In addition, 

prepackaged materials can be used, as long as the materials are suitable for the 

specific application and exposure conditions. The cement should be of the same 

type used in the concrete being repaired. The water and sand should be suitable 

for use in concrete, and the sand should pass a No. 16 sieve. The cement to sand 

ratio should be between 1:2 and 1:4, by volume, depending on the application 

technique. Only enough water should be added to the cement-sand mixture to 

permit placing, which is usually a thick, creamy consistency if it is placed by 

hand. 

(3) Application 

For larger areas, best results with replacement mortar are obtained when the 

material is pneumatically applied using low-pressure, mortar spraying equipment. 

Equipment commonly used for shotcreting is too large to be satisfactory for the 

ordinarily small size mortar repairs of new concrete. However, small equipment, 

such as that shown in figure 87, has been satisfactory for small-scale repair work 

when the mortar was premixed to a consistency of dry-pack material. 

Figure 87. Using low-pressure spray equipment to apply Portland cement mortar. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

No initial application of cement, cement grout, or wet mortar should be made. If 

repairs are more than 1 inch deep, the mortar should be applied in layers not more 

than 3⁄4 inch thick to avoid sagging and loss of bond. After completion of each 

layer, there should be a lapse of 30 minutes or more before the next layer is 

placed. It is not necessary to scratch or otherwise prepare the surface of a layer 

before applying the next layer, but the mortar must not be allowed to dry between 

applications. 

When completing the repair, the defect should be slightly overfilled. After the 

material has partially hardened but can still be trimmed off with the edge of a 

steel trowel, excess material should be shaved off, working from the center 

toward the edges. Extreme care must be used to avoid impairment of bond. 

For minor restorations, satisfactory mortar replacement may be performed by 

hand. The success of this method depends on complete removal of all defective 

concrete, good bonding of the mortar to the concrete, elimination of shrinkage of 

the patch after placement, and thorough curing. 

(4) Curing 

The most common cause of failure of Portland cement mortar is improper 

curing. It is essential that mortar repairs receive a thorough water cure starting 

immediately after initial set and continuing for 14 days. In no event should the 

mortar be allowed to become dry during the 14-day period following placement. 

Following the 14-day water cure, and while the mortar is still saturated, the 

surface of the mortar should be coated with two coats of a curing compound that 

meets Reclamation concrete curing specifications. If this curing procedure cannot 

be followed, or if conditions at the job site will not allow it, it would be more cost 

effective to use a different repair material. 

c. Dry Pack and Bonded Dry Pack 

Dry pack is a combination of Portland cement and sand passing a No. 16 sieve, 

mixed with just enough water to hydrate the cement (when formed into a ball, by 

hand, it is fairly stiff but sticks together). The material is placed in holes using 

vigorous rodding and tamping methods. If done properly, dry pack is a very 

durable, long-lasting repair method that is fairly low cost and easy to apply. 

Dry pack should be used for filling holes that have a depth equal to, or greater 

than, the least surface dimension of the repair area. Dry pack repair is suitable for 

cone bolt holes, she bolt holes, core holes, grout holes, holes left by the removal 

of form ties, and for narrow slots cut for repair of dormant cracks. It can be used 

I-108 
Chapter D: Standard Methods of Concrete Repair 

 

 

to cover the exposed ends of cut reinforcement after the reinforcement is removed 

to a minimum 2-inch depth below the surface. 

Do not use dry pack for relatively shallow depressions where lateral restraint 

cannot be obtained, for filling behind or under reinforcement, or for filling holes 

that extend completely through a concrete section. For dry pack to be successful, 

it must have a restraining recess to pack against. 

For the dry pack method of concrete repair, holes should be sharp and square at 

the surface edges, but corners within the holes should be rounded, especially 

when it is required to be watertight. The interior surfaces of holes left by cone 

bolts and she bolts should be roughened to develop an effective bond. This can be 

done with a notched, tapered reamer or a star drill. Other holes should be 

undercut slightly in several places around the perimeter, as shown in figure 88. 

Holes for dry pack should have a minimum depth of 1 inch. 

Figure 88. Cutting a slight key into the hole to help hold the repair 

material in place. 

(1) Preparation 

Before applying dry pack mortar, carefully inspect the hole to make sure it is 

thoroughly clean and free from loose or cracked pieces of aggregate. One of the 

three following methods should be used to ensure good bond of the dry pack 

repair. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(a) Method 1 

The preferred method of ensuring good bond starts with presoaking the hole with 

wet rags or burlap. The hole is left slightly wet, with a small amount of free water 

on the inside surfaces. Immediately prior to placing the dry pack material, spray 

the hole with oil-free air until the surfaces just start to dry. These steps ensure 

that the concrete repair surface is SSD. 

(b) Method 2 

The next preferred method is to apply a stiff mortar or grout bond coat 

immediately before applying the dry pack mortar for holes that are more than 

2 inches in minimum cross section and that have rough sides. The bond coat is 

used to prefill rough areas and holes within the repair void before applying the dry 

pack. The bonding grout mixture is 1:1 cement and fine sand, by volume, mixed 

with enough water to produce a thick fluid paste consistency. All surfaces of the 

hole are thoroughly brushed with the grout, and dry packing takes place quickly 

before the bonding grout can dry. Under no circumstances should the bonding 

coat be so wet, or applied so heavily, that the dry pack material becomes more 

than slightly rubbery. When a grout bond coat is used, the hole to be repaired can 

be dry. Presoaking the hole with wet rags or burlap prior to dry packing may 

sometimes give better results by reducing the loss of hydration water, but there 

must be no free surface water in the hole when the bonding grout is applied. 

(c) Method 3 

Under special circumstances; for example, with older, poor quality concrete, a 

third method of ensuring bond is to use an epoxy bonding resin. The epoxy 

bonding resin should meet the requirements of ASTM C-881 for a Type II, 

Grade 2, Class B or C resin, depending on the job site ambient temperatures. 

Epoxies bond best to dry concrete. It may be necessary to dry the hole 

immediately prior to dry packing using compressed oil-free air, heating, or other 

appropriate methods. The concrete temperature, however, should not be high 

enough to cause instant setting of the epoxy. After being mixed, the epoxy is 

thoroughly brushed to cover all surfaces. Excess epoxy should be immediately 

removed. Dry pack mortar is then applied before the epoxy starts to harden. The 

epoxy must be either fluid or tacky when dry packing takes place. If it appears 

that the epoxy may become hard before dry packing is complete, fresh fluid epoxy 

can be brushed over epoxy that has become tacky. If the epoxy becomes hard, it 

must be removed before a new coat is applied. The epoxy ensures a good bond 

between the dry pack repair and the old concrete. It also reduces the loss of 

hydration water from the repair to the surrounding concrete, thus assisting in good 

curing. However, the epoxy-bonded dry pack still requires curing as discussed 

below. It is not recommended that epoxy be used on the surface, instead of a 

curing compound, on Reclamation projects. 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

Using bond coats should never be considered a substitute for quality work. In 

addition, if not properly used, bond coats can be problematic and will reduce the 

effectiveness of the repair. 

(2) Materials 

Dry pack mortar is usually a mixture (by dry volume or weight) of 1 part cement 

to 2-1⁄2 parts sand that will pass a No. 16 screen. While the mixture is rich in 

cement, the low water content prevents excessive shrinkage and gives high 

strengths. A dry pack repair is usually darker than the surrounding concrete, 

unless special precautions are taken to match the colors. Where uniform color is 

important, white cement may be used in sufficient amounts (as determined by 

trial) to produce a uniform appearance. For packing cone bolt holes, a leaner mix 

of 1:3 or 1:3-1⁄2 will be sufficiently strong and will blend better with the color of 

the wall. Sufficient water should be used to produce a mortar that will just stick 

together while being molded into a ball with the hands, and will not ooze water 

but will leave the hands damp. The proper amount of water will produce a mix 

that is just at the point of becoming rubbery when solidly packed. Using any less 

water will prevent a sound, solid pack, and any more water will result in excessive 

shrinkage and a loose repair. 

(3) Application 

Dry pack mortar should be placed and packed in layers that are thin enough to 

ensure complete packing of the lift. For small holes, the lifts may have a 

compacted thickness as small as about 3/8 inch. Layers that are too thick will not 

be well compacted at the bottom of the lift. The surface of each layer should be 

scratched to facilitate bonding with the next layer. One layer may be placed 

immediately after another, unless an appreciable rubbery quality develops. If this 

occurs, delay the repair work to allow the dry pack to stiffen slightly, usually 

about 30 to 40 minutes. Under no circumstances should alternate layers of wet 

and dry materials be used. Each layer should be solidly compacted over the entire 

surface by placing a hardwood dowel or rod against the mortar and striking the 

rod with a hammer. These rods should be long enough to reach the bottom of the 

hole, and they should leave enough clearance above the hole to allow easy 

striking with a hammer. The diameter of the rod should be sufficiently small to 

allow for good compaction. The use of hardwood rods is preferred, rather than 

metal bars, because the latter tend to polish the surface of each layer, thus making 

a less certain bonding and a less uniform fill. Much of the tamping should be 

directed at a slight angle and toward the sides of the hole to ensure maximum 

compaction in these areas. After the last lift, the holes should be slightly 

overfilled, then dry packing should be completed by laying the flat side of a 

hardwood piece against the fill and striking it with several good hammer blows. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

If necessary at a later time, a few light strokes with a damp rag or wood float may 

improve appearance. Steel finishing tools should not be used, and water must 

not be used to facilitate finishing. 

(4) Curing and Protection 

Procedures for curing and protecting dry pack are essentially the same as those 

used for concrete, and they are described in section D.3.a. Additionally, the dry 

pack repair area should be protected and not exposed to freezing temperatures for 

at least 3 days after application of the curing compound. In some cases, it may be 

possible to cover the repair with a damp cloth and tape plastic over it to provide a 

moist cure. 

d. Polymer Concrete, Including Epoxy Mortar 

Polymer concrete (PC) is a concrete material in which Portland cement is replaced 

with a polymeric resin binder. The binder is combined with fine and coarse 

aggregate (and perhaps other fillers) to make PC. Typically, the aggregates 

consist of fine to coarse sand. Water is not used in the mix. There are many types 

of resins used in PC with a wide range of properties and application requirements. 

Typical polymeric binders include many epoxies, vinyl esters, polyurethanes, and 

methyl methacrylates, to name a few. Epoxy PC systems tend to be stiffer than 

other PC systems. Throughout this section, the term “PC” includes all of the

many types of polymer resins used in mortars, including epoxy resins. 

PC strengthens and hardens during a chemical reaction between the liquid resin 

(monomer) and various initiators, promoters, and/or hardeners to chemically link 

and cross link the monomers. This reaction forms a hard, plastic-like material 

known as a polymer. There is a wide variety of commercially prepared PCs 

formulated for a wide variety of concrete repair applications. Whenever a PC is 

deemed the appropriate repair material, properties and mixing procedures of 

candidate commercial products should be evaluated. It may be advisable to 

perform trial placements on mockups. The material with the best performance for 

the specific application should be selected for use. This process was recently used 

to help select epoxy mortar for the repair of concrete surfaces of some of the draft 

tubes at Grand Coulee Dam (Bureau of Reclamation, 2012). 

The polymers used in PCs are formulated to provide special properties needed for 

high performance repair materials. Some of these systems cure very quickly and 

are very useful in repairing structures that must be immediately returned to 

service. As an example, some types of PCs are commonly used to repair potholes 

in concrete highway bridge decks, thereby eliminating the need for long and 

costly road closures or detours. They are also useful for repairs to structures, such 

as tunnel linings, that can be maintained in a dry condition for only short periods 

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Chapter D: Standard Methods of Concrete Repair 

of time, as well as for cold weather repairs down to temperatures as low as 15 °F. 

PC repairs can be accomplished in thicknesses varying from about 1⁄4 inch to 

several feet if appropriate precautions are taken. Epoxy PC systems must meet 

the appropriate requirements of ASTM C881 (100-percent solids, Type III, 

Grade 2, Class B or C). Class B epoxy is used between 40 and 60 °F. Class C 

epoxy is used above 60 °F up to the highest temperature defined by the epoxy 

manufacturer. 

PC should be used where the exposure conditions are expected to remain at a 

relatively constant temperature. PCs have thermal coefficients of expansion that 

may be significantly different from conventional concrete. If such materials are 

used under conditions of wide and frequent temperature fluctuations, they will 

cause failure just below the bond surface in the base concrete. For this reason, 

current Reclamation practice discourages the use of PC under conditions of 

frequent or large temperature fluctuations. Examples of suitable applications 

include tunnel linings, indoor or interior concrete, the underside of concrete 

structures such as bridge decks, continuously inundated concrete such as stilling 

basin floors, canal linings below water line, or concrete pipe. 

Many PC systems must be applied to dry concrete. Some of them (especially 

some epoxy mortars) can be applied to damp concrete. Properly applied 

PC repairs have a long history of successful performance on Reclamation 

concrete when used under appropriate conditions. 

Different formulations have different thermal coefficients, and a suitable material 

may be found for a specific application by considering different resins and 

aggregates. In some circumstances, it may be necessary to use PC for its special 

properties (i.e., curing in very cold weather), even though it might be in an 

environment not ideally suited for the material (i.e., high seasonal temperature 

fluctuations). In those cases, the practitioner needs to realize that the repair will 

likely not be long lasting. 

Applying PC to repair areas of concrete deterioration caused by corroding 

reinforcing steel is not recommended. The materials have different 

electrochemical properties than the surrounding concrete. These areas where 

materials have differing properties and are connected with a conductor 

(reinforcing steel) can form a corrosion cell that will accelerate corrosion at the 

repair area perimeters. 

PC can develop strength and durability properties very quickly and is useful 

where rapid repairs to concrete are required. They can be quite strong and very 

durable. Some PCs can be put into service in a very short time. This feature 

makes them useful as protective overlays on conventional concrete exposed to 

corrosive or severe environments. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

CGSL personnel can provide guidance and recommendations for the use 

of these materials. 

(1) Preparation 

Concrete preparation for PC repairs should be in accordance with section B.5. 

Although some manufacturers say that PC may be used for feather edge repairs, 

Reclamation recommends at least a 1⁄4-inch squared edge to improve repair 

quality. Special care should be taken to ensure that the base concrete is dry prior 

to application of the repair material if required by the PC system manufacturer 

(figure 89). If a dry substrate is required, it must remain dry throughout the 

curing process. Generally, the concrete can be considered suitably dry if no 

moisture appears under a sheet of transparent polyethylene taped to the concrete 

surface during a minimum 2-hour exposure to full sunlight. Flowing water may 

remove the fresh polymer concrete if it is allowed on the concrete prior to 

development of initial set. 

Figure 89. Drying the surface of concrete using oil-free compressed air to meet the 

surface moisture requirements of the manufacturer. 

If rebar is encountered in the repair, it may require a bond coat if required by the 

manufacturer. As with other repairs, the rebar must be clean and free of materials 

that will impair bond. If the rebar is corroded and is the cause of damage, the use 

I-114 
Chapter D: Standard Methods of Concrete Repair 

of PC should be carefully evaluated to avoid additional corrosion, as described 

above. For some applications of PC, the concrete may need to be heated to 

sufficient depth, so that the surface temperature does not drop below the 

minimum temperature requirements during the application and curing of the 

mortar. This may require several hours of preheating with radiant heaters or other 

approved means (figure 90). If existing conditions prohibit meeting these 

temperature requirements, suitable modifications should be adopted upon the 

approval of the inspector or other responsible official. The concrete temperature 

during preheating should never exceed the upper limits set by the product 

manufacturer, nor should the PC components be heated above manufacturer 

requirements. 

Figure 90. Using heaters in an enclosed area to increase the temperature to meet 

application requirements. 

(2) Materials 

A number of manufacturers have developed prepackaged PC systems containing 

aggregate, resins, and other necessary ingredients. It is also possible for the user 

to extend the polymer concrete, particularly when used to fill depressions deeper 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

than 1 inch, by supplying and adding coarse aggregate to the prepackaged 

PC system during mixing. The prepackaged polymer concretes may also contain 

bond coat systems that must be mixed and applied to the base concrete prior to 

application of the polymer concrete mixture. 

For critical repair jobs, such as areas of high velocity flow, or for repairs requiring 

a considerable quantity of materials, the staff at the CGSL should evaluate 

samples of resin and aggregates for use in mix design determinations. The 

samples should consist of a minimum of 1 gallon total quantity of resin 

components and a minimum of 50 pounds of graded sand and/or aggregate. 

Samples should be submitted at least 30 days prior to use and be labeled or 

otherwise identified with the specifications number under which the material is to 

be used. 

(3) Mixing and Handling 

PC systems have specific mixing requirements as directed by the PC 

manufacturer. Mixing PC involves premixing proper quantities of resin and other 

ingredients, and then mixing the resin system with sand or aggregate. 

The PC components require accurate combination of components and mixing 

prior to use. Once mixed, the material has a limited pot life and must be used 

quickly. Pot life refers to the period of time elapsing between mixing of 

ingredients and their stiffening to the point where the material cannot be used 

satisfactorily. The repair resin should be prepared by adding the required quantity 

of hardener to the resin, in proportions recommended by the manufacturer, 

followed by thorough mixing using equipment made for mixing resin systems. 

Because the pot life of the mixture depends on the temperature (longer at low 

temperature, much shorter at high temperature), the quantity mixed at one time 

should be applied within about 30 minutes. The addition of nonreactive thinners 

or diluents to the resin mixture is not permitted because they weaken the PC. 

The PC is composed of aggregates and resin suitably blended to provide a 

workable mix. Mix proportions should be established, batched, and reported on a 

weight basis, although the dry sand and mixed resin may be batched by volume 

using suitable measuring containers that have been calibrated on a weight basis. 

If equivalent volume proportions are being used, care must be taken to prevent 

confusing them with weight proportions. 

Figures 91 and 92 show simple methods for combining mortar ingredients that are 

adequate for mixing epoxy mortar for both small and large repairs. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 91. Using a simple 

bucket mixer to mix epoxy 

resin. 

Figure 92. Mixing epoxy mortar ingredients in buckets. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(4) Application 

Each manufacturer of packaged PC provides detailed instructions for storing, 

proportioning, mixing, and applying its product. These instructions must be 

closely followed to obtain a satisfactory repair. 

If required by the PC manufacturer, a bond coat system is mixed and applied to 

the prepared concrete prior to application of the PC. Care must be taken to 

proportion and mix the bond coat components properly. Some manufacturers 

specify that the bond coat be applied and cured prior to placing the PC. Others 

specify that the PC be applied while the bond coat is still in the liquid state. It is 

important to follow the procedures recommended by the manufacturer of the 

product actually being used. 

Polymer concrete can be mixed in paddle-type, rotary drum-type, or other types of 

power equipment suitable for mixing concrete repair mortars. Small quantities of 

PC can even be mixed in the original shipping containers. For conventional 

mixing for larger quantities, it is common practice to first add the dry powder and 

aggregate components to the mixer, and then add the liquid resin. With some 

systems, the liquid component may require a separate premixing step to combine 

the monomer with the catalyst or initiators needed for polymerization. Other 

manufacturers include the initiators in the powder-fine aggregate component, 

thereby eliminating the premixing requirement. 

The mixed PC can be placed using the same tools and procedures used for 

conventional concrete (figure 93). Some PC mixtures can be almost self-leveling 

and require only a minimum finishing operation, while others can be very stiff. 

Other formulations can be mixed to the consistency of drywall taping compound 

and applied using drywall mud application techniques (figure 94). Still others can 

be spray applied, using mortar spray equipment, and then smoothed with a float or 

trowel. 

Light mechanical vibration should be provided to consolidate placements thicker 

than 2 or 3 inches (figure 95). Once the PC has been placed and consolidated, it 

should be screeded to proper grade and quickly finished. The top surface of the 

repair can form a “skin” soon after placement. If troweling is attempted after the 

skin forms, it will tear and cause an unsightly surface. 

Polymer concrete develops a strong bond to most materials. If forms are used, 

they must be leakproof and provided with some kind of bond breaker or release 

agent. Wrapping the forms with polyethylene film has proven very effective for 

preventing bond between the form and the PC. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 93. Placing polymer 

concrete to repair shallow 

damage to a stilling basin. 

Figure 94. Using drywall mud application tools to apply epoxy mortar. 

I-119 
 

Figure 95. 

Consolidating 

polymer 

concrete with a 

vibrator. 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(5) Curing 

Polymer concretes can harden very quickly under most ambient conditions and 

can develop nearly full strength relatively quickly (from a few hours to a few 

days, depending on the system). During this time, the fresh concrete must be 

protected from water and not disturbed (figure 96). Epoxy PC systems must be 

formulated for the anticipated ambient and placement conditions, and placements 

must occur within the temperature limits specified by the epoxy resin 

manufacturer. Cure times for all polymer materials are affected by temperature. 

Some PC systems allow mixture ingredients to be adjusted to shorten or lengthen 

cure times in colder or hotter weather. Alternately, the repairs can be made 

during different parts of the day to better match curing requirements. 

I-120 

Figure 96. 

Protecting the 

polymer 

concrete until it 

gets hard. 
Chapter D: Standard Methods of Concrete Repair 

 

Postcuring, if required or allowed by the manufacturer, can then be initiated at 

elevated temperatures by heating the PC and the concrete beneath the repair. 

Post-curing should continue for a minimum of 4 hours at a surface temperature 

generally not less than 90 °F and not more than 110 °F. The heat could be 

supplied by portable propane-fired heaters, infrared lamp heaters, or other 

approved sources that are positioned to attain the required surface temperatures 

(figure 97). 

Figure 97. Applying heat to speed curing of a polymer concrete repair. Note the 

soil berms to prevent water from flowing into the repair area. 

(6) Storage 

Some polymer concrete components are heat sensitive and flammable. These 

materials should be stored out of direct sunlight, in the original shipping 

containers, and in well-ventilated areas away from sources of ignition. The 

storage temperature should not exceed 80 °F. Storage requirements must meet the 

manufacturer’s recommendations.

e. Epoxy-Bonded Replacement Concrete 

Epoxy-bonded concrete repairs are used for special circumstances. No other type 

of bonding agent is approved by Reclamation, unless it is a bonding agent 

required by a specific repair material manufacturer. If there is uncertainty about 

using a specific bonding agent, consult with CGSL staff. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Using a bonding agent for replacement concrete repairs is usually not appropriate 

or necessary. Rather, every effort should be made to perform proper surface 

preparation, repair material placement, and curing to ensure quality repairs. All 

too often, bonding agents are used as a substitute for quality work. 

Epoxy-bonded replacement concrete is generally used for repairs to concrete that 

are between about 1-1⁄2 and 6 inches thick. In general, this method should be used 

when the parent concrete is of questionable quality, and deeper repairs are not 

practical. In this case, the epoxy bond coat is used to somewhat improve the 

existing concrete, giving the replacement concrete a somewhat stronger substrate. 

The epoxy bonding resin is used to improve bond between the existing concrete 

and the replacement concrete. 

When making this decision, it is important to consider all aspects of the repair. 

For example, the durability of the substrate concrete in freezing and thawing 

weather could be an important consideration. If the substrate is not durable in this 

exposure, it is important to determine whether the epoxy bond coat might trap 

moisture in the substrate, thereby increasing the rate of deterioration in freezing 

and thawing weather. Also, as with PC, care should be exercised if epoxy-bonded 

concrete will be used to repair shallow deterioration resulting from corroding 

reinforcement. The epoxy bond coat may create electrical potentials that differ 

sufficiently from those in the surrounding concrete, resulting in accelerated 

corrosion at repair perimeters. 

(1) Preparation 

Concrete to be repaired with epoxy-bonded concrete must be prepared as 

described in section B.5. 

(2) Materials 

The materials used in epoxy-bonded concrete repairs consist of conventional 

Portland cement concrete and an epoxy resin bonding agent. 

The concrete used for epoxy-bonded repairs is the same as that used for 

replacement concrete repairs (section D.3.a.). 

A number of proprietary epoxy formulations prepared for bonding new concrete 

to old concrete are available. Many of these materials are high quality products 

that can be used with reasonable certainty. Care should be taken to use only the 

epoxy bonding resins that meet the requirements of ASTM C-881 for a Type II, 

Grade 2, Class B or C epoxy system. Class B epoxy should be used when the 

temperatures are above 40 °F but below 60 °F. Class C epoxy should be used 

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Chapter D: Standard Methods of Concrete Repair 

 

 

when concrete temperatures are from 60 °F up to the maximum temperature 

recommended by the epoxy manufacturer. 

The epoxy resin used for epoxy-bonded concrete is a two component, 100-percent 

solids resin system that requires accurate proportioning and thorough mixing prior 

to use. Manufacturer recommendations should be followed during preparation 

and application of the resin. Concrete should be used as described in 

section D.3.a. 

(3) Application 

Use of epoxy-bonded concrete in repairs that require forming, such as on steeply 

sloped or vertical surfaces, is only appropriate when sufficient time is available to 

place concrete into the forms while the epoxy bonding resin is still fluid. If the 

resin cures before the concrete is placed, no bond will develop between the old 

and new concrete. It is a good idea to practice installing forms at least once 

before actually applying the epoxy bond coat. 

Immediately after application of the epoxy resin bonding agent, and while the 

epoxy is still fluid, concrete should be placed using appropriate concrete placing 

practices (section D.3.a., figure 98). After placement, the concrete should be 

given a proper finish, as required. Troweling, if required, should be performed at 

the proper time and with heavy pressure to produce a smooth, dense surface free 

of defects and blemishes. 

Figure 98. Placing concrete on an epoxy bonding resin. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(4)	 Curing 

Even though an epoxy bond coat is used, it is still important to properly cure 

epoxy-bonded concrete. As soon as the epoxy-bonded concrete has hardened 

sufficiently to prevent damage, the concrete should be properly cured 

(section D.3.a.). 

f.	 Packaged Cementitious and Chemical Repair 

Mortars 

There are a large number of products that fall into this category of repair 

materials. Some products contain Portland cement and other hydrating 

cementitious compounds, while others contain various chemically reacting 

cementing compounds that do not hydrate with water (for example, magnesium 

phosphate compounds). They are proportioned to have a wide variety of 

consistencies, ranging from self-consolidating (requiring little or no vibration), to 

very stiff for vertical and overhead application. These products typically gain 

strength fairly quickly, although rapid strength gain is usually not necessary for 

Reclamation repair work and can lead to shrinkage problems. They can also be 

proportioned to be durable in a variety of different exposure conditions, including 

acid exposure. They are generally proportioned to repair shallow defects from 

about 1⁄4 inch to 2 inches thick. In many cases, they can be used for deeper 

repairs; however, as repairs get larger, the material savings of using cast in place 

concrete becomes important. 

Unfortunately, the performance of these products has been inconsistent (Smoak 

and Husbands, 1996). Thus, Reclamation has been reluctant to use them and 

typically classifies them as nonstandard repair materials (chapter E). Recently, 

there have been some improvements in this area, in that some materials have been 

specially proportioned to greatly reduce or eliminate shrinkage cracking. 

Cracking (figure 99) of some of these thin repair mortars is a significant issue for 

long-term durability. Formulations for these products frequently change, so 

testing the products before use is advised. 

Recently, a select few products have been specified for some Reclamation 

concrete repair work. The CGSL staff should be consulted for specific material 

recommendations. Some manufacturers may claim that their packaged repair 

mortars can be applied with feather edges, but Reclamation experience shows 

otherwise. Squared-up perimeters of repair areas are required if high quality 

repairs are to be achieved. In some applications, it may be appropriate to ask the 

material manufacturer to certify that their product is suitable for use for the 

intended application. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 99. Extensive cracking in a packaged thin repair mortar applied to a 

spillway crest. Unfortunately, this occurs too often for thin repair mortars. 

(1) Preparation 

Concrete that will be repaired with packaged cementitious and chemical repair 

mortars must be prepared as described in section B.5. In addition, some of these 

repair mortars may have specific surface preparation requirements in addition 

to those mentioned in section B.5. Some products may require application to 

SSD surfaces, or require a bond coat, and some products may require that the 

existing concrete surface be dry. If a bond coat is recommended, the user should 

ensure that it is absolutely necessary before applying it; otherwise, it may simply 

serve as another area where the repair could eventually fail. 

(2) Application 

Due to the large number of products available, manufacturer recommendations 

should always be followed. Application methods for one product could be vastly 

different for another product, even if both products are supplied by the same 

manufacturer. In general, high slump products are applied to horizontal surfaces 

or into forms. If the higher slump materials are placed in forms, the provisions 

described in section D.3.a. apply. The forms must be tight, structurally adequate, 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

and well anchored. Products made for vertical and overhead application (very 

stiff) must be applied with sufficient force and effort to ensure they are in intimate 

contact with the substrate to facilitate an adequate bond (figure 100). Many of 

these types of products can generate significant heat during curing, and some may 

require that the repair material be placed in thin lifts to prevent the heat from 

damaging it. In addition, some products are suitable for spray application 

methods (spray-applied mortars). When using these materials, it is always 

advisable to use trained workers and to perform test placements. 

Figure 100. Applying a stiff repair mortar using hand packing. 

(3) Curing 

As with application, there are numerous products that have various methods to 

achieve curing. Manufacturer’s recommendations should always be followed. 

Some require normal concrete curing practices; some require moist curing for 

a few days, followed by drying; and some require no special curing steps. 

However, they all must be protected until the concrete hardens, and some require 

that temperatures remain within specified ranges for a limited time. 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 


 

	 

	 

	 

3. Thick Repairs
 

In general, thick repairs refer to repairs that are about 3 inches thick and that 

completely encompass at least some reinforcing steel from the existing structure. 

If the repairs do not encompass any steel from the existing structure, they are 

typically at least 6 inches thick. In such cases, consideration should be given to 

anchoring additional reinforcement (that will be embedded in the repair material) 

to the existing concrete. Typical examples of thick repairs include replacement 

concrete, preplaced aggregate concrete, shotcrete, and silica fume concrete. 

a. Replacement Concrete 

Replacement concrete is the most predominant concrete repair method 

Reclamation uses. It will meet the needs of a majority of concrete repair projects. 

It is generally the most cost-effective method and usually works better than other 

methods. This method should be used: 

	 When repairs are made with concrete without special bonding agents 

	 When the repair area exceeds about 1⁄2 square foot and has a depth 

sufficient to expose more than one-third of the circumference of 

reinforcing steel (requiring removal of concrete around the steel), or when 

the repair area is 6 inches deep and no reinforcing is present 

	 For holes greater than about 3 inches across and that extend entirely 

through concrete sections 

Replacement concrete repairs are made by placing new concrete in the repair area 

without the use of a bonding agent or Portland cement grout. The combination of 

an appropriate repair thickness, quality concrete, good surface preparation, and 

good curing practices ensures adequate hydration and a good bond between the 

new concrete and existing substrate. Because the defective concrete is being 

replaced with high quality concrete, the properties of the repair material are 

reasonably similar in many ways to the parent concrete. For this reason, 

replacement concrete is the best repair method in many cases. 

(1) Preparation 

Deteriorated or unsound concrete should be removed, following the methods 

described in section B.5. The perimeter of the repair area should be saw cut to a 

minimum depth of 1 inch. If the shape of the defect makes it advisable, the 

remainder of the concrete may be removed by chipping below the vertical saw cut 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

and continuing until an appropriate depth is reached. Reinforcing steel should not 

be left partially embedded. Instead, concrete should be removed around each bar 

to provide at least 1 inch of clearance, or the maximum aggregate size of the 

replacement concrete plus 1⁄4 inch, whichever is greater. 

Repairs to exposed horizontal flat surfaces are fairly straightforward. Forming is 

fairly basic, and no special access to place the concrete is needed. However, 

repairs to vertical surfaces, the underside of beams, enclosed horizontal surfaces, 

or sloped surfaces will require special formwork and steps to ensure that the 

concrete is properly placed and consolidated. 

For concrete replacement repairs to damage in walls, the saw cut should be made 

square to the surface, and concrete should be removed in a way that creates an 

upward slope (generally about 1:3) from the back of the repair to the front, from 

which the concrete will be placed (see figure 30, section B.5). This slope is 

necessary so that concrete can be placed without leaving air pockets at the top of 

the repair. Sometimes, when the damage extends through a wall or beam, it may 

be necessary to fill the area from both sides and modify the slope at the top of the 

repair accordingly. 

The bottom and sides of the repair area should be square with the face of the 

structure. When the defect or repair area extends through the concrete section, 

perimeter saw cuts are also needed on the back face to prevent spalling and 

feather edges. All interior corners should be rounded to a minimum radius of 

1 inch to prevent trapping air. 

For repairs on surfaces subject to destructive water action, and for other repairs on 

exposed surfaces, the perimeters of areas to be repaired should be saw cut as 

directed and, if possible, to a depth of 1-1⁄2 inches before the defective concrete is 

removed. The new concrete should be secured by keying methods, if possible. 

Figure 101 shows the invert of an outlet works properly prepared for replacement 

concrete. 

The construction and setting of forms are important steps in the procedure for 

satisfactory concrete replacement, where the concrete must be placed from the 

side of the structure. An example of form details for walls is shown in figure 102. 

To obtain a tight and acceptable repair, the guidelines below should be followed: 

	 For low slump conventional concrete, the front forms for wall repairs 

more than 18 inches high should be constructed in horizontal sections, so 

the concrete can be conveniently placed in lifts not more than about 

12 inches thick. For concrete formulated with a higher slump (for 

example, self-consolidating concrete), higher lifts can be used. The back 

form may be built in one piece. As concreting progresses, the fit of form 

sections to be set should be tested before placement begins. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 101. An outlet works repair being prepared for replacement concrete. 

Figure 102. Form details for placing concrete in vertical repair holes. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

	 To exert pressure on the largest area of form sheathing, tie bolts should 

pass through wooden blocks fitted snugly between the walers and the 

sheathing. 

	 For irregularly shaped holes, chimneys may be required at more than one 

level. When beam connections are required, a chimney may be necessary 

on both sides of the wall or beam. For such construction, the chimney 

should extend the full width of the hole. 

	 Unless a low shrinkage, low bleed concrete mixture is used, forms should 

be sufficiently strong so that pressure can be applied to the chimney using 

a pressure cap. The pressure cap can help offset the effects of shrinkage 

and bleed water. 

	 Forms must be mortar tight at all joints between adjacent sections, 

between the forms and concrete, and at tie bolt holes to prevent the loss of 

mortar if pressure is applied during the final stages of placement. Jute, 

twisted or stranded caulking cotton, folded canvas or burlap strips, or 

similar material should be used as the forms are assembled to make them 

mortar tight. 

	 For concrete proportioned to be high slump, placement practices and form 

design must be adjusted to accommodate the higher slumps (see 

Reclamation’s concrete guide specifications in Part II). 

Surfaces of old concrete to which new concrete is to be bonded must be clean, 

rough, and in a SSD condition. 

(2) Materials 

For larger placements, and for standard concreting practices, including placing, 

consolidating, finishing, and curing, consult Reclamation’s concrete guide 

specifications in Part II to select the appropriate concrete mixture types and 

proportions. For smaller placements that can be mixed by hand or in small 

portable mixers, some bagged cementitious and chemical repair mortars can be 

used (refer to section D.2.f.). 

For replacement concrete repair applications, special emphasis should be placed 

on using low shrinkage and low bleed concrete mixtures. Concrete for repair 

should have the same water to cementitious ratio as used for similar new 

structures, but it should not exceed 0.45, by weight, of cementitious materials. 

The largest appropriate maximum size aggregate, and a slump as low as is 

consistent with proper placing and thorough vibration, should be used to minimize 

water content and shrinkage. Sometimes, especially when repairing new concrete 

because of large voids or rock pockets in the placement, a repair material is 

batched with the same mixture that was used as the parent concrete, except that 

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Chapter D: Standard Methods of Concrete Repair 

 

 

the large aggregate is removed. This practice is inappropriate. The resultant 

mixture will have a higher paste content than needed, and it will very likely 

experience excessive shrinkage and bleed water. Instead, a new mixture should 

be used that is properly proportioned and is low shrinkage. 

In almost all cases, the concrete should be air entrained. Where surface color is 

important, the cement should be carefully selected or blended with white cement 

to obtain the desired results, or coloring agents should be used, as described in 

Reclamation’s concrete guide specifications in Part II. 

Shrinkage related to replacement concrete can be a significant issue because it 

may lead to disbonding and cracking. Reclamation’s concrete guide 

specifications contain materials and proportioning guidelines for placing low 

shrinkage concrete, including the use of chemical and dry shrinkage reducing 

additives. To minimize shrinkage, the concrete should be kept as cool as practical 

during placement, preferably at about 70 °F or lower. Materials should, therefore, 

be kept in shaded areas during warm weather. It may sometimes be necessary to 

use ice in mixing water. Batching of materials should be by weight, but batch 

boxes may be used if they are of the exact size needed. Because batches for this 

class of work will be small, the uniformity of the materials is important. 

For two recent concrete replacement repair projects in remote areas, concrete 

batches were prepared dry in large sacks (3,000 pounds) and then shipped to the 

site (see section C.7). After arrival, the sacks were emptied into transit mixers, 

water and additional admixtures were added, and the concrete was then mixed and 

placed. This method resulted in high-quality, high-strength concrete needed to 

resist abrasion erosion. However, as with all concrete batches, it is important to 

follow proper quality assurance procedures to ensure that the ingredients are as 

specified and are proportioned properly in the bags. 

(3) Application 

For general concrete placement considerations, Reclamation’s concrete guide

specification should be consulted. When placing concrete in lifts, placement 

should not be continuous. For conventional concrete, some time should elapse 

between placements to allow for some water bleeding and slight stiffening of the 

concrete. However, in no case should the concrete be so stiff that the concrete 

vibrator cannot easily penetrate the previous lift. When chimneys are required at 

more than one level, the lower chimney should be filled and allowed to remain for 

about 30 minutes between lifts. When chimneys are required on both faces of a 

wall or beam, concrete should be placed in only one of the chimneys and allowed 

to move to the other chimney because air pockets may become trapped in the 

concrete if it is placed in both chimneys at the same time. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

The quality of a repair depends not only on use of high-quality concrete, but also 

on the thoroughness of the vibration during and after concrete placement. Care 

should be taken to use proper vibration methods. Immersion-type vibrators 

should be used if there is suitable access. If not, this type of vibrator can 

sometimes be effectively used on the outside of the forms for smaller repairs. 

Form vibrators should also be considered. Form vibrators can be used to good 

advantage on forms for large inaccessible repairs, especially on a one-piece back 

form, or they can be attached to large metal fittings such as hinge base castings. 

If self-consolidating concrete is used, vibration is likely not needed or advised. 

For repairs that will use pressure caps to help reduce the effects of shrinkage and 

bleed water, pressure should be applied, and the form should be vibrated 

immediately after the repair area has been completely filled. This operation 

should be repeated at about 30-minute intervals until the concrete hardens enough 

to no longer respond to vibration. Pressure is applied by wedging or by tightening 

the bolts that extend through the pressure cap (figure 102). When filling the top 

of the form, concrete to a depth of only 2 or 3 inches is needed in the chimney 

under the pressure cap. A greater depth tends to dissipate the pressure. After the 

hole has been filled and the pressure cap is placed, the concrete should not be 

vibrated without a simultaneous application of pressure. Doing so may produce a 

film of water at the top of the repair that will prevent bonding. 

Traditionally, aluminum powder was sometimes added to concrete, which causes 

the concrete to expand, as described in section 182 of the Concrete Manual 

(Bureau of Reclamation, 1975). Now there are other shrinkage compensating 

additives and admixtures also available for use. Under favorable conditions, these 

compensated mixtures have been successfully used to secure tight, well-bonded 

repairs in locations where the replacement material was introduced from the side. 

Forms similar to those shown in figure 102 should be used. Time should not be 

allowed for settlement between lifts. When the top lift and the chimney are filled, 

no pressure need be applied, but the pressure cap should be secured in position, so 

that expanding concrete will be confined to, and completely fill, the area 

undergoing repair. There should be no subsequent revibration. For information 

about additives and admixtures that can be used to reduce or eliminate shrinkage 

and bleeding, consult CGSL. 

Concrete replacement in open top forms (such as for reconstruction of the tops of 

walls, piers, parapets, and curbs) is a comparatively simple operation. The best 

durability will be achieved by using the largest practical maximum size aggregate 

and the lowest practical percentage of sand. No special features are required in 

the forms, but they should be mortar tight when vibrated, and they should give the 

new concrete a finish similar to the adjacent areas. The top surfaces should be 

sloped to provide drainage. Manipulation during finishing operations should be 

held to a minimum, and a wood float finish is preferable to a steel trowel finish. 

Reclamation concrete guide specifications do not permit steel trowel finishing of 

air-entrained concrete exposed to freezing and thawing weather. Edges and 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

 

 

 

 

 

corners should be tooled or chamfered. Use of water for finishing is prohibited. 

As for many other repair cases, use of low shrinkage materials will improve repair 

results. 

Forms for concrete replacement repairs can usually be removed the day after 

casting, unless form removal would damage the green concrete. In this case, 

stripping of forms should be postponed. The concrete left in the chimneys should 

normally be removed within 24 hours of placement. If the trimming is done 

earlier, the concrete tends to break back into the repair. The chimneys should 

always be removed by working up from the bottom because working down from 

the top tends to break concrete out of the repair. The rough area resulting from 

trimming should be filled and stoned to produce a surface comparable to that of 

surrounding areas. If necessary, a Portland cement mortar repair can be used to 

smooth the surface. 

Some replacement concrete does not require forms. Replacement of damaged or 

deteriorated paving or canal lining slabs, wherein the full depth of the slab is 

replaced, involves procedures no different from those required for the best results 

in original construction. Contact edges at the perimeter should be saw cut square 

with the surface. 

Special repair techniques are required for restoring damaged or eroded surfaces of 

spillway or outlet works tunnel inverts and stilling basins. In addition to the usual 

forces of deterioration, such repairs often must withstand enormous dynamic and 

abrasive forces from fast flowing water and, sometimes, from suspended solids. 

For repairs to be durable in this environment, high-quality aggregate and high 

compressive strength concrete are needed. High strength silica fume concrete 

(section D.3.d.) is the repair material of choice for these types of repairs. 

(4) Curing and Protection 

The importance of curing replacement concrete repairs cannot be 

overemphasized. Complete failure of repairs has been attributed to improper 

curing. There is no known condition, aside from flooding the repaired structure 

(which, in itself, is an excellent curing method), that does not require curing of 

cementitious repairs. Because of the relatively small volume of most repairs, and 

the tendency of old concrete to absorb moisture from new material, water curing 

is a highly desirable procedure, at least during the first 24 hours after placement 

or form removal. When forms are used for repair, they can be removed and then 

reset to hold a few layers of wet burlap in contact with new concrete. One of the 

best methods of water curing is to lay burlap over the repair area, followed by 

placing a soil soaker hose beneath a plastic membrane. 

When a curing compound is used, the best curing combination is to allow an 

initial water curing period of 7 days (never less than 24 hours) and then apply a 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

uniform coat of curing compound while the surface is still damp. It is always 

essential that repairs, even dry pack repairs, receive some water curing and be 

thoroughly damp before the curing compound is applied. If nothing better can be 

devised for the initial water curing of the dry pack and similar repairs, a reliable 

worker should be assigned to make the rounds with water and a large brush, or a 

spraying device, to keep the repaired surfaces wet for 24 hours prior to application 

of a curing compound. White curing compound may be used only when its color 

does not create an objectionable contrast in appearance. 

b. Preplaced Aggregate Concrete 

Preplaced aggregate concrete is an excellent repair material that has not been used 

much in recent years. Preplaced aggregate concrete is made by injecting Portland 

cement grout, with or without sand, into the voids of a formed, compacted mass 

of clean, graded, coarse aggregate. The preplaced aggregate is washed and 

screened to remove fines before it is placed into the forms. As the grout is 

injected or pumped into the forms, it displaces any included air or water and fills 

the voids around the aggregate, thus creating a dense concrete having a high 

aggregate content. 

Because the aggregate has point-to-point contact prior to grout injection, 

preplaced aggregate concrete undergoes very little settlement, curing, or drying 

shrinkage during hydration. Drying shrinkage of preplaced aggregate concrete 

containing 1-1⁄2 inch maximum size aggregate is about 200 to 400 millionths, 

whereas drying shrinkage of conventional concrete containing the same size 

maximum aggregate is about 400 to 600 millionths. 

Another advantage of preplaced aggregate concrete is the ease with which it can 

be placed in certain situations where placement of conventional concrete would 

be extremely difficult or impossible. Preplaced aggregate concrete is especially 

useful in underwater repair construction. It has been used in a variety of large 

concrete and masonry repairs, including bridge piers and the resurfacing of dams. 

It has been used to construct atomic reactor shielding and plugs for outlet works 

and tunnels in mine workings, and it has been used to embed penstocks and 

turbine scroll cases. Figure 103 shows the upstream face of Barker Dam, near 

Boulder, Colorado, which was resurfaced with a combination of precast facing 

elements and preplaced aggregate concrete cast between the facing elements and 

the existing dam. 

Although preplaced aggregated is adaptable to many special repair applications, it 

is essential that the work be undertaken by well-qualified personnel who are 

willing to follow the construction procedures required for this repair material. 

Form work for preplaced aggregate concrete requires special attention to prevent 

grout loss. Leaking forms can cause significant problems. The injected grout 

flows much more easily than plastic concrete, and it takes longer to set. Forms, 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

 

 

 

 

therefore, must be constructed to handle more pressure than would be necessary 

with conventional concrete. Form bolts should fit tightly through the sheathing, 

and all possible points of grout leakage should be plugged or caulked. Additional 

information is available from ACI (ACI 304.1, 2005). 

Figure 103. The upstream face of Barker Dam was repaired with 

a combination of precast panels and preplaced aggregate 

concrete. 

(1) Preparation 

The preparation of concrete to be repaired by preplaced aggregate concrete is 

identical to the preparation required for replacement concrete (section D.3.a.) if 

the development of bond is required. 

(2) Materials 

Grout for preplaced aggregate concrete can be mixed with sand either of the 

gradation specified for conventional concrete or with fine sand, fly ash, 

water-reducing admixtures, and pumping admixtures as dictated by the smallest 

void space between the coarse aggregate particles. If the smallest coarse 

aggregate particle is 1-1⁄2 inches, then the sand gradation is that specified for 

conventional concrete. The Portland cement, water, and sand are mixed using 

high-speed centrifugal grout mixers that produce well-mixed grouts of a creamy 

consistency. If coarse aggregate particles are as small as 1⁄2 inch, a grout 

mixture is prepared containing fine sand passing a No. 8 screen, and with at least 

95 percent passing a No. 16 screen. Best pumping characteristics will be obtained 

with a fineness modulus between 1.2 and 2, and with the rounded shape of natural 

sands as opposed to crushed sands. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Adding fly ash and water-reducing admixtures improves the grout’s ability to 

flow and increases its ultimate strength. Proprietary pumping admixtures are 

commonly used to increase the penetration and pumpability of the final grout. 

The consistency of grout for preplaced aggregated should be uniform from batch 

to batch and capable of being readily pumped into the voids at relatively low 

pressure. Consistency is affected by water content, sand grading, filler type and 

content, cement type, and admixture type. For each mix, there are optimum 

proportions that produce the best grout pumpability or consistency, and tests are 

necessary for each job to determine these optimum proportions. Each proposed 

grout mix should be evaluated using the appropriate grout tests to ensure that the 

properties are suitable (Madera and Joy, 2014). 

The maximum size coarse aggregate used with the grout is the largest available, 

provided that the aggregate can be easily handled and placed. Coarse aggregate 

should meet all of the requirements of coarse aggregate for conventional concrete. 

It is essential that the coarse aggregate be clean. The aggregate should be well 

graded from the smallest size (1⁄2-inch minimum or 1-1⁄2-inch minimum) up to the 

maximum size, and when compacted into the forms, should have a void content of 

35 to 40 percent. 

(3) Application 

The grout piping system used with preplaced aggregate concrete must be designed 

to serve at least three purposes: (1) to deliver and inject grout, (2) to provide 

means for determining the grout level in the forms, and (3) to serve as vents in 

enclosed forms for the escape of air and water. Proper design and location of the 

grout piping system are essential for successful placement. 

The grout delivery pipeline should be a recirculating system (i.e., the grout 

delivery pipeline should extend from the grout agitator or holding tank to the 

grout pump, then to the injection manifold, and return to the grout agitator tank). 

With this type of pipeline, the grout can be kept moving and circulating in the 

delivery pipeline, even when no grout is being injected into the aggregate. Such a 

system prevents stoppages and clogging of the delivery line. Noncirculating or 

deadheaded systems should not be used. The delivery line should be kept as short 

as possible, and the pipe size should be such that normal grout flow velocities 

range between 2 and 4 ft/s. For most applications, a 1-inch inside diameter (ID) 

grout line will suffice. All valves used in the grout piping system should be quick 

opening ball valves that can be readily cleaned. 

The simplest piping system is a single recirculating delivery line that is attached 

via a manifold and valves to a single injection line. The injection line should 

extend to the lowest point in the form. Multiple injection lines are used for larger 

projects. Spacing of the injection lines is variable, depending on the form 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

configuration, aggregate gradation, and other factors, but spacing of 4 to 6 feet is 

common. In preparing the layout of the grout delivery system, it is normally 

assumed that the slope of the grout face will be 4:1 for work in the dry and 6:1 for 

underwater work. Much flatter slopes are common with actual grout surfaces. 

Sounding wells constructed from 2-inch ID slotted pipe are installed to allow 

determination of the level of grout during injection. Similarly, windows can be 

installed in the forms to allow visual determination of grout levels. The number 

and location of sounding wells are determined by the size and configuration of the 

aggregate mass. The ratio of sounding wells to injection pipes should be from 

1:4 to 1:8. 

Grout injection should begin at the lowest point of the form and continue 

uniformly until the entire form is filled. After sufficient grout has been pumped 

to raise the level of grout in the form to about 18 inches above the outlet of the 

injection line, the injection line can be progressively raised, maintaining about 

12 inches of pipe embedment below the level of the grout surface at all times. A 

great deal of thought and planning is required if multiple injection lines are used. 

The objective is to entirely fill the form without trapping air or water. Vents must 

be located where needed, and the injection sequence must be designed to promote 

complete filling. 

It is not possible to use internal vibrators to consolidate preplaced aggregate 

concrete. External vibrators, however, can be attached to the forms and used 

advantageously. External vibration will eliminate the splotchy appearance that 

can occur where coarse aggregate particles contact the forms. 

Underwater applications of preplaced aggregate concrete require additional 

considerations. During injection, grout pumping must continue until an undiluted 

flow of grout emerges from the top of the form. Formwork is usually closed at 

the top to prevent washout or dilution of the grout after placement, especially if 

flowing water is encountered. Anti-washout admixtures might prove useful for 

underwater applications of preplaced aggregate concrete. Care must be taken 

when using several different types of admixtures (e.g., anti-washout, pumping 

aids, or high-range water reducers) to ensure that undesirable combinations are 

avoided. For example, some anti-washout admixtures can significantly reduce the 

pumpability benefits of some high-range water reducers. 

The minimum volume of the grout mixer tank and the grout agitator tank should 

be 17 cubic feet. The grout should be mixed using a high-speed centrifugal mixer 

operating at a minimum of 1,500 rotations per minute. The grout pump should be 

a progressive cavity pump (commonly known as a “Moyno” grout pump) that is 

capable of pumping at least 20 gallons of grout per minute at the specified 

injection pressure. More information about grouting equipment and requirements 

can be found in Reclamation’s grouting guide specification.

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Quality control of preplaced aggregate concrete lies with proper compaction of 

the aggregate into the forms and maintenance of proper grout consistency 

throughout the job. Compaction requirements must be satisfied by visual 

inspection during placement and before grout is introduced into the forms. 

(4) Curing 

The curing requirements for preplaced aggregate concrete are the same as for 

replacement concrete (section D.3.a.). Preplaced aggregate concrete placed 

during underwater applications will normally achieve excellent curing. 

c. Shotcrete 

Shotcrete, sometimes called gunite, is an application method for concrete. 

Typically, the concrete materials are selected and proportioned to make 

application effective. Shotcrete is defined as “mortar or concrete pneumatically

projected at high speed onto a surface” (ACI 506R, 2005). There are two basic 

types of shotcrete: dry mix and wet mix. In dry mix shotcrete, the dry cement, 

sand, and coarse aggregate, if used, are premixed with only sufficient water to 

reduce dusting. This mixture is then forced through the delivery line to the nozzle 

by compressed air. At the nozzle, sufficient water is added to the moving stream 

to meet the requirements of cement hydration. For wet mix shotcrete, the cement, 

sand, and coarse aggregate are first conventionally mixed with water, and the 

resulting concrete is then pumped to the nozzle, where compressed air propels the 

wet mixture onto the desired surface (figure 104). 

Figure 104. 

Using shotcrete 

to repair a 

spillway floor. 

Shotcrete was 

used here 

because of the 

remoteness of 

the site. 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

The two types of shotcrete produce mixes with different water contents and 

different application characteristics as a result of the distinctly different mixing 

processes. Dry mix shotcrete suffers high dust generation and rebound losses that 

vary from about 15 percent to 50 percent. Wet mix shotcrete must contain 

enough water to permit pumping through the delivery line. Wet mix shotcrete, as 

a result, may experience significantly more cracking problems due to more water 

and drying shrinkage. Advances in the development of high-range, water 

reducing admixtures; pumping aids; and concrete pumping equipment since about 

1960 have greatly reduced these problems, and wet mix shotcrete is now used 

more frequently in repair construction. 

Shotcrete is a very versatile construction material (figure 105) that can be readily 

placed and successfully used for a variety of concrete repair applications. The 

necessity of form work can be eliminated in many repair applications by using 

shotcrete. Shotcrete has been used to repair canal and spillway linings and walls, 

faces of dams, tunnel linings, highway bridges and tunnels, deteriorating natural 

rock walls, and earthen slopes, as well as to thicken and strengthen existing 

concrete structures. Provided that the proper materials, equipment, and 

procedures are employed, shotcrete repairs can be accomplished quickly and 

economically. However, the apparent ease of application should not lead to the 

mistaken belief that shotcrete repair is a simple procedure, or one that can be 

haphazardly or improperly applied. The following two paragraphs contain a very 

descriptive warning of such practices: 

Figure 105. Even though space was limited, due to the complicated geometry 

of this outlet works, shotcrete was used to make concrete repairs. The 

shotcrete was later finished to a smooth surface. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

“Regardless of the considerable advantages of the shotcrete process and 

its ability to provide finished work of the highest quality, a large amount 

of poor and sometimes unacceptable work has unfortunately occurred in 

the past, with the result that many design and construction professionals 

are hesitant to employ the process. As with all construction methods, 

failure to employ proper procedures will result in inferior work. In the 

case of shotcrete the deficiencies can be severe, requiring complete 

removal and replacement. 

Deficiencies in shotcrete applications usually fall into one of four 

categories: failure to bond to the substrate, delamination at construction 

joints or faces of the application layers, incomplete filling of the material 

behind reinforcing, and embedment of rebound or other unsatisfactory 

material.” (Warner, 1995) 

Each of these deficiencies has occurred on Reclamation repair projects. Perhaps 

more important with shotcrete than with any other standard concrete repair 

method, if highly qualified, well trained, and competent personnel cannot be 

employed, it is advisable to consider using some other repair procedure. The 

quality of shotcrete closely depends on the skill and experience of one person: the 

nozzle operator. Reclamation specifications require that only formally certified 

nozzle operators be employed for shotcrete repairs. Prior to the nozzle operator’s 

arrival at the job, they should obtain necessary on-the-job training to develop the 

experience and skill needed to obtain certification for Reclamation work. 

For repair work that will involve shotcrete, Reclamation’s guide specification for 

shotcrete should be consulted. 

(1) Preparation 

Concrete to be repaired with shotcrete should be prepared in a manner identical to 

the preparation required for replacement concrete (section D.3.a.(1)). It is 

essential that the shotcrete have a clean, sound concrete base for bond. 

(2) Materials 

Cement used for shotcrete should meet the same requirements as cement used for 

replacement concrete. For example, if sulfate exposure conditions exist, type V 

Portland cement should be specified. Normally, however, Type II, low alkali 

(LA) cement is adequate. 

Water, sand, and coarse aggregate used in shotcrete should also meet the 

requirements shown in Reclamation’s shotcrete guide specification in Part II. 

Likewise, admixtures and additives should meet the requirements in the guide 

specification. In addition, specialty admixtures can be used to increase 

strength and reduce shrinkage. 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

 

 

Generally, shotcrete should be proportioned to contain 6- to 8-percent entrained 

air. It is sometimes desirable to use accelerating admixtures in shotcrete where 

rapid setting or rapid strength development is required. Calcium chloride 

accelerators have long been used, but there are now sufficient nonchloride 

containing accelerators available to make the use of calcium chloride inadvisable. 

The use of calcium chloride accelerators is particularly unadvisable in shotcrete 

applications containing reinforcing steel or steel fibers. ACI has published a 

guide for fiber reinforced shotcrete (ACI 506.1R, 2008), and this document 

should be consulted if the use of fiber reinforced shotcrete is considered. It 

should be recognized that application of fiber reinforced shotcrete is more 

difficult and requires more experienced nozzle operators. 

(3) Application 

A detailed discussion of shotcrete application techniques and technology is 

beyond the scope of this Guide; however, ACI has published a recommended 

practice and a specification for materials, proportioning, and application of 

shotcrete (ACI 506R, 2005) (ACI 506.2, 2013). In addition, Reclamation has 

developed guide specifications for using shotcrete. These documents should be 

consulted before shotcrete repairs are attempted. 

(4) Curing 

Proper curing of shotcrete is essential if high-strength properties, durability, and 

long service life are to be obtained. It is important to begin curing by applying 

approved curing compounds or water spray before there has been evaporative 

water loss from the shotcrete, particularly during periods of high temperatures, 

low humidity, or high wind conditions. Improvements in quality and a reduction 

in potential shrinkage cracking will be obtained by curing for longer periods. 

d. Silica Fume Concrete 

Silica fume concrete (SFC) is conventional Portland cement concrete that contains 

silica fume. Silica fume is an ultrafine powder that results from the production of 

silicon and ferrosilicon alloy. The particles are spherical and extremely fine (on 

the order of 150 nanometers [nm]). When mixed into Portland cement concrete, 

silica fume acts as a “super pozzolan.” Concrete that has a low water to 

cementitious materials ratio and contains 10- to 15-percent silica fume, by weight, 

of cement can develop 10,000- to 15,000-psi compressive strengths at 28 days’ 

age, and have a reduced tendency to segregate, very low permeability, and 

enhanced freeze-thaw and abrasion-erosion resistance. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Special repair techniques are required for restoration of eroded surfaces of 

spillway or outlet works tunnel inverts and stilling basins. In addition to the usual 

forces of deterioration, such repairs often must withstand large dynamic and 

abrasive forces from fast flowing water and, sometimes, from suspended solids. 

The enhanced abrasion-erosion resistance and high strength of SFC makes it the 

repair material of choice for these types of repairs (figure 106). Polymer 

concretes can also be used for this purpose, but they are much more expensive. It 

should be recognized, however, that the cause(s) of the original damage must be 

mitigated if a permanent repair is to be achieved. Otherwise, the repair material 

will be similarly damaged, but should last much longer than the original concrete. 

Figure 106. Abrasion-erosion test results showing that the SFC mixture 

withstood abrasion erosion much better than conventional concrete. 

Reclamation’s concrete guide specifications provide guidance for SFC. The net 

water cementitious materials ratio for these mixtures is typically low and should not 

exceed 0.35, by weight, for achieving high strength. The addition of silica fume to 

concrete will increase the water requirement, due to the high surface area of the 

very fine silica fume particles. It is necessary to use a high-range, water-reducing 

admixture (HRWRA) to obtain the maximum strength and durability with SFC. 

Because SFC usually has a low water to cementitious materials ratio, it is very 

important to place and finish SFC quickly, before excessive mix water evaporates 

and stiffening occurs. The slump gain from the HRWRA commonly offsets some 

of the “stickiness” of SFC. Depending on the actual compressive strength desired, 

an air-entraining agent may not be necessary. Set-retarding and extending 

admixtures have been successfully used when the interval between mixing and 

placing is quite long. Recently, these high-strength mixtures have been 

proportioned with a chemical and drying shrinkage reducing additive to reduce 

cracking with very good results. 

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Chapter D: Standard Methods of Concrete Repair 

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SFC can be used for thin or thick repairs. However, because of the types of repairs 

for which SFC is typically used, it is almost always applied as a thick repair. For 

thin repairs, it is advisable to place SFC no less than 2 inches thick. SFC requires a 

very thorough curing procedure, however, and should not be used unless this 

procedure can be thoroughly accomplished. Otherwise, this repair material is used 

in accordance with the provisions for conventional replacement concrete. 

The silica fume admixture is generally supplied as a densified silica fume powder 

with or without HRWRA and other dry admixtures. It is sometimes also available 

in a water slurry with HRWRA and other admixtures. 

The densified powder form is currently the most convenient form to ship and use. 

In this form, the silica fume powder is compacted and densified, so it does not 

produce nearly as much dust as the undensified form. Because it has been 

compacted into clumps, sufficient mixing is needed to fully break up and disperse 

the densified silica fume admixture in the concrete mixture. 

As with any concrete mixture, it is essential that trial batches be prepared and tested 

during mix design to ensure development of the desired concrete properties. Silica 

fume increases the cohesion or “stickiness” of the concrete, and it can result in 

workability and finishing problems for workers who are inexperienced in proper 

finishing techniques. It is recommended that trial placements be performed using 

similar placement geometries and haul times, along with finishing and curing 

methods, so that construction personnel can become familiar with the material. 

(1) Preparation 

Concrete to be repaired with SFC should be prepared in accordance with the 

requirements of section B.5. 

(2) Materials 

Materials for SFC are the same as for conventional concrete, except for the addition 

of the silica fume, the low water to cementitious materials ratio, and the addition of 

HRWRA to make the mixture workable. Complete material information is 

provided in Reclamation’s concrete guide specification. 

(3) Application 

Silica fume concrete must be mixed, transported, and placed in accordance with the 

procedures for conventional concrete and with the provisions of section D.3.a. and 

Reclamation’s concrete guide specification. 
 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Silica fume concrete is placed and finished using conventional equipment (figure 57). 

As previously discussed, placement should take place quickly to allow finishing 

before drying and stiffening occur. Consolidation and compaction should be 

accomplished with internal vibrators. Vibrating screeds can be used for larger 

placements; usually, a single pass of multirow screeds will provide an adequate 

surface finish. Hand troweling silica fume concrete is usually not very effective, 

except for small repairs, because it takes too long. There is very little bleed water 

development after placing SFC. This can result in plastic shrinkage cracking under 

conditions of elevated temperatures, low humidity, and high wind conditions, which 

cause rapid water evaporation from the concrete surface (see section (4) below). The 

use of a long chain, cetyl alcohol, evaporation retarding aid is highly recommended 

under such conditions. 

(4) Curing 

Silica fume concrete must be properly cured to achieve a successful repair. As stated 

above, fresh silica fume concrete has very low or no bleed water development, due to 

the affinity silica fume has for water and the low water to cementitious ratio of the 

mix. If the rate of evaporative water loss from the surface of freshly placed silica 

fume concrete exceeds the rate of bleed water development, plastic shrinkage 

cracking of the surface will result. Evaporative water loss can be prevented by 

immediately applying curing compound, covering the fresh concrete with a plastic 

membrane, water fogging or flooding, or using an evaporation retarder. The common 

practice with conventional concrete of allowing the development and evaporation of 

bleed water from the surface prior to beginning curing will almost always result in 

cracking of silica fume concrete. It is best to begin the curing of silica fume concrete 

immediately after finishing. Very successful curing of stilling basin repairs has 

resulted from flooding the repair area with water immediately after the silica fume 

concrete has attained initial set. Even so, water evaporation from the concrete surface 

must be prevented prior to flooding. Water soaker hoses can be placed under 

polyethylene as soon as the concrete has attained initial set, and water should be 

applied continuously for 14 days. If good proportions are developed, and good 

placing and curing practices are followed, the repairs should be virtually crack-free. 

4. Crack and Water Leak Repairs 

Crack and leak repair methods are described below. They are treated separately 

from other concrete repair methods because they are significantly different from 

methods for thin or thick repairs. In many ways, properly repairing cracks and leaks 

can be the most difficult type of repair. In many Reclamation structures, if the 

concrete cracks, there is also a water leak. In addition, improperly constructed or 

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Chapter D: Standard Methods of Concrete Repair 

I-145 

 

 

deteriorated joints can leak water. As with repairs in general, Reclamation’s sevenstep process should be followed for crack repairs. In other words, the cause and 

extent of the cracks or leaks should be determined, including whether the cracks are 

dormant or active (moving); exposure conditions should be considered, wetting and 

drying, etc. (section C.11). 

There are two basic types of crack repair: (1) resin injection, and (2) adding 

additional reinforcement. These two methods can be performed separately or in 

combination. Additional reinforcement is typically added if the shear or tensile 

capacity of a structural element has been, or might be, exceeded. This can occur if 

existing reinforcing is somehow damaged (for example, by corrosion), or if loading 

conditions or design standards have changed (for example, earthquake loads may be 

higher than originally thought). These types of repairs can be performed a number 

of different ways, including anchoring posttensioning wires or bars to existing 

elements (figure 107) or gluing special high-strength fiber mats (glass or carbon, for 

example) to portions of structures (figure 108). Usually, adding additional 

reinforcement involves a significant design and construction effort, so a discussion 

of that repair method is beyond the scope of this document. Reclamation has 

prepared a guide specification for using carbon fiber reinforced polymer for repair of 

large-diameter concrete pipe (figure 108). A copy can be obtained from the CGSL. 

Figure 107. Adding additional reinforcement to the exterior of a largediameter siphon. 
 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 108. Installing carbon fiber reinforced polymer to repair a large 

concrete pipe. 

a. Resin Injection 

Resin injection is used to repair concrete that is cracked or delaminated, as well as 

to seal cracks or joints in concrete that is experiencing water leakage. Two basic 

types of resin injection techniques are used to repair Reclamation concrete: 

(1) use of epoxy resins, and (2) use of polyurethanes and methacrylic acrylates. 

Epoxy resins are used to structurally rebond cracks that are dormant and relatively 

dry, while various polyurethanes and some methacrylic acrylates are used to seal 

cracks or joints that leak water. It is usually not possible to structurally rebond 

cracks that are leaking water, are dirty, or are very wet. Also, due to the high cost 

of resin injection, it is not normally used to repair shallow cracks, drying 

shrinkage cracks, or pattern cracking. Therefore, if repairs are needed for these 

types of cracks, a sealing approach is usually more effective. 

(1) Epoxy Resins 

Epoxy resins cure to form solids with high strength and relatively high modulus 

of elasticity. These materials bond readily to concrete and are capable, when 

properly applied, of restoring the original structural strength to cracked concrete. 

The high modulus of elasticity causes epoxy resin systems to be unsuitable for 

rebonding cracked concrete that will undergo subsequent movement. 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

Cracks to be injected with epoxy resins should be between 0.002 inch to 0.25 inch 

in width. It is difficult or impossible to inject resin into cracks less than about 

0.002 inch in width, and it is very difficult to retain injected epoxy resin in cracks 

greater than 0.25 inch in width, although high viscosity epoxies have been used 

with some success. Epoxy resin bond strengths can easily exceed the shear or 

tensile strength of the concrete. If these materials are used to rebond cracked 

concrete that is subsequently exposed to loads that exceed the tensile or shear 

strength of the concrete, cracks will likely recur adjacent to the epoxy bond line. 

In other words, epoxy resin should not be used to rebond “working” cracks.

Epoxy resins will bond with varying degrees of success to wet concrete. There 

are a number of special techniques that have been developed and used to rebond 

and seal leaking cracks with epoxy resins. These special techniques and 

procedures are highly technical and, in most cases, are proprietary in nature. 

They may have application on Reclamation projects, but only after a thorough 

analysis has been performed to ensure that the more standard repair procedures 

will not be successful or cost effective. 

Epoxy resins used to rebond concrete should meet the requirements of 

ASTM C881, “Standard Specification for Epoxy-Resin-Base Bonding Systems 

for Concrete” (ASTM C881/C881M, 2013). In addition to information in this 

guide for epoxy resin injection, ACI (ACI 503.7, 2007) provides a guide 

specification. 

(2) Polyurethane and Methacrylic Acrylate Resins 

These resins are used to seal and eliminate or reduce water leakage from concrete 

cracks and joints (Joy, 2013) (von Fay and Joy, 2013). They can also be injected 

into cracks that experience some degree of movement. Such systems, except the 

two-part solid polyurethanes, have relatively low strengths and should not be used 

to structurally rebond cracked concrete. 

Cracks to be injected with polyurethane resin should not be less than 0.005 inch in 

width, while cracks smaller than that can be injected with methacrylic acrylates. 

Using methacrylic acrylates requires special mixing procedures and stainless steel 

pumping equipment; however, in some applications, it is very effective at sealing 

very small leaking cracks, due to its very low viscosity. For more information 

about using these products on Reclamation facilities, contact staff from the 

CGSL. No upper limit on crack width has been established for polyurethane 

resins at the time of publication. For very large cracks, expanding resin can exert 

enough pressure that extra steps, such as wood wedges or bulkheads, may be 

needed to contain the grout in the crack. When cracks and voids are injected with 

these materials, the best results are typically obtained when they are confined, so 

they cannot freely expand. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Polyurethane materials can also be used to stop high-volume water leaks under 

some conditions (figure 109). This usually requires gaining control of the water 

and then injecting resin to plug the leak. Steps for this process are described 

below. In addition, a novel approach was recently tested, which involved using a 

solid form of hydrophilic polyurethane that had been ground up into fine particles, 

and then releasing it in front of a high-volume water leak through a contraction 

joint in a dam (Starbuck, 2014). Preliminary results using this approach appeared 

to be successful (figure 110). 

Figure 109. High-volume water leaks can be repaired using polyurethane resins. 

Polyurethane resins are available that have properties and formulations that vary 

substantially from one another. Some polyurethanes cure into flexible foams. 

Other polyurethane systems cure to semiflexible, high-density solids that can be 

used to rebond concrete cracks that are subject to movement, as long as the 

movements are not too large. Most of the foaming polyurethane resins require 

some water to initiate the curing reaction and, therefore, are a natural selection for 

use in repairing concrete that is exposed to water or wet environments. Currently, 

there are no standard specifications for polyurethane resins for injecting cracks in 

concrete that are equivalent to ASTM C-881 for epoxy resins. The lack of 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

 

 

 

 

standards, combined with the wide variations in polyurethane properties, means 

that great care must be exercised in selecting polyurethane resins for concrete 

repair. “Cookbook” type application of these resins will likely be unsuccessful. 

The CGSL is continuously evaluating these very useful resin systems. They can 

provide advice and guidance for field applications on Reclamation facilities if 

requested. 

Figure 110. 

Ground 

hydrophilic rubber 

deposited in front 

of a leaking 

contraction joint. 

Left: Particles 

being pulled into 

the joint. Right: 

Particles 

completely 

plugging the joint. 

(3) Preparation 

Cracks, joints, or lift lines to be injected with resin should be cleaned to remove 

all the contained debris and organic matter possible, including debris next to the 

crack that may prevent bond of a crack seal coat or may block visibility of the 

crack (figure 111). Several techniques have been used to clean debris from 

within a crack, with varying degrees of success. In some cases, blowing oil-free, 

high-pressure air through a small tube directed at the crack can remove debris 

(figure 112). For some types of resin injection, once injection holes have been 

drilled and ports installed, repeated cycles of alternately injecting compressed air, 

followed by water, have been very useful in flushing and cleaning cracks. For 

small cracks, ports may need to be drilled or cored with vacuum bits or water 

wash bits to prevent concrete dust and cuttings from plugging the cracks. 

Successful use of soaps in the flushing water has been reported by some 

practitioners. However, complete removal of such materials once they have been 

injected into cracks is difficult and may create more problems than it is worth. 

The use of acids to flush and clean cracks is not allowed by Reclamation. Cracks 

to be structurally repaired using epoxy injection should not normally be injected 

with water or other liquids. Some epoxy resins will bond to wet concrete, but 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

they will develop higher bond strength when bonding to dry concrete. Finally, 

successfully injecting resins into fine cracks that are partially plugged with calcite 

can be very difficult. 

Figure 111. Cleaning the surface of a crack using a small 

grinder prior to gluing on the port and sealing the face of 

the crack with epoxy resin. 

Figure 112. Using 

compressed air to 

clean dust and 

debris from the 

crack opening. 

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Chapter D: Standard Methods of Concrete Repair 

 

When epoxy resin injection is performed, the resin is typically injected directly 

into the crack opening using glued-on ports (figure 113). For some projects, 

however, drilled-in mechanical ports may be needed. Once the ports are installed, 

the crack opening is sealed using a suitable epoxy capping material (figure 114), 

usually one recommended by the manufacturer of the injection epoxy. 

Figure 113. Ports glued to the face of cracks prior to epoxy 

injection. 

Figure 114. Sealing the crack opening for epoxy resin injection after 

attaching the injection ports. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Because polyurethane resins have relatively high viscosities and fast cure 

times, resin injection holes are typically drilled on alternate sides of the leak 

(figure 115), usually at a maximum spacing of 24 inches. The alternating pattern 

is used to ensure that the crack is intercepted, because the location of the crack 

underneath the surface is usually unknown. For joints, or areas where the leak 

path is known, drilling on one side is acceptable. In these situations, installing 

ports directly into a joint may also be acceptable under certain circumstances (for 

example, leaking concrete pipe joints). For angled holes, the holes are drilled 

offset from the leak opening to intercept the crack at a depth of 8 to 24 inches (as 

concrete thickness allows, these holes should extend as deeply as possible), or at 

the midpoint of the thickness for thinner sections. 

Figure 115. Drilling an injection hole to intercept the leak 

several inches from the face for polyurethane resin injection. 

Once the holes are drilled, ports can be installed (figure 116). Injection ports of 

various designs may be installed in the drilled holes, depending on the injection 

plan and the presence of flowing water. For polyurethane resin injection, the joint 

or crack openings do not always need to be sealed because these resins usually 

cure quickly. Sealing is typically only done if the water leaks are large enough to 

wash the resin out before it cures, or if the opening is so large that the resin is not 

constrained. If the joint or crack needs sealing due to high waterflows, special 

steps are needed to slow the waterflows (see section (6)(b), below). If the 

opening is so large that the resin is not adequately contained, then special jute or 

open cell backer rod (figure 117) can be soaked in resin and pushed into the joint 

or crack to form a bulkhead. For very large cracks, additional steps may be 

needed to contain the grout. 

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Chapter D: Standard Methods of Concrete Repair 

I-153 

 

Figure 116. Ports placed into holes for injecting polyurethane resin into a leaking 

expansion joint in a powerplant deck. The holes are drilled to intercept the joint between 

the rubber waterstop and an embedded metal plate. 

Figure 117. Placing resin soaked jute or open cell backer rod into large cracks or 

joints can help contain the polyurethane injection resin for large cracks and joints. 
 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(4) Materials 

Epoxy resin used for crack injection should be a 100-percent solids resin meeting 

the requirements of ASTM C-881 for Type I or IV, Grade 1, Class B or C 

(ASTM C881/C881M, 2013). If the purpose of injection is to restore the 

concrete to its original design load bearing capabilities, a Type IV epoxy should 

be specified and used. If the purpose does not involve restoration of load bearing 

capabilities, a Type I epoxy is sufficient. Solvents or unreactive diluents should 

not be mixed into the resin. 

As stated above, there are many types of polyurethane resins. Reclamation almost 

exclusively uses water activated, single component hydrophilic or hydrophobic 

resins. Accelerators and catalyst may be used to adjust the reaction rate. 

Elastomeric polyurethanes are two component, and they do not require water to 

react. Reclamation typically uses these polyurethanes only in special 

circumstances (for example, to fill voids behind steel draft tube liners, or to plug 

high-volume water leaks), so they will not be discussed further. Polyurethane 

resins can react and harden within 1 minute to several minutes, and they can 

expand significantly or only slightly, depending on formulation and confinement. 

Hydrophilic resins require water to react, typically at a water-to-resin ratio of 1:1, 

but that ratio can be as high as 20:1. Depending on the amount of water used for 

the reaction, the end product will be either a foam (1:1 to about 5:1 mix ratios) or 

a gel (5:1 and higher mix ratios). A potential problem with hydrophilic foams is 

shrinkage in dry conditions. If the final product is not in a high relative humidity 

environment or in contact with water, shrinkage will occur due to water 

evaporating from the cured grout. After drying and shrinking, many products will 

swell after additional exposure to moisture. Many products can go through 

multiple wet-dry cycles, but the effectiveness of the products may be negatively 

impacted after several of these cycles. 

Hydrophobic resins require little water to react. These products consist of a resin 

mixed with a small amount of catalyst, and they require a small amount of water 

to propagate the reaction. Adding some additional water does not appreciably 

change the reaction, but it may lower the quality of the final product. 

The difference between some modern and historical hydrophobic polyurethanes 

lies in the final product. Traditionally, hydrophobic resins produced foams that 

were very stiff and not very flexible. Today, there are hydrophobic resins 

available that produce a flexible foam, much like hydrophilic resins. This can be 

advantageous because the final product will not shrink very much in a dry 

environment, whereas hydrophilic grouts will shrink. This leads to a much larger 

product base to choose from for a given project. One major difference to consider 

is cost. While the base resin prices are similar for hydrophilic and hydrophobic 

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Chapter D: Standard Methods of Concrete Repair 

 

 

 

resins, hydrophilic resins are injected with equal amounts of water at a minimum, 

which reduces material costs substantially. 

Water activated polyurethane resin used for crack injection should be composed 

of 100-percent polyurethane resin as one part, and water as the second part. The 

polyurethane resin, when mixed with water, should be capable of forming either a 

closed cell, rigid or flexible foam, or a cured gel, depending on the specific resin 

used and the water to resin mixing ratio. However, the resin should, with 

appropriate water to resin mixing ratios, result in a cured resin foam with 

properties that match the crack characteristics and exposure conditions. For 

example, for cracks that are moving significantly or leaking joints, strong bond, 

tensile strength, and high elongation will be needed. If the crack will dry out, 

then hydrophobic grouts should be considered. Contact manufacturers for 

specific recommendations and certification that their product meets job 

requirements before accepting the injection resins for use on a project. 

As stated earlier, there are many, many types of resins and application methods 

available for crack repair. Because of this, CGSL staff should be consulted about 

their use on Reclamation projects. 

(5) Injection Equipment 

Resins can be injected with many types of equipment. Small repair projects can 

be performed using caulk cartridge-type equipment (figure 118), and several firms 

make their products in cartridges for such application. Airless paint sprayers, 

paint pressure pots, and a variety of specialized pumps are examples of the 

equipment that is available. 

Small projects that employ epoxy resin can use any system that will successfully 

deposit the epoxy in the required area. For these systems, the epoxy components 

are mixed together and then poured into the injection equipment (figure 119). 

Once mixed, the epoxy must be injected before it starts to thicken. Longer pot 

life epoxies should be used for this technique. 

Large epoxy injection projects generally require a single-stage injection method 

by which the two epoxy components are pumped independently from their 

separate reservoirs to the mixing nozzle. At the mixing nozzle, the epoxy 

components are mixed and then injected. The epoxy used with this injection 

technique must have a low initial viscosity and a closely controlled set time. 

Several firms have proprietary epoxy injection systems (figure 120) that work 

very well. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 118. Two-component cartridge 

system for injecting resin into cracks. 

Figure 119. A small pressure pot for injecting mixed epoxy resin into 

a crack. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 120. A resin injection system specifically manufactured 

for injecting epoxy resins. 

Many polyurethane resins have a much shorter pot life after mixing than epoxies. 

As stated earlier, there are many types of pumps that can be used for polyurethane 

resin injection (Joy, 2013), depending on the resin being used. Polyurethane 

injection equipment varies from small, hand-operated pumps to full-size 

commercial equipment capable of discharging many cubic feet of resin per hour 

(figures 121, 122, and 123). Use of high-quality, polyurethane resin injection 

equipment is always recommended as a first choice. 

For hydrophilic and two-component (elastomeric) resins, Reclamation usually 

requires that the resins be prepared and injected with multiple component, 

single-stage equipment. In some special situations, commercial grade airless 

paint sprayers can be connected together for injecting multiple components. With 

this method, it can be difficult to control injection pressures, and the resin 

components must be in graduated containers to ensure that the components are 

being properly proportioned. Pressures of the individual pumps may need to be 

adjusted to ensure proper proportioning. Only very experienced personnel should 

be allowed to perform polyurethane injection on a Reclamation project with 

equipment designed for, or adapted from, other operations. 

These resins should always be mixed and injected with the appropriate amount of 

water or other components necessary to achieve the desired final product. Using 

existing water in the leaking joint or crack as mix water for hydrophilic resin is 

almost never allowed because it would be nearly impossible to ensure adequate 

mixing in the joint or crack. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Figure 121. Hand-operated pump used to inject resin in difficult access areas. 

Figure 122. Airless paint sprayers can be used for 

some injection applications. However, personnel 

who use such equipment need to be well versed in 

their use for proper resin injection work. 

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Chapter D: Standard Methods of Concrete Repair 

Figure 123. A high-pressure resin injection pump capable of 

injecting two components and water. 

The pumping pressure required of polyurethane injection equipment may exceed 

2,000 psi. However, because the resin is fairly viscous, the pressures typically 

dissipate within a very short distance of the injection point. On one recent job, an 

impromptu pressure test was performed. Pressures were monitored in an adjacent 

port located about 2 feet from the injection port. No pressure was registered on 

the adjacent ports, even though injection pressures approached 800 psi for a short 

time. 

(6) Application 

The success of resin injection repair projects is directly related to the experience 

and knowledge of the injection contractor. Reclamation requires that an injection 

contractor have a minimum of three similar projects within the last 5 years. 

However, Reclamation may accept an injection contractor who has not had the 

required experience provided that the work is performed under technical 

supervision of the injection resin manufacturer, and provided that the 

manufacturer has a minimum of 10 years of experience providing resins for 

applications similar to those specified. 

(a) Application of Epoxy Resin by Pressure Injection 

The objective of epoxy resin injection is to completely fill the crack or 

delamination being injected and retain the resin in the filled voids until it has 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

cured. The first step in the resin injection process is to thoroughly clean the 

concrete surface in the vicinity of the cracks of all loose or deteriorated concrete 

and debris. The area of injection is then inspected, and the injection port location 

pattern is established. Several different types of injection patterns can be used 

and are discussed below: 

	 If the cracks are clearly visible and relatively open, injection ports can be 

installed at appropriate intervals by installing the ports directly onto the 

crack surface. The ports can be glued directly on the surface if the surface 

is high quality and the injection pressures are not too high (generally less 

than 400 psi). If the surface is not of high quality and/or the injection 

pressure will be high, then mechanical ports can be installed in holes that 

are drilled into the crack from the crack opening or angled in from the side 

of the crack, similar to polyurethane resin injection techniques (see 

below). When drilling the ports, care should be taken to prevent drilling 

debris and dust from blocking or sealing the openings. Special vacuum 

drill bits and water swivel chucks are available for this work. The surface 

of the crack between ports is then sealed with epoxy paste, and the paste is 

allowed to cure. For vertical cracks, epoxy injection begins at the lowest 

elevation port and proceeds along and up the crack to the highest port. 

	 A sometimes more effective but more time-consuming method is to drill 

holes on alternate sides of the crack, angled to intersect the crack plane at 

an appropriate depth below the surface. This method ensures that the 

crack will be intersected, even if it strikes or dips in unexpected directions. 

The top surface of the crack is then sealed with epoxy paste, and injection 

is accomplished as described above. 

Many times, multiple adjacent ports can be injected at the same time (figure 124). 

Usually, better results are obtained by using lower injection pressures and 

allowing more time for the epoxy to fill cracks and voids. It is important to match 

injection time to pot life. The use of high injection pressures may be quicker, but 

it can result in flow blockage and incomplete filling. Whenever injection 

quantities are higher than expected, work should be stopped until a reason for the 

higher quantities is found. The perimeter of repair areas should be observed to 

ensure that the epoxy resin is not traveling to an area where it is not desired. 

When injection is completed at a port or ports, the injected ports are capped or 

closed. Tracking the progress of resin injection is usually possible by observing 

nearby ports that have not been capped or closed. 

The best method to ensure quality epoxy injection work is to require the 

contractor to prepare and submit for approval the overall, detailed injection plan 

and then to obtain small-diameter cores from the injected concrete to verify filling 

of the crack or voids. If more than 90 percent of the voids in the cores are filled 

with hardened epoxy, the injection can be considered complete. If injection is not 

complete, the contractor should be required to reinject the concrete and obtain 

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Chapter D: Standard Methods of Concrete Repair 

additional cores. In addition, observing the crack directly underneath the 

injection port, after injection has been completed, can provide an indication of 

success of the injection (figure 125). 

Figure 124. Simultaneous injection of multiple injection 

ports for epoxy injection. 

Figure 125. The exposed crack, after removing the injection 

port, is filled with cured epoxy. 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

(b)	 Application of Polyurethane Resin by Pressure Injection for Sealing 

Leaks 

The basic procedure for polyurethane injection consists of first gaining control of 

the leaking water if leaks are high, followed by pressure injecting resin to seal the 

cracks. 

For high-volume flows, the first step is to gain control of the waterflow. There 

are several ways this can be done. For example, one method involves drilling 

holes to intercept the flow paths as far as possible from the concrete surface. For 

this method, valved ports, known as “wall spears” (figure 126), are installed in the 

drilled holes, opened, and used to relieve water pressure in the cracks or joints 

near the surface. The cracks or joints are then temporarily sealed with wood 

wedges, or resin soaked jute rope or open-cell backer rod, to prevent excessive 

loss of injection resin. For other situations, it may be necessary to inject a very 

fast-setting resin behind the leak to slow down the flow, and then proceed with 

standard grouting practices. 

Figure 126. There are a wide variety of ports available for resin injection, 

including hammer-in ports, mechanical ports, and twist-in wall spears. 

Another method to seal large waterflows is to intermittently inject resin into a 

port. With this technique, a preselected quantity of resin is slowly injected into a 

port, followed by a waiting period before repeating the injection. Several cycles 

of injection may be necessary to control and seal large waterflows. Once there is 

sufficient control of the waterflow, leak sealing may begin. 

I-162 
Chapter D: Standard Methods of Concrete Repair 

 

 

 

 

 

For lower volume waterflows, the resin may cure so quickly that no special steps 

are necessary to control the flow. In this case, it is fairly easy to judge the 

effectiveness of the grouting because the leaking will slow or cease as grouting 

proceeds. 

Polyurethane resin injection should occur according to a preplanned sequence 

(figure 127). Injection pressures should be the minimum pressures necessary to 

accomplish resin travel and void filling. Even so, pump pressures of 1,500 to 

2,000 psi are common in this work. Each injection hole should be closed by using 

ports that will maintain injection pressure for a period of 10 to 15 minutes after 

injection flow has ceased or the resin has cured. However, holding high pressures 

on some resins (over about 300 to 400 psi) will prevent them from curing 

properly. 

Figure 127. Grouting is progressing from one end of the leaking expansion joint to 

the other. The presence of foam indicates that the joint is full of grout. The grout 

is contained by packing the joint with jute from below, the joint sealant at the top 

of the joint, and the zerk fittings on the ports. 

Maintaining confinement is almost always necessary to ensure that the foam 

attains maximum density in the crack or joint and becomes a permanent repair. 

Allowing the resin to free foam will result in a low-density, poor quality product. 

If such a procedure is followed, the poor quality, low-density foam can be pushed 

out of the crack or joint system by hydrostatic pressure, and repeat injection will 

be required to seal the resulting leakage. 

I-163 
 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

For some types of leak sealing work, it is not unusual for new leaks to appear as 

the old leaks are sealed. This occurs because the water travels to the most open 

path first, and once it is blocked, the water will start leaking out of the next easiest 

path, if one is available. In this case, new ports and additional injection may be 

necessary. 

Hydrophobic resins are usually not mixed with water before injection because it 

takes little water to start the resin’s reaction. Small, wet cracks and voids usually

contain enough moisture to begin the reaction process. Small dry cracks, on the 

other hand, can be injected with water before resin is injected. This practice, 

however, can lead to very poor results for large cracks, joints, and voids. In some 

situations, insufficient water is present to properly cure the resin, so only the outer 

area of the resin is reacted. In other cases, there may be plenty of water available, 

but there is insufficient mixing, so the resin only reacts on exposed surfaces. This 

results in a reacted outer surface and unreacted interior resin, which is sometimes 

referred to as “egg-shelling.” When this occurs, the leak repair will usually be

unsuccessful or will fail prematurely. In these cases, intermittently injecting a 

small amount of water into the grout stream may produce enough mixing to get 

the resin to cure properly. 

Hydrophilic polyurethane resin can be injected with varying water to resin ratios. 

If waterflow is high, it may be desirable to inject water to resin ratios as low as 

0.5:1. To accomplish this, variable ratio pumps are needed. Alternatively, the 

water and resin may be introduced and mixed in a “residence tube” of sufficient 

length before the point of injection so the foaming reaction may be well underway 

upon entering the crack or joint network. 

Special downhole packers can be used to inject resin at points deep within a 

structure. These special packers (figure 128) provide tubes to keep the resin 

components separate until they reach the end of the packer, where they are mixed 

together with a static mixer. 

Figure 128. A 

large packer for 

injecting resin 

through a 

drilled hole. 

The packer is 

about 3 inches 

in diameter and 

4 feet long. 

I-164 
Chapter D: Standard Methods of Concrete Repair 

The necessity of using experienced injection contractors or technical advisors for 

work of this nature cannot be overemphasized. 

(7) Cleanup 

At the completion of resin injection, all injection ports, excess resin, and crack 

surface sealers should be removed from surfaces that are visible to the public. 

This can be accomplished by scraping, high-pressure water blasting, or grinding. 

The use of dry pack mortar or other replacement repair material should be used to 

fill injection holes. 

I-165 

 

 

	 

E. Nonstandard Methods of 

Repair 

1. Use of Nonstandard Repair 

Methods 

The standard concrete repair methods and materials discussed in chapter D will 

meet many concrete repair needs. There will be occasions, however, resulting 

from unusual causes of damage and exposure conditions or special repair needs, 

when the standard repair methods may not meet the performance needs. In these 

instances, nonstandard repair methods may be required. 

Repair materials are considered nonstandard if they have not been thoroughly 

tested and evaluated for Reclamation applications. Many times, the use of 

packaged, thin repair materials (section D.2.f.) falls into this category because 

there are so many of them available, with many different formulations. The use 

of such materials involves a certain element of risk because the performance 

characteristics of these materials are unknown, may be variable, or are not fully 

defined. The application of nonstandard materials can be justified only when it is 

determined that no standard repair material will work, and only if all parties 

associated with, or responsible for, accomplishing the repairs understand the risks 

and agree to accept the uncertainties and possible consequences. 

An example of a situation that required the use of nonstandard concrete repair 

methods was when repairs were needed on small areas of concrete damage on a 

cold, wet tunnel spillway that was subject to cavitation flows in the event of a 

spill. No standard repair method exists for such shallow repairs in areas exposed 

to these conditions. Therefore, in this situation (and in others), it was undesirable 

to remove sound concrete to a sufficient depth for a standard repair. In addition, 

it would be very expensive to gain access to make the repairs. Therefore, facility 

personnel decided it was cost effective to use funds to conduct a study to evaluate 

potential materials that would be suitable for placement and curing under the cold 

temperatures and damp conditions in the spillway tunnel (von Fay K., 2009). Of 

the many materials evaluated, two epoxy mortars and two cementitious mortars 

showed promise. After further testing, one cementitious mortar was selected for 

application. In this example, the facility personnel were informed about the risks 

associated with using an unproven repair material. With the information gathered 

I-167 
 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

from the study, a sound decision could be made that the benefits of performing 

the shallower repairs would outweigh the uncertainties associated with unproven 

performance. 

a. Preparation 

Preparing concrete for repair with nonstandard materials should be in accordance 

with section B.5, unless otherwise required by the material manufacturer. The 

recommendations of the manufacturer should be closely followed. 

b. Materials 

Nonstandard repair materials will usually be proprietary or commercial products. 

Manufacturer's technical representatives should be contacted and made fully 

aware of the nature of the problem and the reasons for selecting nonstandard 

repair materials. They need to be informed of any factors that affect the repair 

plan, such as the need to perform repairs on an emergency basis, or the need to 

coordinate and schedule repairs at facilities that can only be taken out of service at 

certain times. Copies of material warranties should be obtained if available. 

Technical representatives should be questioned closely about the conditions under 

which their materials would not be suitable for use, or when the materials 

warranties would not apply. The manufacturer should be able to supply case 

studies or project histories showing that their materials were used to repair similar 

damage. However, if the manufacturer makes claims that seem too good to be 

true; for example, that no surface preparation is needed, the claims are likely not 

true. 

c. Application 

Application of nonstandard repair materials must be made in exact conformance 

to the manufacturer's recommendations. Failure to apply the materials properly 

will void any warranties and is a commonly cited reason for material failure. 

Construction inspection reports should closely note any contractor variance from 

the manufacturer's recommended application procedures. 

d. Curing 

Curing of nonstandard repair materials must be performed as recommended by 

the materials manufacturer. 

I-168 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Preparing Concrete Surfaces Prior to Repairs and Overlays. MERL 12-17, 

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Bissonnette, B., Vaysburd, A.M., and von Fay, K.F. 2013. Moisture 

Content Requirements for Repair Part 1: Concrete Repair Testing. 

Report No. MERL-2013-63, Denver: Bureau of Reclamation. 

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and Concretes. Report No. Ce40, Denver: Bureau of Reclamation. 

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Bureau of Reclamation. 2003. “IV International Workshop - Bringing the 

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Rehabilitation, Milk River Project, Montana. Vol. Contract 

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Powerplant. Solicitation No. R10PS10048. 

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Corrosion Mitigation Technologies in Concrete Repairs, M-82. 

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Joy, W. 2013. Guide to Chemical Grouting of Joints and Cracks in Concrete. 

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Thinking,” Proceedings, 4th International Conference on Concrete Repair, 

Rehabilitation and Retrofitting, ICCRRR IV, October 5-7, p. 5, Leipzig, 

Germany. 

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Design and Implementation of Concrete Repairs and Overlays. Project 

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and Strengthening Industry. Version 1, June. 

von Fay, K.F. 2007. Laboratory Evaluation of Joint Sealants for Spillway Joints. 

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Materials - Yellowtail Dam Spillway Tunnel Repairs. MERL-2009-36, 

Denver: Bureau of Reclamation. 

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for Glen Elder Dam Spillway Inlet Slab Repair. Memorandum, 

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Guide to Concrete Repair 

Part I: Appendix A 

Historic Development of Durable 

Concrete for the Bureau of Reclamation 

 

 

App IA-1 

 

 

Appendix A
 
 

Historical Development of 

Durable Concrete for the 

Bureau of Reclamation 

Timothy P. Dolen 

Edited for the Guide to Concrete Repair by Kurt F. von Fay 

Introduction 

The Bureau of Reclamation (Reclamation) infrastructure stretches across many 

different climates and environments in the 17 Western States. Many of the dams, 

spillways, pumping plants, powerplants, canals, and tunnels are constructed with 

concrete. These structures were built from Arizona to Montana, across the plains, 

and in the mountains and deserts. Concrete structures have had to remain durable 

to resist both the design loads and the natural environments of the Western 

climate zones. Many natural environments can be quite destructive to concrete, 

and the earliest Reclamation projects were faced with a variety of durability 

problems. The state-of-the-art of concrete construction advanced from hand 

mixing and horse and wagon transporting operations to automated mixing plants, 

underwater canal construction, and pumping and conveyor placing. This 

appendix begins with an overview of the challenges that have faced concrete 

construction beginning in the 20th century. It then traces Reclamation’s role in 

the development of durable concrete to resist the environments of the West. 

What is Concrete? 

The American Concrete Institute (ACI) defines concrete as “a composite material 

that consists essentially of a binding medium within which are embedded particles 

or fragments of aggregate, usually a combination of fine aggregate and coarse 

aggregate; in Portland cement concrete, the binder is a mixture of Portland cement 

and water.”1 The earliest concretes date at least as far back as early Roman times, 

including the aqueducts and the historic Pantheon in Rome. These concretes did 

1 American Concrete Institute, ACI 116R, Report on Cement and Concrete Terminology, 

Farmington Hills, Michigan, 2001. 
 

 

App IA-2 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

not use Portland cement as a binder; rather, they used combinations of lime and 

pozzolanic sands that were mixed with broken rocks and shards of pottery. 

Most modern concrete is composed of about 75-percent aggregates, by volume, 

and about 25-percent “Portland cement paste.” The paste is the binder and 

contains cementitious materials and water. The cementitious materials include 

primarily Portland cement and sometimes an additional cementing material, such 

as a pozzolan. Pozzolans are finely ground, calcined (heated to a high 

temperature) materials that react with lime from cement hydration to form 

compounds similar to Portland cement. Natural pozzolans are formed by events 

like volcanoes. Artificial pozzolans, such as fly ash, are calcined in a kiln. The 

ratio of water to cementitious materials is about 1.5:1 by solid volume, or 1:2 by 

weight. The individual components are mixed wet for about 5 to 10 minutes and 

then are placed in forms to harden into their final shape. 

Concrete does not harden by drying, as do some clay bricks and lime mortars. 

The chemical process that turns the wet concrete into a hardened mass is called 

“hydration,” a reaction between the cement and water that forms strong chemical 

bonds. It must retain the moisture to allow the cement to chemically hydrate; 

usually for about 1 month. The best concrete stays continuously moist at a 

temperature of about 40 to 70 degrees Fahrenheit, such as the center of a mass 

concrete dam. The strongest concretes contain just sufficient water to chemically 

react with the available cement, which is about 25 to 40 percent water to cement, 

by weight. The weakest concretes contain excess water or prematurely dry out, 

which stops the hydration reaction prematurely. Most pozzolanic materials do not 

naturally harden through hydration with water; however, in the presence of either 

calcium hydroxide or lime, combined with water, a hydration reaction occurs. 

Fortunately, one of the chemical byproducts of cement hydration is calcium 

hydroxide (lime). Thus, added pozzolans, when combined with cement and 

water, make concrete even stronger and often more durable. Cement hydration 

also generates heat and can lead to temperature cracking when the interior mass is 

hot, and the exterior contracts as it cools. Thus, any means of reducing the 

cement content or adjusting cement chemistry or cement particle size to reduce 

heat generation lowers the potential for thermal cracking. 

The durability of concrete depends on the durability of its constituents: cement 

paste and aggregates. A concrete with strong paste may not be durable if it is 

combined with poor aggregate, and vice versa. One of the most important 

parameters is the “porosity” of the paste, which is a function of the amount of 

water relative to the cementitious materials. Excess water can dilute the cement 

paste, leaving a more porous medium. This can be attacked more easily by 

deleterious substances and physical processes. The climate is a significant factor 

that influences the long-term durability of concrete structures. One of the reasons 

the ancient structures have survived is because they were constructed in relatively 

dry, temperate climates. 
 

 

 

 


 

App 1A-3 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

Early Obstacles to Durable Concrete
 

Historically, the quality of concrete was impaired by a lack of knowledge about the 

quality of materials and the methods of construction. In some instances, a lack of 

understanding about the quality of basic concrete materials (cement, sand, and 

gravel), as well as the proportioning of ingredients, impaired quality concrete 

construction under the severe exposures and harsh climates of the West. In other 

instances, the methods of batching, mixing, placing, and protecting the concrete 

limited the rate of construction and the overall quality of the structures. In addition, 

the methodology behind concrete design and construction was just developing and 

was not well documented or understood. Over time, however, a number of 

significant events and innovations during the 20th century contributed to the 

development of concrete as a durable engineering material, resulting in what is now 

considered “modern concrete.”

Mechanisms of Deterioration in the 

Western United States 

The three most critical natural deterioration mechanisms that widely affect 

Reclamation structures, primarily because of their age, are sulfate attack, alkali-silica 

reaction (ASR), and freeze-thaw (FT) attack. These three mechanisms are described 

in the paragraphs below. In many cases, concrete deterioration is caused by a 

combination of aggressive environments, such as wetting and drying in concert with 

sulfate attack in some California desert climates, or FT attack and ASR in the 

Northwest. Here, microfractures caused by one destructive element allow moisture 

to more easily penetrate the paste and contribute to a secondary reaction. One 

exposure condition that is common to United States highways and bridges is 

chloride/corrosion of reinforcing steel and the resulting deterioration. There are, of 

course, many other factors that can damage concrete, and those factors that are most 

relevant to Reclamation concrete are described in the Guide to Concrete Repair. 

Concretes that remain durable under these conditions were proportioned in some 

way to withstand the elements, either accidentally or purposely. Some advances in 

the development of durable concrete resulted from observing concretes that 

essentially used chemically resistant cements or “accidentally” introduced beneficial 

admixtures, and then comparing them with those that rapidly fell to pieces. 

Sulfate Attack 

Sulfate attack is a chemical degradation of cement paste that is caused by high 

concentrations of sulfates in soils and ground water. Sulfate attack is caused by 
 

 

 

App IA-4 

 

 

 

 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

chemical interactions between sulfate ions and constituents of the cement paste. The 

disintegration appears to be caused by chemical reactions with cement hydration 

products and the formation of a secondary compound, ettringite, accompanied by a 

large volumetric expansion and cracking of the concrete. Sulfate attack was also 

known as “cement corrosion” in the early 1900s and is very common in the white 

“alkali flats” of the arid Western States and in seawater, particularly tidal zones. 

Sulfate attack was noted in Reclamation structures on the Sun River Project in 

Montana in 1908, shortly after the formation of the U.S. Reclamation Service.2 

Figure 1 shows the disintegration of a concrete canal lining in the Central Valley 

Project only 5 years after construction.3 Early observations of such failures 

identified certain cement brands as more resistant to deterioration than others in 

these exposure conditions. “Bad” cements were less resistant and avoided, if 

possible, in favor of more resistant “good” cements.

Figure 1. Sulfate attack on a 5-year-old concrete canal 

lining, Central Valley Project, California. The ground 

water sulfates infiltrate the concrete and chemically 

react with certain cement hydration products. The 

expansive reaction causes cracking. 

Alkali-Aggregate Reactions 

Alkali aggregate reactions (AAR) are the chemical reactions between certain 

specific mineralogical types of aggregates (either sand or gravel) and the alkali 

compounds (generally less than 2 percent of the cement composition) of cement 

2 Jewett, J.Y., “Cement and Concrete Work of the United States Reclamation Service with 

Notes on Disintegration of Concrete by Action of Alkali Waters,” Proceedings of ASTM, Vol. 8, 

p. 480-493, Philadelphia, Pennsylvania, 1908. 3 Harboe, E.M., Longtime Studies and Field Experiences with Sulfate Attack, American 

Concrete Institute Special Publication No. 77-1, Detroit, Michigan, 1977. 
 

 

 

 

 

App 1A-5 

 

 

 

 

 

 

 

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

in the presence of moisture. “Typical manifestations of concrete deterioration 

through ASR are expansion; cracking, which frequently is of such nature that it is 

designated as “pattern” or “map” cracking; exudations of jelly-like or hard beads 

on surfaces; reaction rims on affected aggregate particles within the concrete; and 

sometimes popouts.”4 The reaction products have a swelling nature, which leads 

to tensile stresses that cause cracking within the concrete. The cracking may 

allow moisture to more readily be absorbed by the silica gel or accelerate 

freeze-thaw damage. 

Alkalies in cement can react with certain “glassy,” siliceous aggregates such 

as opals, chalcedony, cherts, andesites, basalts, and some quartz (termed ASR), 

and certain specific carbonate aggregates (called alkali-carbonate reaction 

[ACR]).5 ACR is rare in the Western U.S. ASR, shown in figure 2, was probably 

first experienced by Reclamation at American Falls Dam in Idaho, which was 

completed in 1927. However, extensive freeze-thaw deterioration and poor 

quality construction practices masked ASR as a primary cause of deterioration at 

American Falls Dam. Some structures, such as Parker Dam and Stewart 

Mountain Dam, suffered early rapid expansion and distress and then became 

relatively stable after a few years as the available alkalis and reactive aggregates 

were consumed early in the process. Other structures, such as Seminoe Dam, are 

showing continued expansion and resulting distress even 50 years after 

construction.6 

Figure 2. One of the 

earliest photos of 

alkali-silica “gel” 

common to expansive 

AAR. These gels swell 

in the confined 

concrete matrix, 

causing expansion 

and cracking in the 

aggregates and 

concrete. Bureau of 

Reclamation Concrete 

Laboratory file photo 

(about 1940). 

4 American Concrete Institute, “Durability of Concrete Construction,” ACI Monograph No. 4, 

Detroit, Michigan, Iowa State University Press, Ames, Iowa, p. 59-60, 1968. 5 Meilenz, R.C., Petrographic Examination of Concrete Aggregate to Determine Potential 

Alkali Reactivity, Highway Research Report No. 18-C, p. 29-35, 1958. 6 Mohorovic, C.E., and T.P. Dolen, 1998-99 Concrete Coring-Laboratory Testing Program, 

Seminoe Dam, Kendrick Project, Wyoming, Bureau of Reclamation Technical Service Center, 

Denver, Colorado, August, 1999. 
 

 

 

 

 

 

 

 

 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Freezing and Thawing Deterioration 

Freezing and thawing (FT) deterioration is the deleterious expansion of water 

within the cement paste, which results in destruction of the concrete. Water 

present in the cement paste expands about 9 percent upon freezing. When 

confined within a rigid, crystalline microstructure, the expanding ice crystals can 

exert pressures far exceeding the tensile capacity of the paste, causing cracking 

and, ultimately, failure of the concrete. 

Figure 3. FT deterioration of a spillway training wall at 

Lahontan Dam in California. The “sand cement” 

concrete, placed in 1915, was severely damaged by 

FT in the colder and mountainous regions of the West. 

Notice that the shady area is less damaged than the 

section exposed repeatedly to cold temperatures at 

night and sunlight during the day. 

The concrete must be saturated, or nearly saturated, when it undergoes freezing in 

order for this form of deterioration to take place. Repeated cycles of FT are 

common in Reclamation water conveyance structures. Areas subject to cyclic 

freezing, such as the spillway shown in figure 3, and particularly those in 

fluctuating water surface levels or in splash or spray zones, are the most 

susceptible to deterioration.7 Freeze-thaw deterioration is most pronounced in 

more porous concrete that has a high water-to-cement ratio and concretes without 

purposely entrained air bubbles; the very same concretes commonly used in early 

20th century construction. 

Freeze-thaw deterioration was first identified early in Reclamation history under 

the general term, “durability of concrete without specific causes or solutions.”

This form of damage is present in the colder and mountainous regions and 

7 Von Fay, Kurt, Guide to Concrete Repair, Bureau of Reclamation Technical Service Center, 

Denver, Colorado, August 2015 (original edition: Smoak, W. Glenn, April, 1997). 
 

 

 

 

 

 

App 1A-7 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

nonexistent in the desert Southwest. A mixture placed on the All-American Canal 

would have no problems, but the very same concrete placed on the Yakima 

Project would be severely affected. 

Developing the State-of-the-Art of 

Concrete Technology 

Even with quality materials, durable concrete could not effectively be mixed and 

placed in the larger Reclamation structures without improved construction 

practices and equipment. The historical development of durable Reclamation 

concrete can roughly be divided into four generations with regard to both 

materials and methods of construction. Each generation contributed to the 

knowledge base of the developing state-of-the-art. The first generation of 

Reclamation concrete technology covers the period from its inception in 1902 

until about World War I. These practitioners were the first “pioneers” of 

Reclamation concrete construction. The next generation, from 1918 until the late 

1920s, began developing concrete as an engineering material. The 

Boulder/Hoover Dam generation began in the late 1920s and continued up to 

World War II. This generation solved many of the fundamental problems 

encountered in massive concrete construction and many of the standardized 

quality concrete construction practices. They uncovered the mysteries of sulfate 

attack, AAR, and FT durability, leading to the first truly engineered, modern, 

durable concretes. The post-war generation (late 1940s to present) incorporated 

the basic concepts of modern concrete into a multitude of applications for dams, 

pumping and power plants, canals, and tunnels under a variety of differing site 

conditions. 

The Early Years - The Concrete Pioneers 

The first generation of concrete practitioners developed the technology largely 

through trial and error and continued observation. The earliest concrete was 

composed of poorly manufactured cements and/or unprocessed aggregates, and it 

was mixed by hand or with small mixers. The materials themselves (cement, 

sand, and gravel) were subject to great variability. The concrete mixture was 

proportioned by “recipe,” based on previous experience, not necessarily on

physical properties of the material. Many early Reclamation projects were 

somewhat isolated geographically, and there was less communication beyond 

regional boundaries. A change in location or structural design was not necessarily 

followed by an appropriate change in concrete mixture design, which resulted in 

spotty performance. Labor was cheap, but equipment and cement were 

expensive. The resulting mixtures contained the least amount of cement 

necessary to meet low strength requirements, at least by today’s standards. 
 

 

 

 

 

 

 

App IA-8 

 

 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Concrete was largely transported by wheelbarrows and compacted in place by 

manual tamping, spading, and rodding. The production rates were very 

slow, resulting in frequent “cold joints” or unplanned flaws that allowed 

seepage and subsequent deterioration. 

A major change in building technology, the introduction of steel-reinforced, 

concrete structures, at first did not improve concrete quality. Pre-1900 structures 

were more massive and used a stiffer concrete that was tamped into place. The 

resulting concrete was less permeable and somewhat more resistant to the 

elements due to its low porosity; water simply had difficulty entering the matrix 

to cause damage. Reinforced concrete structures took advantage of the tensile 

strength capacity of the steel, and the size of structural members was reduced. In 

addition to thinner structures, the reinforcing steel interfered with the placing and 

tamping practices. As a result, water was added to the concrete mixture to make 

it more fluid and, thus, easier to place. However, more cement was not 

necessarily added, and the weaker, more porous concretes started falling apart in 

the field in only a few years.8 

The earliest Reclamation construction projects did not have the benefit of specific 

practices and equipment for concrete construction. Construction practices 

gradually improved during the first Reclamation construction era. Many 

structures fortunately used techniques that helped them resist degradation. 

Theodore Roosevelt Dam in Arizona used masonry facing and cyclopean concrete 

methods: large “plum stones” were placed followed by smaller cobbles and 

boulders, and then the concrete was added to fill the remaining voids. This 

construction technique left large stones across the construction joint surface that 

reduced shear planes. The mixtures had a low cement content on a per-cubic-yard 

basis that reduced thermal cracking and concrete cost.9 

One construction advance, called “chuting” (shown in figure 4), could result in 

poor quality concrete. Considered an “improvement” over the back-breaking 

manual hauling by buckets, long chutes were used to transport concrete to the 

forms. This permitted a centralized concrete batching and mixing location, and 

larger batches could be fed to sometimes intricate, gravity-fed chute systems. 

Water was added to make the concrete flow down relatively flat, sloping chutes. 

The extra water diluted the cement paste in the concrete. These mixes were much 

weaker and had poor durability. The quality of the concrete could vary 

throughout the structure as the chute slope decreased and the distance from the 

mixing location increased. To discourage this practice, engineers finally specified 

that the slope of the chutes could not be flatter than about 35 degrees from 

horizontal.10 

8 Engineering News Record Editorial, Some Doubts About Concrete, Vol. 90, February 1923. 9 Department of the Interior, Bureau of Reclamation, Dams and Control Works, Third Edition, 

Washington, DC, p. 57-60, 1954. 10 Walter, L.W., “Thirty Years’ Experience with Concrete,” Proceedings of the American 

Concrete Institute, Vol. 25, Detroit, Michigan, p. 54, 1929. 
 

 

 

 

 

App 1A-9 

 

 

 

 

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

Figure 4. Chuting 

wet concrete into 

place at Arrowrock 

Dam (about 1912). 

Elaborate chute 

systems required 

a very fluid 

concrete mixture 

to be placed and 

spread in the 

forms. Water was 

the “admixture” of 

choice to improve 

the fluidity! 

(Bureau of 

Reclamation 

historical 

photographs) 

The developing state-of-the-art had a few “hiccups” along the way. 

“Sand-cement” was introduced to reduce the cost of cement by

intergrinding crushed rock flour during the manufacturing process.11 The 

finely ground rock flour was introduced as a “pozzolan” to react with the 

cement for increased strength, and, indeed, the sand-cement mixtures had 

higher 7- and 28- day compressive strengths compared to the control mixtures. 

However, the compressive strength development did not continue much after 

28 days, as is the case with Portland cement plus real pozzolans. Thus, the 

sand-cement reacted faster, but it did not act as a pozzolan because the rock flour 

was not calcined. Arrowrock Dam, in Idaho, constructed using sand-cement in 

1915, was rehabilitated with a higher strength concrete facing in the mid-1930s to 

stop continued FT damage.12 

First generation Reclamation concretes were vulnerable to sulfate attack, ASR, 

and FT deterioration. In spite of these problems, some concretes seemed 

remarkably durable. Engineers and scientists began examining concrete 

materials to try to improve the quality. Beginning in 1914, studies were 

conducted at the Lewis Institute in Chicago to shed new light on the 

engineering properties of concrete. 

11 Savage, J.L., “Special Cements for Mass Concrete,” Second Congress of the International 

Commission on Large Dams, World Power Conference, Washington, DC, Bureau of Reclamation, 

Denver, Colorado, 1936. 12 Studebaker, C.A., Tentative Report on Gunite at Arrowrock Dam, U.S. Department of the 

Interior, Bureau of Reclamation, Boise Project, Boise, Idaho, January 22, 1937. 
 

 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

The Abrams Generation 

The first major advance in concrete technology during the 20th century occurred 

about 1918 with the publication of Duff Abrams’ Design of Concrete Mixtures.

13 

Abrams improved on the recipe proportioning methods through deliberate design 

practices with proportioning methods and mix design tables. Abrams classic 

research and his “water to cement ratio law” provided the foundation of concrete 

mix design still followed today. He found concrete strength and, thus, quality 

could be controlled by the relative proportions of water and cement. He also 

found it was possible to design mixes for the same strength using different 

materials. Concrete mixes could be designed and proportioned to meet a variety 

of conditions and structural requirements. Stronger concretes were developed to 

resist deterioration by the environment. Researchers began investigating the 

fundamental physical-chemical reactions that were needed to advance the 

state-of-the-art. One of the first inroads to developing durable concrete took place 

with the identification of the chemical reaction products of cement hydration, and 

a method to compute the relative proportions of each constituent in cement by 

Bogue in 1927.14 This important step was necessary to formulate different 

compositions of cement. Without the knowledge of its composition, it was not 

possible to purposely change materials and manufacturing processes to enhance 

the performance of Portland cement. 

Concrete manufacturing methods also improved during the 1920s, including 

centrally batched and mixed concrete plants and systems to haul and transport 

concrete to the site, as shown in figure 5. The daily output of concrete plants 

increased, resulting in fewer cold joints. The horse and wagon was being 

replaced by the locomotive and trucks. Larger projects were constructed, and 

more mechanized processes were developed. Still, the process of consolidating 

concrete was left to the common laborer through rodding and spading. The first 

methods to consolidate concrete with mechanical equipment were just being 

developed. Better treatment of cold joints was developed during this time, 

improving the continuity between adjacent placements. For the first time, control 

tests were used to design and monitor concrete mixtures within specific 

parameters. Abrams’ generation of concrete technologists provided the 

foundation of knowledge for the next generation, beginning with the decision to 

construct Boulder (Hoover Dam) on the Colorado River in December 1928. 

13 Abrams, D.A., Design of Concrete Mixtures, Structural Materials Research Laboratory, 

Lewis Institute, Chicago, Illinois, 1918. 14 Bogue, R.H., “Calculation of the Compounds in Portland Cement,” Industrial and 

Engineering Chemical Analysis, Vol. 1, No. 4, October 1929 
 

 

 

 

 

App 1A- 11

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

Figure 5. Early concrete canal lining. Horse and buggy 

transporting gave way to central batch plants and the first 

motorized transporting buggies. Still, the concrete 

placing and compacting processes were performed by 

laborers with shovels (Bureau of Reclamation historical 

photographs). 

Boulder Dam/The “Hoover Generation” 

In 1928, the Boulder Canyon Act ratified the Colorado River Compact and 

authorized construction of Hoover Dam.15 The size of Hoover Dam required a 

completely new technology for large-scale concrete design and construction. 

The Hoover generation raised concrete materials technology, design methods, and 

concrete construction technology to unprecedented heights. This generation of 

concrete technologists formulated large-scale research and development programs 

using special cements to meet the specific engineering properties for massive 

concrete structures. They answered some fundamental questions about cement 

chemistry and its effects on mass concrete. Solving these questions required close 

cooperation and communication between government agencies, manufacturers, 

contractors, and private and academic research institutions. The application of 

scientific methods to solve complex durability problems led to what we now 

know as “modern concrete.”

One of the first steps required for concrete for Hoover Dam was to investigate the 

composition of cement to reduce the amount of heat generated as it hydrated. 

Extensive research on cement composition resulted in developing a low-heat 

cement for mass concrete, now known by the American Society of Testing and 

Materials (ASTM) as Type IV cement. The hydration product “tri-calcium 

15 Bureau of Reclamation, Brief History of the Bureau of Reclamation, Bureau of 

Reclamation History Program, Denver, Colorado, p. 4, July 2000. 
 

 

 

App IA- 12

 

 

 

 

 

 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

aluminate,” abbreviated in a simplified form as “C3A,” was found to be one of the

principal compounds that generates heat during the hydration process. 

Reclamation specified the chemical composition of cement supplied to Hoover 

Dam in 1933 to ensure a low heat of hydration. The low-heat cement also had 

improved durability because the low C3A cements had better resistance to sulfate 

attack. This improved resistance to sulfate attack was the basis for specifying less 

than 5 percent C3A for cement used on the Kendrick Project in 1938, another 

forerunner of the ASTM Type V (sulfate-resisting) cement.16 

Construction of such large projects as Hoover and Grand Coulee Dams could not 

have been accomplished without advances in concrete aggregate processing, 

concrete manufacturing, transporting, and placing. The use of block construction 

techniques (shown in figure 6) and artificial post-cooling reduced the potential for 

thermal cracking. Specialized concrete batch plants with rail transporting and 

“high-lines” or cable ways were used to transport and place large quantities in 

round-the-clock operations. One of the underappreciated advances in concrete 

quality developed by eliminating the back-breaking “tamping” techniques of

consolidation with the high-frequency, mechanical concrete vibrator (shown in 

figure 7).17 Vibrators allowed a lower unit water content of the mixture, thus 

lowering the cement content. The concrete generated less heat, became less 

porous, and it was less costly. 

Figure 6. Mass concrete block construction at 

Hoover Dam (1930s). The size and scope of this 

project led to many innovations ranging from 

advances in cement chemistry to new methods of 

batching, mixing, transporting, placing, cooling mass 

concrete (Bureau of Reclamation historical 

photographs). 

16 Moran, W.T., Bureau of Reclamation Viewpoint on Portland Cement Specifications, 1952. 17 McCarty, M.I., “High Frequency Vibratory Machines for Concrete Placement,”

Proceedings of the American Concrete Institute, Vol. 30, ACI, Detroit, Michigan, 

September 1933. 
 

 

 

 

 

 

 

App 1A- 13

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

Figure 7. The mechanical concrete vibrator was first 

introduced to Reclamation during construction of 

Hoover Dam. The laborer’s job of hand tamping and 

spading was replaced with mechanical equipment. 

However, even though the consolidation process was 

accomplished by machine, it took a strong person to 

manipulate these vibrators! (Bureau of Reclamation 

historical photographs) 

The size of Hoover Dam required not only significant advances in construction 

equipment and materials processing, but also in construction project management 

and process quality control techniques. The designers and constructors of Hoover 

and Grand Coulee Dams were diligent, meticulous, and, to some degree, lucky. 

Fortunately, one of the chemical processes that could cause expansion, cracking, 

and deterioration of concrete (AAR) was avoided at Hoover Dam. The cements 

furnished to the dam had a high alkali content, and fortunately, the concrete was 

mostly free from potentially reactive aggregates (although not by design because 

the alkali-aggregate phenomena had not yet been identified and studied).18 

Two of the indirect products of the Hoover generation were the founding of the 

Concrete Laboratory in Denver, Colorado, in 1931, and the first printing of the 

Concrete Manual in 1936. The Concrete Laboratory and Concrete Manual grew 

out of the need for a better understanding of the behavior of concrete and the 

18 DePuy, William, personal communication, Concrete and Structural Branch, Bureau of 

Reclamation, Denver, Colorado. 
 

 

 

 

 

 

 

 

 

 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

control of concrete construction. Over 100,000 copies of the Concrete Manual 

have been printed in nine editions and at least four languages. “Concrete schools”

were developed for training engineering and field personnel, and they have 

continued to this day. The Reclamation concrete technologists were active 

participants in ASTM and ACI, serving as both committee chairmen and as 

president. This commitment to voluntary standards organizations continues 

today. 

As the U.S. entered World War II, the last two pieces of the durability puzzle 

were identified and largely corrected. AAR was encountered by Reclamation at 

American Falls Dam, and about 150 miles downstream of Hoover Dam at Parker 

Dam. While American Falls Dam was undergoing rehabilitation from a variety of 

causes, Parker Dam was just being completed in 1937. Within 2 years, cracks 

appeared in the dam.19 The cracking at Parker Dam was severe enough to 

warrant a large-scale research investigation and a blue ribbon panel of 

consultants. In the end, the chemical reactions between certain altered andesites 

and rhyolites in less than 2 percent of the aggregates and the alkalies in the 

cement fostered a deleterious, expansive reaction (ASR).20 First observed in 

Pennsylvania in the early 1920s at the Buck Hydroelectric Plant, ASR became a 

noticeable problem throughout the country in the 1930s and early 1940s.21 The 

first solution to ASR was to use petrographic techniques to identify those 

aggregates with the potential for expansion and to specify a 0.6-percent limit of 

alkalies in the cement19 Reclamation quickly instituted the low-alkali limit for 

concrete with potentially reactive aggregates by April 1941.22 

In 1938, the last major advance in developing durable concrete was the result of 

both accident and observation. In New York State, certain highway pavements 

were observed to have superior performance when a particular brand of cement 

was used in the concrete. The highway departments began specifying this 

particular brand of cement for all their highway construction without fully 

understanding the reason for superior performance. Microscopic examination of 

the concrete revealed a paste structure containing tiny, entrained air bubbles 

brought about by using beef tallow in the cement kilns during manufacturing.23 

19 DePuy, G.W., “Petrographic Investigations of Concrete and Concrete Aggregates at the 

Bureau of Reclamation,” ASTM STP-1061, Petrography Applied to Concrete and Concrete 

Aggregates, ASTM, Philadelphia, Pennsylvania, p. 33-46, 1990. 20 Stanton, T.E., “Expansion of Concrete Through Reaction Between Cement and

Aggregates,” Transactions of ASCE, Vol. 66, p. 1781-1811, December 1940. 21 Kammer, H.A., and R.W. Carlson, “Investigation of Causes of Delayed Expansion of

Concrete in Buck Hydroelectric Plant,” Proceedings of ACI, Vol. 37, p. 665, June 1941. 22 Dolen, T.P., “Cement History Database,” Bureau of Reclamation, Science and Technology 

Program, Research Project FI908, Decision Support System for Aging Concrete, 2000. 23 Lawton, E.C., “Durability of Concrete Pavement - Experiences in New York State,” 

Proceedings of ACI, Detroit, Michigan, Vol. 35, p. 561, June 1939. 
 

 

 

 

 

 

 

App 1A- 15

 

 

 

 

 

 

 

 

 

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

This produced the first “air- entrained” cement, accompanied by significantly

improved FT resistance compared to other cements. The microscopic air bubbles 

absorbed the expansive forces of freezing ice crystals within the paste, preventing 

microcracking. Though not a direct player in the initial identification of entrained 

air, Reclamation began testing concrete for FT durability in the mid-1930s as a 

means of evaluating concrete, aggregate quality, and other additives, some of 

which may have accidentally entrained air. The perceived superior durability of 

Grand Coulee Dam concrete in the 1930s may have resulted from specifications 

allowing grinding aids during cement manufacturing that may have entrained 

some air.24 Anecdotal evidence points to other accidental introductions of air in 

concrete in the U.S. as early as the 1920s. These concretes were quickly rejected 

due to lower density and compressive strength! Higginson even refers to the 

possibility of forms of entrained air in stucco specified by Marcus Vitrivius Pollio 

in the first century A.D.25 Reclamation quickly changed its specifications and 

switched to air-entrained concrete by 1942.26 By the end of World War II, 

Reclamation had largely overcome the three primary causes of concrete durability 

problems in the West, resulting in what is considered “modern concrete,” an

engineered concrete capable of resisting the physical and chemical forces of 

nature. 

The Post-War Generation: “The Constructors” 

The post-war generation of concrete technologists applied the fundamentals of 

modern concrete to “customize” it for a variety of new applications and over a

wide range of different environments. This generation began as post-war citizen 

soldiers returned to the U.S. and continued through the Cold War. These people 

were the constructors. During the 1950s and 1960s, Reclamation was completing 

“a dam a year.” Large, thick arch dams became high-strength, double curvature, 

thin arch dams. Projects were constructed across the desert and through 

14,000-foot-high mountain ranges. Some of the largest water development and 

distribution systems were completed during this era: the Central Arizona and 

Central Utah Projects. The concretes used new additives to achieve greater 

durability, economy, and performance. These concretes should remain durable 

through the next century. 

One of the most significant contributions of this generation improved durability 

and also made concrete less expensive. The purposeful addition of natural 

24 Bureau of Reclamation, Effect of the Admixture, T.D.A., on the Durability of Concrete, 

Cement Laboratory Report No. Ce-33, Denver, Colorado, June 30, 1942. 25 Higginson, E.C., “Air-Entrained Concrete in Modern Construction,” presented before the 

Engineering Section of the Colorado-Wyoming Academy of Science, Boulder, Colorado, May 2, 

1952 . 26 Price, W.H., “In the Beginning,” Bureau of Reclamation, Concrete Laboratory Technical 

Conference, December 1981. 
 

 

 

 

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Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

pozzolans in the early 20th century was made, in part, as a cost-saving measure, 

and then later to reduce the temperature rise of mass concrete. Reclamation began 

investigating a power plant byproduct, fly ash, in the 1930s and 1940s, as a 

substitute for natural pozzolans in mass concrete. The first large-scale specified 

use of fly ash was at Hungry Horse Dam in 1950.27 Reclamation continued 

research on fly ash, yielding other benefits such as improving the sulfate 

resistance of concrete. In the 1970s, cement shortages prompted Reclamation to 

begin using fly ash in normal structural concrete and canal linings to save cement. 

The U.S. Environmental Protection Agency’s implementation of the Resource

Conservation Recovery Act, beginning in 1980, strongly encouraged the reuse of 

recycled materials, including fly ash, in concrete.28 The long-term benefits of 

using fly ash will continue for generations, as these concretes are less porous 

and more resistant to sulfate attack and ASR, even more so than sulfate-resisting, 

low-alkali cements.29 

The advances in construction equipment design dramatically increased concrete 

production during this time. Large-size canal linings are now placed at 10 times 

the rate as in the early days. Instead of adding water to increase fluidity, 

superplasticizers are now added to make concrete flow like water, yet be twice the 

strength of its predecessors. Concrete linings were even placed underwater to 

reduce leakage in unlined canals.30 Concrete vibrators capable of consolidating 

25 to 50 cubic yards of concrete per hour were replaced by 10-ton, vibratory 

rollers capable of placing 500 cubic yards per hour in roller-compacted concrete 

(RCC) dams.31 It is interesting to note that the earliest Reclamation concretes 

were of such a consistency that they had to be manually “rammed” into place. 

The era of Reclamation concrete dam construction concluded at Upper Stillwater 

Dam using RCC of such consistency that it was mechanically “rammed” into 

place! 

The Present Generation and Beyond 

By about 1990, the last large dams were being completed, and a new era was 

underway. Most of Reclamation’s construction program is now devoted to 

rehabilitation of the existing structures. The Reclamation Safety of Dams Act of 

27 Bureau of Reclamation, Laboratory and Field Investigations of Concrete, Hungry Horse 

Dam, Hungry Horse Project, Concrete Laboratory Report No. C-699, Denver, Colorado, 

December 4, 1953. 28 Harboe, E.M., “Fly Ash and the EPA Guidelines,” presentation to the Division of Design, 

February 1984. 

29 Kalousek, G.L., L.C. Porter, and E.J. Benton, “Concrete for Long-time Service in Sulfate 

Environment,” Cement and Concrete Research, Vol. 2, Pergamon Press, New York, p. 79-89, 

1972. 

30 Kepler, W.F., “Underwater Placement of a Concrete Canal Lining,” ACI Concrete 

International: Design and Construction, Detroit, Michigan, p. 54-59, June 1990. 31 American Concrete Institute, Guide for Consolidation of Concrete, Committee 309, Detroit, 

Michigan, 1999. 
 

App 1A- 17

 

 

 

Appendix A: Historical Development of Durable Concrete for the Bureau of Reclamation 

1978 provided the Secretary of the Interior with the authority to construct, restore, 

operate, and maintain new or modified features at existing Federal Reclamation 

dams for safety of dams purposes.32 As the inventory of dams was closely 

examined, it became apparent that many dams were in need of attention. The 

safety of dams program recognized that dams constructed prior to changes in the 

state-of-the-art in dam design and construction were candidates for funding under 

this act. In addition to dam safety needs, many aging Reclamation structures were 

in need of some type of repair due to the ravages of time. One example is Tieton 

Dam (figure 8), constructed in Washington in 1925. The concrete-lined spillway 

suffered from serious FT deterioration. It was first rehabilitated in the 1970s, and 

again in 1999, with operations and maintenance funding. Concrete canals, power 

and pumping plants, and appurtenant structures are also being rehabilitated 

throughout the West. The present generation of concrete technologists benefitted 

from four generations of research and development. They must continue to apply 

the hard won practical knowledge of their predecessors to maintain the existing 

infrastructure well into the 21st century. 

Figure 8. Tieton Dam spillway 

reconstruction in 1999, Yakima 

Project, Washington. The 

challenge for the 21st century: 

identify, protect, and preserve. 

The spillway was completed in 

1925 and suffered from severe 

FT deterioration. It was 

extensively repaired after 

about 40 years and 

reconstructed in 1999. These 

types of rehabilitation efforts 

will take center stage in 

21st-century Reclamation 

construction. (Construction 

records, Yakima Construction 

Office, Washington) 

32 U.S. Government, Public Law 95-578, November 2, 1978. 
 

 

 

 


 

	 

	 

	 

	 

	 

App IA- 18

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Conclusions
 

This paper reviewed the most significant causes of concrete deterioration and 

Reclamation’s role in improving the technology to the current state-of-the-art. 

Without durable concretes, Reclamation could not have developed the western 

water resources infrastructure we enjoy today. The development and rapid 

implementation of these advances kept Reclamation at the forefront of the 

state-of-the-art through the 20th century. This has extended the long-term service 

life of its infrastructure well into the 21st century. Figure 9 summarizes many of 

the steps encountered in developing durable, modern concrete. Although the list 

of accomplishments is long, the author nominates the following as the “top five”

contributions to durable concrete in the 20th century (in chronological order): 

1.	 Abrams’ design of concrete mixtures and “water-cement ratio law.”

Abrams applied engineering practices to concrete mixtures, and he was the 

first to institutionalize control of the water content to improve concrete 

quality. 

2.	 Development of special cements to improve concrete quality, such as 

low-heat and sulfate resisting cements. 

3.	 Development of the internal vibrator to consolidate concrete, which 

significantly reduced the water content of concrete, making it less 

permeable. 

4.	 Determination of the causes of and solutions to AAR and FT attack, using 

scientific methods such as petrographic mineralogical examination and 

long-term testing, to identify the parameters which affected the durability 

of concrete under these conditions. 

5.	 Incorporation of fly ash in Reclamation concrete construction, which 

improved concrete workability, decreased the porosity of the cement 

paste, and improved its resistance to sulfate attack and ASR. 
App IA- 19

 

Bureau of Reclamation 

Steps to developing durable concrete 

Poor Quality Better Quality Best Quality “Modern Concrete” 

“Pioneers” “Abrams” “Hoover” “Post War” 

Hand mixing 

Low output (cold joints) 

Poor quality materials 

Sulfate attack 

Alkali-aggregate reaction 

Freeze-thaw attack 

Recipe mix design 

Reinforced concrete 

“Add more water!” 

Water/cement ratio 

Quality materials 

Mix design 

Volumetric batching 

Sulfate attack 

Alkali-aggregate reaction 

Freeze-thaw attack 

“Chuting” 

“Add more water!” 

Weigh batching 

Internal vibration 

(less water) 

Block construction 

Low-heat cement 

Use of pozzolans 

Type II, V cement 

Low-alkali cement 

Air-entrained concrete 

Process quality control 

Concrete Laboratory 

Concrete Manual 

“Add more water!” 

Pozzolans 

(fly ash) 

Automoted 

Construction 

(tunnels, canals) 

Admixtures 

Concrete repair 

Superplasticizers 

Silica fume 

Roller-compacted 

concreteCC 

1902 1918 1928 1948 2002 

Figure 9. Steps leading to the development of durable Reclamation concrete throughout the 20th 

century. 

 

Guide to Concrete Repair 

Part I: Appendix B 

Petrographic Analysis for Concrete 

 

 

 

 

 


 

App IB-1 

Appendix B
 

Petrographic Analysis for 

Concrete 

By Doug Hurcomb, Bureau of Reclamation 

Introduction 

Petrography is an observational science, performed by a person who is usually 

titled “the petrographer,” which is used to study concrete quality and technology

problems. The petrographer is usually asked to help answer questions about the 

quality of concrete and concrete aggregates, and to help determine cause and 

extent of damage to existing concrete. 

One well-known petrographer described his role as the “eyes of the engineer, the

chemist, and concrete technologist investigating the properties of concrete and the 

materials that go into making concrete” (DePuy, 1990). Usually, the petrographer 

evaluating concrete is a geologist with at least 5 years’ experience in petrographic 

examination of concrete and concrete-making materials. The concrete 

petrographer should have knowledge to evaluate the effects of aggregates and 

supplementary cementing materials on the physical and chemical properties of 

hardened concrete, including concrete durability. 

The Reclamation petrographer performs the analysis of hardened concrete in 

accordance with American Society for Testing and Materials Standard Guide 

C 856, Standard Practice for Petrographic Examination of Hardened Concrete 

(ASTM, 1999) and USBR 4856, Petrographic Examination of Hardened 

Concrete (Bureau of Reclamation, 1992). 

Value of Petrographic Examination 

Petrography is a way to diagnose concrete problems and to evaluate the 

performance of repairs. Unfortunately, there is no apparatus that allows rapid and 

thorough examination of concrete and provides complete analysis. Concrete 

petrography is the commonly accepted method of diagnosing the quality and 

condition of concrete and concrete-making materials. 

The concrete petrographer assists the engineer who is contemplating a repair by 

providing an assessment of the concrete quality and composition. If the concrete 
 

 

 

	 

	 

	 

	 

	 

	 

	 

	 

App IB-2 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

is damaged, the petrographer determines the cause and extent of concrete damage 

so that a proper repair can be designed and engineered. 

The petrographic examination helps answer questions about what caused concrete 

failure and the extent of damage. Experience has shown that performing repairs 

without properly identifying the cause and extent of concrete damage usually 

leads to failed repairs. 

Petrography can provide the information needed to help with repair decisions. 

The petrographer helps to formulate the sampling plan. Typically, samples 

(concrete cores) are selected from competent concrete and damaged concrete. If a 

concrete core sample is obtained through the damaged area to competent concrete, 

the petrographer can determine the quality of underlying concrete and the depth of 

deterioration. That information helps determine the depth of excavation needed 

for a good repair and assists in providing some diagnostic information about the 

damaged materials and the cause and extent of deterioration. 

Information Provided by a Petrographic 

Examination 

The Bureau of Reclamation’s Petrographic Laboratory has experience 

investigating materials associated with the design and construction of 

Reclamation structures. The petrographer uses various techniques, instruments, 

and expertise based on training and experience. 

Concrete petrography can provide: 

	 Detailed description of concrete or grout condition and composition. 

	 Quality evaluation of concrete and concrete aggregates. 

	 Air void system parameters including percent air content. 

	 Composition of segregated areas of grout and concrete. 

	 Quality of lift joint bond. Any materials affecting the contact between two 

concrete masses are easily observed and analyzed. 

	 Degree of cement hydration and estimates of water-cement ratio. 

	 Cause and extent of deterioration. 

	 Identification of physical quality problems including freezing and thawing 

damage. 
Appendix B: Petrographic Analysis for Concrete 

 

 

 

	 

	 


 

	 

	 

	 

	 

App IB-3 

	 Identification of finishing and workmanship problems. 

	 Identification of deleterious materials such as alkali-silica gel or 

alkali-reactive glasses in aggregates.
 

	 Identification of secondary reactions and products. Petrography can 

identify the crack filling or void filling material or the alteration of 

concrete, grout, or mortars due to exposure. 

	 Carbonation depth. Carbonation occurs when concrete is exposed to CO2 

in the air. Carbonation results in lower pH of the affected concrete and 

decreased porosity. The area around superficial cracks and surface 

exposures is typically carbonated, which is not a problem. Concrete is 

designed to be dense, and minor carbonation is not significant. However, 

carbonation can be a good indicator that the concrete has experienced 

other cracking due to ASR or freezing and thawing deterioration. 

	 Loss of mass due to acid attack. Flowing acidic waters can quickly attack 

concrete surfaces and cause significant deterioration. 

	 Diagnosis of concrete repair failures. 

How Petrography is Used 

The main power of petrography is information. Usually, the information is used 

by the person requesting the petrographic examination to solve a problem, 

identify materials or processes, or identify and document the condition of 

materials. 

Hardened concrete, typically a concrete core, is submitted to the Petrographic 

Laboratory to evaluate condition or quality of the concrete, such as satisfactory, 

fair, or poor; to determine cause of inferior quality, distress, or deterioration; to 

evaluate specimens tested to failure; or to determine air void parameters. 

The petrographic report details condition and workmanship; determines cause and 

extent of inferior quality, distress, and/or deterioration; describes aggregate rock 

types and physical and chemical quality, paste composition and condition, voids, 

secondary and hydration products, and fractures; and determines air void 

parameters including air content and size and distribution of air voids. 

 

	 

	 

	 

App IB-4 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

Uses of the Petrographic Report
 

The petrographic report documents the condition of the as-received samples, 

sample locations, background information such as who requested the petrographic 

examination, purpose of the petrographic examination, techniques used, and 

results. 

The report typically contains an examination sheet, which provides detailed 

information on aggregates, paste, voids, secondary and hydration products, 

fractures, and other salient and notable features of the concrete. The information 

is evaluated, and conclusions address the concerns of the client and the general 

condition of the samples. 

After completing the petrographic examination, results are interpreted and 

conclusions are made concerning the quality of the concrete based upon apparent 

durability and extent of damage. 

	 Satisfactory quality concrete generally exhibits only minimal damage that 

will not affect the durability or service life of the structure. 

	 Fair quality concrete exhibits minimal to moderate damage, and the 

durability and service life of the structure will not be seriously affected. 

	 Poor quality concrete exhibits extensive damage, and the durability and 

service life of the structure will be seriously impaired. 

The report can be filed for future use, appended to an engineer’s report, or stand 

alone as the primary report. 

Tools of the Petrographer 

Techniques and instruments include chemical analysis, X-ray diffraction analysis, 

X-ray fluorescence, petrographic and stereoscopic microscopy, scanning electron 

microscopy, energy dispersive X-ray microanalysis, and other miscellaneous 

techniques. The instruments are only as good as the skill and experience of the 

petrographer in obtaining and interpreting scientific evidence. 

The stereoscopic, petrographic, and reflected light microscopes are the work 

horses of the petrographer. The stereoscopic microscope is simply a microscope 

equipped with a light source and zoom magnification. It is used for low 

magnification examinations of foundation rock, soil, concrete aggregate, riprap, 

concrete, and Portland cement grout, as well as for photomicrographs on the order 

of several millimeters in diameter. 
Appendix B: Petrographic Analysis for Concrete 

App IB-5 

 

 

 

The petrographic microscope is a microscope with a polarized light source used 

for higher magnification examinations. Polarized light analyzes properties of the 

material, and the information is used by the analyst to identify materials. It is 

used for low to higher magnification examination of thin sections and small 

particles of foundation rock, soil, concrete aggregate, riprap, concrete, and 

Portland cement grout, as well as for taking photomicrographs on the order of 

fractions of a millimeter. 

The reflected light microscope is similar to the petrographic microscope and 

typically uses top-light illumination to examine polished specimens of concrete 

and Portland cement grout. The microscope may also be used to identify opaque 

minerals. 

X-ray diffractometry (XRD), X-ray bombardment of a powder sample or a single 

crystal, provides identification of crystalline compounds (i.e., calcium carbonate). 

Typical samples are fine-grained rock, soil, concrete, and Portland cement grout, 

as well as precipitates, cement, pozzolan, stains, scales, coatings, paint pigments, 

sludge, filter residues, organics, corrosion products, and metals. XRD produces a 

“fingerprint” and is a fast, inexpensive way to analyze fine-grained materials. 

Scanning electron microscopy (SEM), or electron bombardment of the sample, 

produces images with very high magnifications. The SEM and its accompanying 

energy dispersive spectrometer (EDS) can be used to analyze both crystalline and 

noncrystalline materials. The instruments can provide detailed images of very 

small particles on a submicron scale and provide their elemental compositions. 

The elemental data from EDS data, coupled with compound information from 

XRD, can potentially identify any compound previously identified using a 

database of X-ray diffraction data. 
 

 

 

 

 

App IB-6 

Guide to Concrete Repair, Part I: Reclamation's Methodology for Concrete Maintenance & Repair 

References 

ASTM 1999. C856, “Standard Practice for Petrographic Examination of 

Hardened Concrete,” 1999 Annual Book of Standards. Section 4, 

Vol. 04.02, p. 413-427. 

Bureau of Reclamation. 1992. USBR 4856, “Petrographic Examination of 

Hardened Concrete,” Concrete Manual. Part 2, 9th edition, p. 597-615. 

DePuy, G.W., 1990. ASTM STP 1061, Petrographic Investigations of Concrete 

and Concrete Aggregates at the Bureau of Reclamation, Petrography 

Applied to Concrete and Concrete Aggregates. B. Erlin and D. Stark (eds.), 

American Society for Testing and Materials, Philadelphia, Pennsylvania. 

Sheldon, G.J. 1985. Petrographic Laboratory Analytical Techniques and 

Capabilities Reference, 28 pp. 
Guide to Concrete Repair
 

Part II: Standard Specifications for 

Repair and Maintenance of 

Concrete, M-47 

 

M0470000.715 

Standard Specifications for 

Repair and Maintenance of 

Concrete, M-47 

U.S. Department of the Interior 

Bureau of Reclamation 

Technical Service Center 

Concrete, Geotechnical, and Structural Laboratory 

Denver, Colorado August 2015 

 

 

 

 

 

Standard Specifications for 

Repair and Maintenance of 

Concrete 

In order to achieve the best results in the repair and maintenance of concrete, 

follow the seven-step repair process described in detail in Part I of this Guide to 

Concrete Repair (Guide), as well as the information presented here in Part II. 

Part II of the Guide begins with the assumption that steps 1 through 4 (as 

described in part I, chapter A) have been properly conducted and that repairs are 

planned and budgeted. After a repair material/technique has been properly 

selected, it becomes fairly straightforward to select which specification section to 

use. Thus, the next logical step is preparing repair specifications, either as a 

stand-alone project or as a part of a larger project. The best results will be 

obtained by using the information in Part I, chapter D, to help adjust the guide 

specification for an actual project. In addition, because it can be difficult to 

achieve long service life concrete repairs, and these documents do not cover all 

possible repair scenarios, personnel in the Concrete, Geotechnical, and Structural 

Laboratory (CGSL) are always available to provide expert advice and assistance. 

Part II includes an appendix with the following separate specification sections: 

 Concrete removal, including hydrodemolition 

 Concrete repair, including small and large repairs 

 Concrete surface repair using polymer concrete (including epoxy mortar) 

 Crack repair using epoxy injection 

 Chemical grout to seal leaks 

 Concrete crack healer and penetrating sealer 

 Coating concrete 

Appendix IIA also includes the Bureau of Reclamation’s (Reclamation) concrete 

and shotcrete guide specifications, which pertain to concrete that might be used 

for replacement concrete, shotcrete, silica fume concrete, or other forms of 

concrete used for repair (such as self-consolidating concrete). 

While preplaced aggregate concrete is a very effective repair method, it has rarely 

been used by Reclamation, especially over the last 20 years; therefore, if a repair 

using preplaced aggregate concrete is under consideration, please contact staff at 

CGSL for assistance. 

When developing concrete repair specifications that are appropriate for a specific 

job, users can select which specification section, or parts of a section, to use. 

II-1 
 

 

 

 

 


 


 


 


 

Guide to Concrete Repair, Part II: Standard Specifications for Repair and Maintenance of Concrete 

(Refer to guidance contained in Part I of the Guide.) It will also be helpful to 

consult with CGSL staff, as they continually update these guide sections. Finally, 

it should be recognized that no two repair projects are the same, so each project 

will require modification and changes to these specification sections. 

The standard concrete repair and maintenance materials and techniques described 

in this Guide have been developed and evaluated by Reclamation over many 

years. In many cases, repair is synonymous with maintenance – the activities 

followed are similar, and the goal of extending the service life is the same. 

Sometimes, the distinction is only related to the scope or size of a project. 

As mentioned above, the Guide now contains a section on coating concrete. If a 

decision is made to coat concrete for purposes of repair or maintenance, there 

must be specific reasons and objectives for the coating, and a logical process must 

be followed to ensure that the coating will last as long as possible. 

These guide specifications will be updated periodically (more frequently than the 

entire Guide to Concrete Repair). For questions related to this Guide, any 

assistance with concrete repair and maintenance issues, or to obtain information 

about the latest concrete repair guide specifications, please contact: 

Kurt von Fay, Westin Joy, Warren Starbuck, or Matthew Klein 

Bureau of Reclamation
 

Technical Service Center
 

Concrete, Geotechnical, and Structural Laboratory
 

Attention: 86-68530 

PO Box 25007 

Denver Federal Center
 

Denver, CO 80225 

The Seven Steps of Concrete Repair 

and Maintenance 

Unfortunately, many repair failures have occurred on Reclamation concrete 

structures, even though very durable repair materials were specified and used. 

This has been a problem not only for Reclamation, but for the entire concrete 

repair industry. As a result, in the early 1970s, the industry started receiving more 

attention and resources to help improve the performance of concrete repairs. 

In evaluating the causes of these failures, one lesson that was learned is that it is 

essential to consistently use a systematic approach to repairing concrete. Several 

agencies and authors have developed similar systems, and this Guide does not 

discuss or evaluate which of these systems is best for any set of field conditions. 

The purpose of this Guide is to present a concrete repair system Reclamation has 

II-2 
The Seven Steps of Concrete Repair and Maintenance 

 

 

 

 

 

used over a long period of time, which has resulted in many successful concrete 

repairs. This system, known as “The Seven Steps of Concrete Repair and 

Maintenance,” is suitable for both construction defects in new concrete and for 

old concrete that has been damaged by long exposure to field conditions. When 

using this approach, it is necessary to take the steps in the correct order. Many 

times, the first questions asked when damaged concrete is detected are: “What 

should be used to fix this?” and “How much will the repair cost?” These are good 

questions, but they are asked at the wrong time. With a systematic approach, 

these questions are asked after enough information is available to provide good 

answers. 

The seven steps of concrete repair and maintenance are: 

1. Determine the cause(s) of damage 

2. Evaluate the extent of damage 

3. Evaluate the need to repair 

4. Select the repair method and material 

5. Prepare the existing concrete for repair 

6. Apply the repair method 

7. Cure the repair properly 

It is also important to view the information gathered as part of a system of the 

existing structure and the quality of the concrete, the deterioration or damage 

affecting the concrete, and its service environment for the repairs to be as durable 

and long lasting as possible. Always consider how these aspects will interact so 

that a repair plan is developed that will not worsen the damage or deterioration. 

Step 1. Determine the Cause(s) of Damage 

It is essential to determine the causes(s) of damage to the concrete in order to 

achieve long-lasting repairs. If the cause of damage is not discovered or an 

incorrect determination is made, the repair will most likely deteriorate for the 

same reason the original concrete became damaged. The repair will be short 

lived, and the new repair will likely be larger and more expensive. 

Step 2. Evaluate the Extent of Damage 

The objective of this step is to determine how much of the structure is damaged 

and to what extent it is damaged. This helps designers and planners to properly 

determine how much concrete, steel, etc., might require removal (in the case of 

repair) or how much of the surface should be sealed or coated (in the case of 

maintenance). 

II-3 
 

 

 

 

 

 

 

Guide to Concrete Repair, Part II: Standard Specifications for Repair and Maintenance of Concrete 

Step 3. Evaluate the Need to Repair 

Not all damage to concrete needs repair. Repairs should be undertaken only if 

they will result in longer or more economical service life, a safer structure, or 

necessary cosmetic improvements in the structure. This step also includes 

determining when the structure can be taken out of service for repairs, estimating 

how long repairs will last, and deciding how the costs of the repairs will be 

budgeted. 

Steps 1-3, as explained above, are the major components of a condition 

assessment or survey. Steps 4-7 of the concrete repair process should only be 

taken after steps 1-3 have been properly performed. 

Step 4. Select the Repair Method and Material 

After completing steps 1-3, and considering the existing condition and quality of 

the concrete and its service environment, an appropriate repair system can be 

selected that takes into consideration the many factors essential to a successful 

repair. In a majority of repair situations, the standard materials and methods in 

this specification will fully meet all repair or maintenance needs. However, 

certain service conditions or special repair situations will occur when these 

“standard methods and materials” will not meet the special requirements, and it

will be necessary to resort to “nonstandard” repair materials or methods. 

Nonstandard repair materials are continually being tested and evaluated by 

Reclamation laboratory and field offices. They include materials that may have 

performed well in laboratory tests but have not yet been applied in the field, 

materials that do not yet have long or sufficient field service to determine service 

life expectancy, or newly developed commercial materials that have not yet been 

tested or evaluated by Reclamation. 

The only time it is appropriate to use nonstandard or unproven repair materials is 

when a determination is made that none of the standard repair methods and 

materials will work properly, and only when all involved parties fully understand 

and agree that the risks of using unproven materials are justified by the expected 

benefits of the repair. 

Step 5. Prepare the Existing Concrete for Repair 

The most common cause of repair failure is poor preparation of the existing 

concrete prior to application of the repair material. Even if every other step is 

done perfectly, if this step is done improperly, the repair will likely fail. Even the 

best repair materials will give poor service life if they are bonded to dirty, 

weakened, or deteriorated concrete. The specification sections that follow 

II-4 
The Seven Steps of Concrete Repair and Maintenance 

 

 

provide only the minimum preparation requirements. Also, different repair 

materials may have special preparation requirements. For example, the 

preparation requirements for replacement concrete differ from those for polymer 

concrete. Therefore, to find the preparation requirements for a specific type of 

concrete repair, refer to the section of this Guide that pertains to the repair 

materials under consideration. 

Step 6. Apply the Repair Method 

Each standard and nonstandard repair material has application procedures specific 

for that material. As noted above, the procedures necessary for replacement 

concrete are vastly different from those necessary for polymer concrete. It is 

essential that proper application techniques for each material be followed exactly. 

Step 7. Cure the Repair Properly 

Another common cause of repair failures involves improper or inadequate curing. 

Each repair material has specific curing requirements. For example, replacement 

concrete benefits from long periods of water curing, while some packaged repair 

mortars require a few hours of water curing, followed by drying. Polymer 

concrete has essentially no curing requirements (protect until hard), while those of 

silica fume concrete are exceedingly exact. Failure to achieve proper cure for the 

proper duration will likely result in an inferior repair at the final step of the 

process. 

II-5 

 

Guide to Concrete Repair
 

Part II: Appendix A 

Guide Specifications 

 

 

 


	


	

Feature name
	

Spec Title Solicitation No.
	

SECTION 03 30 00 

CAST-IN-PLACE CONCRETE 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR - BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 11/20/14 

Content Revisions: 

11/13/13 Significant changes throughout Section, too numerous to list. 

4/6/09 Changed Section number 

3/12/08 Added optional paragraphs for Contractor Quality Testing. Added 

requirement that curing compound in contraction joints prevents bond. 

8/3/07 Revised cementitious materials payment footnote, added appendix A address 

for M-47 reference, revised repair submittal, added ICRI requirements for 

surface prep of construction joints and existing concrete, added mortar 

requirement to U2 finish when used for U3, added broom finish, and added 

finish slope requirements for unformed finishes. 

Editorial/Format Revisions: 

7/24/15 Changed template 

4/6/09 Changed template 

8/3/07 Changed template and added blank page code to end. 

Template: CSI_15a.dotx 

NOTES 

(1) ASTM C94 has three options for concrete mixture: Option A - Manufacture required 

to assume full responsibility for selection of proportions of concrete mixture. Option 

B - Purchaser assumes full responsibility for proportioning of concrete mixture. 

Option C - Manufacturer required to assume full responsibility for selection of 

proportion of concrete mixture with minimum allowable cement content specified. 

This guide is written assuming Option A applies. 

Cast-In-Place Concrete (Ready Mix Form) 

03 30 00 - 1 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


	


	

Feature name
	

Spec Title Solicitation No.
	

SECTION 03 30 00 

CAST-IN-PLACE CONCRETE 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR - BUREAU OF RECLAMATION 

(2) Recovered/Recycled materials: 

Agencies that procure $10,000 or more worth of cement and concrete, including 

concrete products, in one fiscal year are required by 40 CFR 247 to specify that such 

items contain coal fly ash (Class C or F) or ground granulated blast furnace slag 

(GGBF). Exceptions are made only if fly ash is too costly, not readily available, or 

not suitable for performance requirements. 

Solicitations mandating use of fly ash must contain FAR clauses 52.223-4 “Recovered 

Material Certification” and 52.223-8 “Estimate of percentage of Recovered Material 

Content for EPA-Designated Products – Alternate I”. Coordinate with issuing office 

to ensure these clauses are included in the solicitation. 

(3) TSC Concrete, Geotechnical, and Structural Laboratory (CGSL - 86-68530) may be 

contacted when assistance or specialized knowledge for concrete is required. (Contact 

phone number - 303-445-2373) 

(4) Quality Testing: Historical practice for Reclamation was to have Government 

personnel perform extensive Quality Assurance testing for concrete. Due to various 

factors, Reclamation has at times needed to rely on testing agencies to perform testing 

for Quality Assurance purposes. See the footnote attached to Contractor Quality 

Testing Article (2.11) or discussion of testing procedures and appropriate 

specifications editing. 

(5) When concrete structures are very simple and tolerances are not required, Very Short 

Form version of Cast-In-Place Concrete guide spec may be used. When concrete 

tolerances are required, this guide spec should be used. 

Standard drawings: 

40-D-6263 General Notes and Minimum Requirements for Detailing Reinforcement 

40-D-7012 General Concrete Outline Notes 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

Cast-In-Place Concrete (Ready Mix Form) 

03 30 00 - 2 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


	


	

	 

		

		

		

		

		

		

		

		

		

	 

	 

	 

	 

	 

	 

	 


	


	

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

Feature name
	

Spec Title Solicitation No.
	

SECTION 03 30 00 

1

CAST-IN-PLACE CONCRETE 

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 2[Concrete: 

1.		 3[Measurement: Volume of concrete measured to structure neatlines shown on 

drawings.] 

a.		 4

[Where concrete is placed on or against excavated surfaces, measurement 

will be made to lines for which payment for excavation is made. 

b.		 Measurement of other concrete will be made to structure neatlines shown 

on drawings. 

c.		 Volume of openings, recesses, embedded pipes, and metalwork larger than 

100 square inches in cross section will be deducted.] 

2.		 Payment: Cubic yard price offered in the Price Schedule. Includes cost of labor 

and materials for concrete 5

[except as specified]. 

a.		 6

[Includes cost of concrete reinforcement.] 

B.		 7[Cementitious Materials: 

1.		 Measurement: Weight of cementitious materials used in concrete based on batch 

weights and batch counts at batch plant measured in most practical manner. 

1		 Delete “(Ready Mix Form)” from footer. (Match Section title) 

2		 When appropriate for the job, this Section may have multiple pay items for concrete with pay item titles 

describing the structures included in each pay item. In the rare situation that all concrete will be paid for in 

other item(s) of work, delete concrete pay items and include appropriate statements in Cost paragraph. 

3		 Revise as required. Delete measurement when concrete is paid by lump price (infrequently used). 

4		 Delete or revise as required 

5		 Include when cementitious materials is separate pay item. Delete when cementitious materials cost is 

included in price offered for concrete. See footnote for Cementitious Materials pay item. 

6		 Delete when solicitation includes separate pay item for Concrete Reinforcement. Include when cost of 

concrete reinforcement is included in price offered for Concrete. 

7		 Delete this pay item when the Contractor is responsible for mix design. Cost of cementitious materials 

should be included in payment for concrete when the Contractor is responsible for concrete mix design. 

This guide is written assuming Contractor is responsible for mix design (see Article 2.08). 

Include payment for cementitious materials when Government will be responsible for concrete mix design 

(the Contractor does not have control over how much cementitious materials are used per cubic yard of 

concrete). Coordinate with Mix article (2.08) as required. 

Cast-In-Place Concrete (Ready Mix Form) 

03 30 00 - 3 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


	


	

		

		

		

		

		

		

		

	 

		

	 

		

		

		

		

		

	 

	 

	 


	


	

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

		

Feature name
	

Spec Title Solicitation No.
	

a.		 Includes portland cement, {blended hydraulic cement,} and supplementary 

cementitious materials (SCM). 

b.		 One bag of cement will be measured as 0.047 ton. 

c.		 Does not include weight of cementitious materials in concrete that is 

wasted. 

2.		 Payment: Ton price offered in the Price Schedule.] 

C.		 8[Cost: 

1.		 Include cost of concrete for chain link fence in price offered in the Price Schedule 

for Chain Link Fence. 

2.		 Include cost of concrete for bridge deck in price offered in the Price Schedule for 

Pretensioned Concrete Bridge Beams.] 

1.02		 ACRONYMS 

A.		 NRMCA: National Ready Mixed Concrete Association 

1.03		 DEFINITIONS 

A.		 9[Architectural Concrete: Concrete of special architectural importance placed as shown 

on the drawings. 

1.		 Colored Concrete: Cast-in-place concrete using integral coloring additives added 

at batch plant and delivered in concrete mixture. 

2.		 Stained Concrete: Cast-in-place concrete with penetrating stain applied after 

hardening. 

3.		 Textured Surface Form Lined Concrete: Cast-in-place concrete that is placed 

against textured form.] 

B.		 10[Chemical and Drying Shrinkage-Reducing Additive Concrete (CDSRA Concrete): 

Concrete with use of Chemical and Drying Shrinkage-Reducing Additive (CDSRA) 

specified. Applicable concrete mix(es) in Table 03 30 00A - Concrete Mixes are 

identified as CDSRA Concrete in Notes column.] 

8		 Include when contract includes items that require concrete and cost of concrete for those items is included 

in prices offered for those items. Some examples are provided. Edit cost items as appropriate for job. 

9		 Delete when job does not include architectural concrete. Not frequently used. Edit list of architectural 

concrete types as appropriate for job. 

10		 Delete when specifications do not include CDSRA Concrete. Specify CDSRA Concrete only for 

applications requiring special control of shrinkage. Not required for most applications. Use will be based 

on structure type. 

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C.		 11[Shrinkage Reducing Admixture Concrete (SRA Concrete): Concrete with use of 

Shrinkage Reducing Admixture (SRA) to reduce material shrinkage due to drying. 

Applicable concrete mix(es) in Table 03 30 00A – Concrete Mixes are identified as SRA 

Concrete in the Notes column.] 

D.		 12[Reinforced Structural Mass Concrete (RSMC): Placement greater than {2.5-feet} in 

least direction {and designated as RSMC on drawings}. Specified requirements for 

RSMC lessen potentially detrimental thermal stresses from heat generated during curing.] 

E.		 13[Self-Consolidating Concrete (SCC): Highly flowable, non-segregating concrete that 

spreads into place, fills formwork, and encapsulates congested reinforcement, without 

mechanical vibration.] 

F.		 Supplementary Cementitious Materials (SCM): Cementitious materials other than 

portland cement. 

1.04		 REFERENCE STANDARDS 

A.		 American Concrete Institute (ACI) 

11		 Delete when specifications do not include SRA Concrete. Specify SRA Concrete only for applications 

requiring control of shrinkage caused by drying. This is not an alternative for CDSRA Concrete. Use will 

be based on structure type. 

12		 Delete when specifications do not include concrete placements that are relatively thick. Include when job 

contains thick concrete placements and a determination is made that special measures are required to deal 

with heat generated during curing. Revise dimension as appropriate for job. 

The statement “and designated RSMC on the drawings” may be deleted when all placements exceeding
	

specified minimum thickness shall be mixed and placed in accordance with RSMC requirements. Include 

statement when only some placements exceeding the specified minimum dimension need RSMC
	

requirements. Designate those placements on the drawings.
	

Note to Designers: RSMC generally consists of concrete placements where the minimum section is greater
	

than 2 to 3 feet. Consult with 86-68530 for dimension that is appropriate to use for specific jobs.
	

Designate placements that are RSMC on drawings.
	

Without preventive measures, heat generated during curing may result in unacceptable stresses due to
	

thermal gradients in mass concrete before adequate strength is developed. Preventive measures specified
	

include: Increased content of pozzolan in cementitious material, lower concrete mix temperature at
	

placement, insulating during initial curing (as needed), and internal cooling (as needed). Finite element 

analysis (can be performed by 86-68110), or ConcreteWorks software may be useful to determine limits,
	

http://texasconcreteworks.com.
	

Even though minimum dimensions exceed the threshold, nonstructural (and possibly some structural)
	

concrete placements where potential cracking due to thermal stresses is not critical do not need RSMC
	

requirements specified.
	

Inclusion of RSMC in the specifications requires this Section to be edited to include various Articles and
	

paragraphs in other locations of the Section.
	

13		 Delete when job does not include self consolidating concrete. Not frequently used. Use as needed based 

on concrete placing requirements. When included, edit Section 03 11 10 - Concrete Forming to require 

submittal of design calculations certified by a P.E. Calculations shall be based on full hydraulic head of a 

placement. 

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1.		 14[ACI 117 - 10 Tolerances for Concrete Construction and 

Materials 

2. ACI 201.2R – 08		 Guide to Durable Concrete 

3. ACI 301-10		 Structural Concrete 

4. 15 [ACI 303.1-97		 Cast-In-Place Architectural Concrete] 

5.		 ACI 304R-00(2009) Guide for Measuring, Mixing, Transporting, 

and Placing Concrete 

6. ACI 305.1-14		 Hot Weather Concreting 

7. ACI 306.1-90(2002)		 Cold Weather Concreting 

8.		 ACI 318-11 Building Code Requirements for Structural 

Concrete 

B.		 ASTM International (ASTM) 

1.		 ASTM C31/C31M-12 Making and Curing Concrete Test 

Specimens in the Field 

2. ASTM C33/C33M-13		 Concrete Aggregates 

3.		 ASTM C39/C39M-15a Compressive Strength of Cylindrical 

Concrete Specimens 

4.		 ASTM C42/C42M-13 Obtaining and Testing Drilled Cores and 

Sawed Beams of Concrete 

5. ASTM C94/C94M-15		 Ready-Mixed Concrete 

6. ASTM C114-17 Chemical Analysis of Hydraulic Cement 

7.		 ASTM C117-13 Materials Finer than 75-μm (No. 200) Sieve 

in Mineral Aggregates by Washing 

8.		 ASTM C136-14 Sieve Analysis of Fine and Coarse 

Aggregates 

9.		 ASTM C138/C138M-14 Density (Unit Weight), Yield, and Air 

Content (Gravimetric) of Concrete 

10. ASTM C143/C143M-12		 Slump of Hydraulic-Cement Concrete 

11. ASTM C150/C150M-12		 Portland Cement 

12.		 ASTM C157/C157M-08(2014) Length Change of Hardened HydraulicCement Mortar and Concrete 

13. ASTM C171-07 Sheet Materials for Curing Concrete 

14		 Delete this reference for most jobs. This reference included only when Surfaces Tolerances Table 

(03 30 00D) is not included. Specs need to be revised to incorporate this reference. 

15		 Delete this reference for most jobs. Include only if decorative or architectural concrete is specified. 

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14.		 ASTM C231/C231M-14 Air Content of Freshly Mixed Concrete by 

the Pressure Method 

15. ASTM C260/C260M-10a		 Air-Entraining Admixtures for Concrete 

16.		 ASTM C309-11 Liquid Membrane-Forming Compounds for 

Curing Concrete 

17. ASTM C494/C494M-13		 Chemical Admixtures for Concrete 

18. ASTM C595/C595M-14		 Blended Hydraulic Cements 

19.		 ASTM C618-12a Coal Fly Ash and Raw or Calcined Natural 

Pozzolan for Use in Concrete 

20. 16[ASTM C979/C979M-10		 Pigments for Integrally Colored Concrete] 

21.		 17[ASTM C989/C989M-14 Slag Cement for Use in Concrete and 

Mortars] 

22.		 ASTM C1017/C1017M-13 Chemical Admixtures for Use in Producing 

Flowing Concrete 

23.		 ASTM C1064/C1064M-12 Temperature of Freshly Mixed HydraulicCement Concrete 

24.		 18[ASTM C1074-11 Estimating Concrete Strength by the 

Maturity Method] 

25.		 ASTM C1260-14 Potential Alkali Reactivity of Aggregates 

(Mortar-Bar Method) 

26.		 ASTM C1293-08b Determination of Length of Change of 

Concrete Due to Alkali-Silica Reaction 

27.		 ASTM C1315-11 Liquid Membrane-Forming Compounds 

Having Special Properties for Curing and 

Sealing Concrete 

28.		 ASTM C1567-13 Determining the Potential Alkali-Silica 

Reactivity of Combination of Cementitious 

Materials and Aggregate (Accelerated 

Mortar-Bar Method) 

29.		 19[ASTM C1581/C1581M-09a Determining Age at Cracking and Induces 

Tensile Stress Characteristics of Mortar and 

Concrete under Restrained Shrinkage] 

Include only when colored concrete specified. 

17 Include only when slag cement is included as Supplementary Cementitious Material (SCM). 

18 Include only when estimating concrete strength by maturity method is specified. 

19 Include only when CDSRA is specified. 

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30.		 ASTM C1602/C1602M-12 Mixing Water Used in the Production of 

Hydraulic Cement Concrete 

31.		 20[ASTM D1751-04(2013) Preformed Expansion Joint Filler for 

Concrete Paving and Structural Construction 

(Nonextruding and Resilient Bituminous 

Types)] 

32.		 21[ASTM D1752-04a(2013) Preformed Sponge Rubber Cork and 

Recycled PVC Expansion Joint Fillers for 

Concrete Paving and Structural 

Construction] 

C.		 U.S. Army Corps of Engineers (COE) 

1.		 COE CRD-C 662-10 Determining the Potential Alkali-Silica 

Reactivity of Combinations of Cementitious 

Materials, Lithium Nitrate Admixture and 

Aggregate (Accelerated Mortar-Bar 

Method) 

D.		 International Concrete Repair Institute (ICRI) 

1.		 ICRI 310.2-2013 Guide for Selecting and Specifying Concrete 

Surface Preparation for Sealers, Coatings, 

and Polymer Overlays (formerly No. 03732) 

E.		 Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

2.		 USBR Concrete Manual Concrete Manual, Eighth Edition, Revised 

Reprint, 1981 

F.		 NSF International (NSF) 

1.		 NSF/ANSI 61-2013 Drinking Water System Components – 

Health Effects 

20		 Include when bituminous joint filler specified. Delete when sponge rubber joint filler specified or there is 

no joint filler required (i.e. no expansion joints). 

21		 Include when sponge rubber joint filler specified. Delete when bituminous joint filler specified or there is 

not joint filler required (i.e. no expansion joints). 

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1.05		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 30 00-1, Approval Data: 

1.		 Mix Design: For each concrete mix. 

a.		 Mixture proportions. 

b.		 Material sources. 

1) Name and manufacturer of each cementitious material. 

2) Name of aggregate source(s). 

3) Product name and manufacturer of admixtures to be used in mix. 

Certify that admixtures:
	

a) Contain no purposefully added chlorides. 

b) Chloride ion limits in accordance with ACI 201.2R. 

4)		 Government reserves the right to require submission of samples of 

concrete materials for testing before or during use in concrete. 

c.		 Physical properties: 

1)		 Compressive strength: 

a) Test data: ACI 301, paragraph 4.2.3.4. 

b) Field test data: Performed within past 24 months. 

c) Trial mixtures: 

i.		 Incorporate admixtures that will be used in 

production mixes into trial mixes. 

ii.		 Results from trial batches made within past 6 

months. 

iii.		 Trial mix test results, three six-inch diameter 

cylinders each at 7, and 28 22[, and 56] days. 

iv.		 Average compressive strength of trial batch 

cylinders at specified design age. 

2) 23[Shrinkage test results for CDSRA Concrete mix.] 

3) 24[Shrinkage test results for SRA Concrete mix.] 

22		 Include when RSMC requirements included. Delete when RSMC not required. Design compressive 

strength of RSMC is specified at 56 days to control heat of hydration. Other design ages may be specified, 

but very infrequently used. 

23		 Delete unless CDSRA Concrete specified. 

24		 Delete unless SRA Concrete specified. 

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d. Resubmit mix design for change in material source or type. 

2.		 Name and manufacturer of curing compounds, and joint filler. 

a.		 Include application instructions for curing compound. 

3.		 25[Concrete coloring admixture: 

a.		 Manufacturers brand names, instructions and recommended dosages, and 

standard color chart.] 

4.		 Certifications and test reports: 

a.		 Sealed by Professional Engineer. 

b.		 Less than 12 months old. 

c.		 Certifications and test reports: 

1) Cementitious materials manufacturer. 

2) Aggregate producer for: 

a) ASTM C33 physical properties 

b) ASR testing reports for each aggregate source. 

3) Mixing water: ASTM C1602. 

d.		 Submittal of certifications and test reports shall not relieve Contractor of 

responsibility for furnishing materials meeting specified requirements. 

C.		 26[RSN 03 30 00-2, Concrete Placement Drawings: 

1.		 Drawings for individual concrete placements. More than one placement may be 

shown on a drawing. 

a.		 An individual concrete placement is defined as a portion of concrete work 

placed in one continuous operation between specified lines or joints. 

b.		 List contract drawing(s) from which details for placement were obtained. 

c.		 Show locations, elevations, dimensions, blockouts, openings, recesses, 

waterstops, and finishes. 

d.		 Show details of items embedded in or associated with placement except 

reinforcing steel. 

e.		 Reference related reinforcement drawing(s) associated with placement. 

25		 Delete unless colored concrete specified. 

26		 Delete when concrete placement drawings not required. Coordinate requirement for placement drawings 

with designers. 

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2.		 Include separate drawing(s) showing placement sequence.] 

3.		 Identify proposed changes to joint locations. 

D.		 27[RSN 03 30 00-3, Concrete Placement Schedule: 

1.		 Complete, detailed concrete placement schedule showing Contractor’s plan for 

individual placements including placement of reinforcement and embedded items. 

2.		 Detail as necessary to show location, sequence, and date of concrete placements 

scheduled for each item of concrete work. 

3.		 28{Show submittal schedule for placement and reinforcement drawings.}] 

E.		 29 [RSN 03 30 00-4, RSMC Temperature Control Plan: 

1.		 Design temperature control plan using finite element type software capable of 

running thermal analysis to evaluate internal concrete temperature with ambient 

and construction influences. 

2.		 Show location, sequence, and date of concrete placements scheduled for each 

RSMC designated structure. 

a.		 Anticipated maximum temperature of concrete in each placement and 

methods used to calculate maximum temperature. 

b.		 Methods used to control temperature. 

c.		 When internal cooling will be used, include detailed cooling plan with at 

least the following. 

1)		 Type, size, location, spacing, and diameter of cooling pipes; water 

cooling equipment; and flow. 

d.		 Identify how sequencing of adjacent RSMC placements will be 

determined. 

3.		 Include name and manufacturer of temperature monitoring device, placement 

locations and temperature monitoring plan.] 

F.		 RSN 03 30 00-5, Certifications: 

1.		 NRMCA Certification of Production Facilities. NRMCA certification shall 

include automatic digital recording of cementitious materials, aggregate, water, 

and chemical admixtures. 

27		 Delete if not required. Coordinate requirement for placement schedule with designers. Simpler jobs do not 

require placement schedule.
	

Submit RSN 03 30 00-2, Concrete Placement Drawings before or at the same time as RSN 03 30 00-3, 

Concrete Placement Schedule and RSN 03 20 00-1, Reinforcement Diagrams and Lists.
	

28		 Verify placement and reinforcement drawings are required. 

29		 Delete unless RMSC included. Include when RMSC specified. 

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2.		 30[ACI Aggregate Testing Technician certification(s). 

3.		 ACI Concrete Flatwork Finisher certification(s). 

4.		 ACI Concrete Field Testing Technician certification(s). 

5.		 ACI Concrete Strength Testing Technician certification(s).] 

G.		 31[RSN 03 30 00-6, Estimating Concrete Strength by Maturity Method Plan: 

1.		 List concrete placements where estimating concrete strength by maturity method 

will be used for early form removal or loading. 

2.		 Name and manufacturer of maturity monitoring devices. 

3.		 Placement locations of maturity monitoring devices. 

4.		 Report of maturity relationships {for applicable mixes} used in accordance with 

ASTM C1074.] 

H.		 RSN 03 30 00-7, Cementitious Materials Certification and Test Reports 

1.		 Less than 3 months old. 

2.		 Certify materials were tested during production or transfer in accordance with 

specified reference standards. 

I.		 32[RSN 03 30 00-8, Test Reports 

1.		 Aggregate test results as required by Table 03 30 00B – Contractor Batch Plant 

Quality Testing. 

2.		 Concrete test reports as required by Table 03 30 00E- Contractor Field Quality 

Testing. 

30 Coordinate inclusion of certifications for technicians with appropriate Articles. Delete certifications for 

those technicians not included those Articles 

Aggregate testing technician: Batch Plant Quality Testing (2.12) 

Finishers: Finishing Article (3.06.C). 

Field testing and strength testing technicians: Contactor Field Quality Testing (3.10). 

31 Include only when maturity method included in specifications. See Mix Article (2.08.G) 

Paragraph 4. - Delete “for applicable mixes” when there is only one mixed specified for the job. 

Recommended submittal time in Table 01 33 00A: At least 28 days before using maturity values to predict 

strength 

32		 Coordinate with Contractor Quality Testing articles (2.11 and 3.10). Include RSN when Contractor Quality 

Testing is specified. 

Recommended submittal time: Within 24 hours after completion of tests. 

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1.06		 QUALIFICATIONS 

A.		 Ready mix plant: Certified by NRMCA. NRMCA certification shall include automatic 

digital recording of cementitious materials, aggregate, water, and chemical admixtures 

B.		 33[ACI Aggregate Testing Technician: Currently certified ACI Aggregate Testing 

Technician - Level 1 

C.		 ACI Concrete Flatwork Finisher: Currently certified as ACI Concrete Flatwork Finisher. 

D.		 ACI Concrete Field Testing Technician: Currently certified ACI Concrete Field Testing 

Technician - Grade I. 

E.		 ACI Strength Testing Technician: Currently certified ACI Strength Testing Technician] 

1.07		 34[MOCK-UPS 

A.		 {Colored Concrete Test Panels: 

1.		 Place cast-in-place colored concrete test panels at least 28 days prior to placement 

of colored concrete. 

2.		 Demonstrate forming methods and equipment for cast-in-place colored 

architectural concrete.} 

B.		 {Architectural Concrete Test Panels: 

1.		 Place cast-in-place architectural concrete test panels at least 28 days prior to 

placement of colored concrete. 

2.		 Demonstrate sand-blasted finish for exposed, architectural concrete surfaces.}] 

1.08		 DELIVERY, STORAGE, AND HANDLING 

A.		 Furnish legible and digitized batch ticket with each batch of concrete in accordance with 

ASTM C94. Deliver ticket to COR at jobsite during batch delivery. 

B.		 35[Sponge rubber joint filler storage: 

33		 Coordinate inclusion of qualifications for technicians with appropriate Articles. Delete qualifications for 

those technicians not included those Articles. 

Aggregate testing technician: Batch Plant Quality Testing (2.12) 

Finishers: Finishing Article (3.06.C). 

Field testing and strength testing technicians: Contactor Field Quality Testing (3.10). 

34		 Include only when field mock-ups required for colored or architectural treatment of concrete specified. Not 

used very often. Edit as appropriate. 

35		 Delete when sponge rubber joint filler not specified. Sponge rubber joint filler used for expansion joints. 

See Joints and Edges Article (3.07). 

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1.		 Store in protected area at temperature of 70 degrees F (21 degrees C) or less. 

2.		 Do not expose to direct sun.] 

1.09		 36[PRE-PLACING MEETING 

A.		 At least 14 days before first concrete placement {for _______}, meet with COR for preplacement meeting. 

B.		 Coordinate time and place of meeting with COR at least 14 days before meeting. 

C.		 Contractor attendees shall be at least the following: 

1.		 Contractor onsite supervisor. 

2.		 Concrete forming, placing, and finishing onsite supervisor(s); Contractor or 

subcontractor(s) employee as applicable. 

3.		 Technical specialist from ready-mix supplier. 

4.		 Concrete pump subcontractor onsite supervisor, if applicable. 

5.		 Testing agency onsite supervisor(s).] 

PART 2 PRODUCTS 

2.01		 CEMENTITIOUS MATERIALS 

A.		 Portland cement: 

1.		 ASTM C150, Type 37[____]. 

a. Meet equivalent alkalies requirements of ASTM C150 - Table 2. 

1)		 Low-alkali limitation for portland cement may be waived when 

tests of concrete aggregate source show that low-alkali cement is 

not required for ASR mitigation. See Concrete Aggregate 

Materials article (2.03). 

b.		 Meet false-set requirements of ASTM C150 - Table 4. 

36		 Include pre-placing meeting requirement based on potential problems with concrete supply, or complexity 

of concrete placements.
	

Paragraph A. - Revise time (14 days) as required. List structures that need discussions when only part of
	

the work requires. Do not include list (i.e. delete {for___}) when all of the work needs discussion.
	

Paragraph B - Revise time (14 days) as required. 

Paragraph C - Revise list when appropriate. 

37 Specify Type. Default is type II. Consult with 86-68530 for selection. Types of portland cement covered 

in ASTM C150: I, IA II, IIA, II(MH), II(MH)A, III, IIIA, IV, and V. Note: I/II is not a type. 

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B.		 Blended hydraulic cement: 

1.		 ASTM C595, Type 38 [____]. 

2.		 Meet equivalent alkalies requirement of ASTM C595, Table 2, Option G. or 

Table 3. 

C.		 SCM: 

1.		 Pozzolan: 

a.		 ASTM C618, Class F 

1)		 Except: 

a) Sulfur trioxide, maximum: 4.0 percent. 

b) Loss on ignition, maximum: 2.5 percent. 

2) In addition: 

a) Meets Effectiveness in Controlling Alkali-Silica Reaction 

in Table 3 Supplementary Optional Physical Requirements 

of ASTM C618. 

b) Calcium oxide, maximum: 8.0 percent. 

c) Pozzolan “R” factor less than 2.5. Pozzolan with this “R” 

factor shall not decrease sulfate resistance of concrete. 

i.		 R = (C-5)/F 

ii.		 C: Calcium oxide content of pozzolan in percent 

determined in accordance with ASTM C114. 

iii.		 F: Ferric oxide content of pozzolan in percent 

determined in accordance with ASTM C114. 

2.		 39[Slag Cement: 

a.		 ASTM C 989, Grade {100} or {120}.] 

2.02		 WATER 

A.		 ASTM C1602, including optional requirements of Table 2. 

2.03		 AGGREGATE MATERIALS 

A.		 Fine aggregate: ASTM C33 

1.		 40[Percent material passing No. 200 sieve: Less than 3 percent.] 

38 IP or IS. (use HS) if type V is needed 

39 Include when slag cement is option. Select appropriate grade or include both. 

40 Include for most jobs. For purchasing of fine aggregate, ASTM C33, paragraph 4.2.4.3 - states “The 

appropriate limit for material finer than 75-μm (No. 200) sieve (see Table 1). If not stated, the 3.0% limit 

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B.		 Coarse aggregate: ASTM C33, Class 4S, Size No. specified in Table 03 30 00A – 

Concrete Mixes. 

C.		 Alkali Silica Reaction (ASR): 

1.		 Test fine and coarse aggregates in accordance with ASTM C1260 for potential 

deleterious ASR. 

a.		 41 [For ASTM C1260, and other tests when required, continue readings for 

28 days after the zero readings. 

b.		 Acceptance criteria specified below are based on 42[{14} {28} day 

readings after the zero readings.] 

c.		 Expansion is no greater than 0.10 percent: Aggregates are acceptable. 

d.		 Expansion is greater than 0.10 percent: 

1)		 Test aggregates according to ASTM C1567 using components (e.g. 

coarse aggregate, fine aggregate, cementitious materials, and ASR 

inhibiting admixtures) in proportions proposed for mixture design 

a)		 For mixes using lithium admixtures use test procedure COE 

CRD-C 662. 

b)		 Expansion of proposed mixture design test specimens, 

tested in accordance with ASTM C1567 does not exceed 

0.10 percent: 

i.		 Aggregates are acceptable. 

c)		 Expansion of proposed mixture design test specimens is 

greater than 0.10 percent: 

i.		 Aggregates are not acceptable unless adjustments to 

mixture design can reduce expansion to less than 

0.10 percent, or testing by ASTM C1293 indicates 

aggregates will not experience deleterious 

expansion. 

2)		 Use tested materials. Materials may be rejected if they do not 

match tested materials. 

shall apply.” Table 1 allows up to 3% passing the 75-μm (No. 200) sieve for concrete subject to abrasion, 

and up to 5% passing the 75-μm (No. 200) sieve for all other concrete. Including the statement in the specs 

precludes any ambiguity for that requirement. 

41		 Include when slow or late reacting aggregates are a possibility. Extended testing ages are necessary for 

regions with slow reacting aggregates; based on preliminary aggregate survey or local experience. Known 

areas include but are not limited to parts of ID, NM, and AZ. The normal period for taking readings is 14 

days after the zero reading. 

42		 Select appropriate days for readings. 14 days is appropriate unless slow or late reacting aggregates are 

possible. See previous footnote. 

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2. ASTM C1293 test results may be substituted for ASTM C1260 test results. 

a.		 Average ASTM C1293 concrete prism expansion less than 0.04 percent at 

one year: Aggregates acceptable. 

D.		 Appropriate for use in accordance with ASTM C 295. 

2.04		 ADMIXTURES 

A.		 Air-entraining admixture: ASTM C260. 

B.		 Chemical admixtures: 

1.		 Do not use chemical admixtures which contain more than 0.1 percent chloride, by 

weight. 

2.		 Admixtures shall be compatible with each other. 

3.		 Allowable chemical admixtures: 

a.		 43ASTM C494, Type A, D, F, G, or S. 

b.		 44ASTM C1017, Type I or II. 

c.		 45[ASTM C494, Type C and E, provided they do not contain chlorides.] 

C.		 46[Specialized chemical admixtures: 

1.		 When batch plant has not previously used a specialized chemical admixture, 

admixture manufacturer shall provide on-site representative to assist with mix 

design and to trial batch plant personnel in dispensing and mixing operations. 

2.		 Do not use specialized chemical admixtures which contain more than 0.1 percent 

chloride, by weight. 

3.		 47 [CDSRA: 

43		 Admixture types: 

A – Water-reducing Admixtures
	

D – Water-reducing and retarding admixtures.
	

F – Water-reducing, high range admixtures
	

G – Water-reducing, high range, and retarding admixtures
	

S - Specific performance admixtures
	 44		 Admixture types: 

I – Plasticizing
	

II – Plasticizing and retarding.
	 45 Include for cold weather use or when high-early strength is required only. Admixture types: 

C – Accelerating admixtures 

E – Water-reducing and accelerating admixtures 

46		 Include specialized admixtures only when required. Coordinate with Mix article. 

47	 Include only when low shrinkage concrete specified. Typically only needed for thin overlays or placement 

where recommended maximum joint spacing will be exceeded. Coordinate with Mix article. 

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a.		 PREVent-C manufactured by Premier Magnesia, Construction Products 

Group. www.premiercpg.com; or equal, with the following essential 

characteristics: 

1)		 Designed to facilitate expansion of concrete at essentially the same 

rate as shrinkage during curing period. 

2) Designed to reduce capillary surface tension of pore water. 

3) Provides at least 60 percent shrinkage reduction. 

4) Formulated for use in freezing weather. 

5) Mortar and concrete under restrained shrinkage test, ASTM 

C1581: No cracking for minimum 90 days. 

b.		 Coordinate with manufacturer regarding dosage.] 

4.		 48[SRA: 

a.		 ASTM C494, Type S 

b.		 Provides length change not exceeding 0.05 percent when tested in 

accordance with ASTM C157.] 

5.		 49[Alkali Silica Reaction (ASR) Inhibiting Admixture: 

a.		 Lithium Nitrate Admixture for ASR mitigation of reactive aggregates 

having the following characteristics: 

1) Meets NSF/ANSI 61. 

2) Nominal 30 percent aqueous solution of Lithium Nitrate 

a) Density: 10 pounds/gallon [1.2 kg/L}. 

b) Approximate chemical constituents (percent by mass): 

i.		 LiNo3 (Lithium Nitrate): 30 plus or minus 0.5 

ii.		 SO4-2 (Sulfate Ion), maximum: 0.1 

iii.		 Cl- (Chloride Ion), maximum: 0.2 

iv.		 NA+ (Sodium Ion), maximum: 0.1 

v.		 K+ (Potassium Ion), maximum: 0.1 

b.		 Coordinate with manufacturer regarding Lithium Nitrate dosage.] 

c.		 Do not use Lithium Nitrate Admixture for concrete in continuous or nearly 

continuous contact with water. 

6.		 50[Extended set control admixture: 

48	 Include when drying shrinkage reduction is required vs. chemical and drying shrinkage reduction. Contact 

86-6180 before specifying 

49		 Include for VERY SEVERE ASR ONLY. Contact 86-68180 before specifying. 

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a.		 51Delvo Stabilizer manufactured by BASF Construction Chemicals, Inc. 

www.basf-admixtures.com; or equal, with the following essential 

characteristics: 

1) Meets ASTM C494, Type B. 

2) Retards setting.
	

3) Does not reduce concrete strength.
	

b.		 Use within manufacturer’s time limits. 

c. Include admixture on batch ticket. 

d.		 Admixture quantity required to stabilize concrete shall be pre-determined 

using jobsite materials. Initial concrete setting time shall be monitored 

and adjusted during project by qualified concrete technician. 

7.		 52[Viscosity Modifying Admixture: 

a.		 V-Mar 3 manufactured by Grace Concrete Products, 

www.na.graceconstruction.com; or equal with the following essential 

characteristics: 

1) Meets ASTM C494 Type S. 

2) Designed to increase viscosity of concrete while still allowing
	

concrete to flow without segregation. 

3) Does not contain chlorides. 

4) Does not significantly affect slump, air content or time of set. 

b.		 For controlling rheology of concrete mixtures: Incorporated into concrete 

mix at batch plant in manufacturer’s recommended dosage.] 

8.		 53[Anti-washout admixture: 

a.		 Rheomac UW 450 manufactured by BASF Construction Chemicals, Inc., 

www.basf-admixtures.com; or equal with the following essential 

characteristics: 

1) Water-soluble polymer. 

2) Designed to minimize washout of fines and cement. 

3) Does not significantly affect slump or time of set.
	

50		 Include extended set control admixture only when concrete haul times are expected to be greater than 90 

min. ASTM C 494 Types D and G are also retarding (are water reducing and retarding). They are allowed 

in paragraph B - Chemical admixtures. 

51		 Use Delvo stabilizer to control cement hydration for concrete subjected to hauls in excess of 1-1/2 hours or 

concrete placements requiring specific delays in setting time. 

52		 This admixture is used to prevent segregation and is often used when pumping concrete. 

53		 Use when placing concrete underwater. 

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b.		 For {fresh concrete placed in contact with water} {drilled shaft} concrete 

only. 

c.		 Incorporate into concrete mix at batch plant in manufacturer’s 

recommended dosage.] 

2.05 54[CONCRETE COLOR ADMIXTURES 

A.		 Integral color additive made for use in concrete. 

B.		 {Color chart number/ name}, manufactured by { }; or equal with the following 

essential characteristics: 

1.		 Concentrate mineral pigment milled for mixing into concrete. 

2.		 Resistant to alkalis, weathering, and ultraviolet. 

3.		 Meets ASTM C979. 

C.		 Obtain COR approval of color selection of color additive prior to casting {items of 

colored concrete} {colored concrete test panels}.] 

2.06		 CURING MATERIALS 

A.		 Water: ASTM C1602, including optional requirements of Table 2. 

B.		 55[Curing compound: {ASTM C309} {ASTM C1315}. 

54		 Include only when color concrete specified. When test panels are required, coordinate with mock-ups 

article in Part 1. 

55		 For general construction, specifying C309 for curing compound is adequate. ASTM C1315 would only be 

specified when special properties are required. ASTM C1315, Class A is specified when non-yellowing 

curing compound is required. ASTM C309-11, Section 6 limits moisture loss to 0.55 kg/m2 in 72 hours. 

ASTM C1315-11, Section 6 limits moisture loss to 0.40 kg/m2 in 72 hours 

Curing compound types: 

ASTM C309:		 (dissolved solids shall be one of the classes) 

Type Description 

Type 1 Clear or translucent without dye 

Type 1-D Clear or translucent with fugitive 

dye 

Type 2 White pigmented 

Class Description 

Class A No Restrictions 

Class B Must be a resin defined in 

Terminology D883 

ASTM C309 compounds are generally easy to remove. Class A is wax base, general purpose. Class B is 

resin base, will meet Class A, and clings better to vertical surfaces. 

ASTM C1315: 

Type Description 

Type I Clear or translucent 

Class Description 

Class A Essentially non-yellowing 

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1.		 Capable of meeting moisture retention at manufacturer’s application rate. 

2.		 Meet Federal, state, and local regulations for VOCs. 

C.		 Sheet materials: 

1.		 Polyethylene film: ASTM C171, 56[{white opaque} {clear}]. 

2.		 57[White burlap-polyethylene sheeting: ASTM C171.] 

2.07		 ACCESSORIES 

A.		 58[{Sponge rubber joint filler: 

1.		 ASTM D1752, Type I, except: 

a. Test specimen compression load: 50 to 150 lb/in2 

. 

2.		 Joint filler adhesive: Nonbituminous adhesive recommended by filler 

manufacturer.} 

B.		 {Bituminous joint filler: ASTM D1751.}] 

C.		 59[Elastomeric sealant: ASTM C920, polyurethane, Use M, Grade NS, Class 25.] 

D.		 60[Temperature monitoring devices for monitoring RSMC placements : 

Type II White pigmented Class B Moderate yellowing not 

prohibited 

Class C Not restricted with regard to 

yellowing or darkening 

ASTM C1315 is more permanent and is also considered as a sealer. Often used on bridge structures and 

roadways. It adds salt protection, resists drying and sunlight, and is super high performance. ASTM 

C1315 compounds are generally significantly more costly than ASTM C309 compounds. 

56		 Specify white opaque for exterior use. Specify clear for interior use. 

NOTE: Do not specify “Black” - ASTM C171 includes only clear and white opaque as types for 

polyethylene film. Black is not a color option. Also, black polyethylene film would not increase the 

protection of concrete from freezing during cold weather (coldest temperatures occur when the sun is not 

shining). Specifying black polyethylene film could result in temperature rise during the day that could 

cause undesirable thermal stresses in the concrete. Protection of concrete during cold weather is addressed 

in Protection article. 

57		 Include when specified in “Formed Surfaces” and “Unformed Surfaces” tables. Use for colored concrete 

flatwork or other flatwork 

58		 Include when expansion joints specified. Include appropriate paragraphs for type of material used for 

expansion joints. Delete when expansion joints not required. 

59		 Include only when elastomeric sealant required and is not specified in another Section. Sealants often 

covered in Division 7. Class M - multicomponent. Grade NS - nonsag when applied between 40 and 122 

degrees F. Class 25 - withstands 25 percent decreases or increase in joint width. 

60		 Include when RSMC specified 

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1.		 Measuring device: Thermocouple, thermistor, or Resistant Temperature Device 

(RTD) 

a.		 Operating range: 14 degrees F to 185 degrees F. 

b.		 Accuracy: 1.8 degrees F (1 degree C) or better.] 

2.		 Recording device: 

a.		 Record temperature as a function of time. 

b.		 Records temperature at least once per hour and maximum and minimum 

over a 24-hour period can be obtained. 

c.		 Records data in digital format. 

E.		 61[Temperature monitoring devices for estimating concrete strength by the maturity 

method: 

1.		 Embedded digital devices that measure temperature with recording device that 

stores data as a function of time. 

2.		 Measuring devices: 

a.		 Thermocouple, thermistor, or Resistant Temperature Device (RTD) 

b.		 Accuracy: 1.8 degrees F (1 degree C) or better. 

3.		 Recording device: 

a.		 Commercial maturity instruments that automatically compute and display 

either temperature-time factor or equivalent age. 

b.		 Recording time interval shall be 1/2-hr or less for the first 48 hours and 1-

hour or less thereafter. ] 

F.		 62[Evaporation control: 

1.		 MasterKure ER 50 manufactured by BASF Construction Chemicals, Inc., 

www.basf-admixtures.com; or equal having the following essential 

characteristics: 

a.		 Monomolecular film forming compound applied to exposed concrete slab 

surfaces for temporary protection from rapid moisture loss. 

b.		 For application after finishing and prior to applying curing compound. 

c.		 For use when the evaporation rate is high. 

2.		 Do not use as finishing aid.] 

61		 Include when estimating concrete strength by maturity method specified. 

62		 Include only when extra low humidity and high wind situations are anticipated or silica fume concrete is 

specified. Consult 86-68530 for proper use 

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G.		 63[Plastic vapor retarder: 

1.		 Preformed flexible membrane meeting ASTM E1745, Class { }. 

a.		 Thickness: 10 mils, minimum. 

2. Sealing materials for laps and protrusions: Recommended by manufacturer.] 

2.08		 MIX 

A.		 The Contractor shall design and adjust concrete mix. 

1.		 64The Government reserves the right to adjust mix proportions when need for 

adjustment is indicated by results of materials testing. 

a.		 When required, adjustment of mix proportions by the Government will be 

in accordance with USBR Concrete Manual. 

B.		 65[Cementitious materials options: 

1.		 66[Specified portland cement only.] 

2.		 Specified portland cement plus specified pozzolan by percent weight specified in 

Table 03 030 00A - Concrete Mixes. 

3.		 67[Specified portland cement plus specified slag cement by percent weight 

specified in Table 03 03 00A - Concrete Mixes.] 

4.		 68[Blended Hydraulic: ASTM C595 provided, specified portland cement with 

percent of specified pozzolan or specified slag cement specified in Table 

03 03 00A - Concrete Mixes.] 

63		 Include only when specified. Typical use of plastic vapor retarders are on top of soil or granular fill 

beneath concrete building slabs. Vapor retarders reduce moisture condensation within a structure therefore 

impeding growth of molds, mildews, and fungi; protect flooring materials installed on the concrete slab 

from detrimental moisture; and can be used a component of sulfate resistance or radon mitigation systems. 

ASTM E1745 specifies three classes - A, B, and C. All three classes require maximum water vapor 

permeance of 0.3 perms. The difference between the classes is the tensile strength and puncture resistance, 

with Class A being the strongest (see ASTM E1745 for values). Minimum mil thickness requirement 

would be in addition to ASTM E1745 requirements. It may be desirable to specify minimum thickness to 

get a stronger material. The 10 mil thickness is only an example. 

Add ASTM E1745 to Reference Standards article. 

Vapor retarder for walls would be covered in Div. 7 

64		 Use statement at client’s request 

65		 Modify allowed cementitious materials options as appropriate for job. 

66		 Include only when circumstances require. Examples when portland cement only will be required or 

allowed are high early strength concrete or integrally pigmented concrete. Consult with 86-68530 for 

structural concrete requiring high early strength. Coal fly ash (Class F pozzolan) may not be suitable for 

inclusion with pigments. Consult with project architect for integrally pigments concrete. If fly ash will not 

be allowed, complete form “Exception to the Use of Recovered Materials.” 

67		 Include when slag cement option is specified in Table 03 30 00A - Concrete Mixes. 

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5.		 69[Ternary blends.] 

C.		 Design concrete mixes in accordance with Table 03 30 00A – Concrete Mixes. General 

concrete mix shall be used for concrete unless otherwise specified. 

1.		 Net water-cementitious materials ratio (w/c) is maximum, by weight. 

Cementitious material weight is cement plus SCM. 

2. [Slump at point of placement: In accordance with ASTM C143{, except SCC 

3.		 SCC slump flow at point of placement: In accordance with ASTM C1611.] 

4.		 Air Entrainment: Percent air by volume of concrete as discharged at point of 

placement, in accordance with ASTM C231.] 

70Table 03 30 00A – Concrete Mixes 

Mix 

No Feature f’c (lb/in2

) 

71Max 

w/c* 

72NMSA 

** 

Percent 

SCM*** 

A: Class F 

Pozzolan 

B: Slag Cement 

C: Silica Fume 

Slump

73[or 

Slump 

flow] 

(in) 

74Air 

Content 

(%) 

Notes 

1 General 

Concrete 

4500 at 

28 days 

0.45 [No. 

457, 57, 

467, or 

67] 

A or B: 20 ± 5 2 to 4 4.5 to 

7.5 

2 Structural 

Concrete 

4500 at 

28 days 

0.45 [No. 

457, 57, 

467, or 

67] 

A or B: 20 ± 5 2 to 4 4.5 to 

7.5 

[1, 5] 

68		 Edit as appropriate for inclusion of pozzolan and/or slag. 

69		 Include only when needed to achieve specified mix properties. Ternary blends are a combination of three 

or more cementitious materials, sometimes necessary to obtain special properties, including ASR 

mitigation of highly reactive aggregates. 

70	 Revise table for project requirements. Feature names provided are some of the more typical examples. 

Delete unnecessary rows. Fill in all cells for mixes specified. 

71		 Select w/c ratio based on durability requirements (freeze/thaw, sulfate resistance) and desired strength. 

Consult 86-68530 and designers. See table 5, USBR 4211, USBR Concrete Manual, Part 2, Ninth Edition. 

A w/c of 0.45 should be the maximum selected for most jobs. A lower w/c may be required for some 

applications – durability issues, saturated concrete, exposer to freeze/thaw. 

72		 Select appropriate size. Consult 86-68530 and designers. Recommended sizes for most applications: 

ASTM C 33 No. 467 (1-1/2 in. to No. 4) or No. 57 (1 in. to No. 4). 

73		 Slump flow required for SCC. Delete when SCC not included. 

74		 Select air content based on maximum aggregate size and freeze-thaw environment; see Concrete Manual or 

ACI 318. 

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70Table 03 30 00A – Concrete Mixes 

Mix 

No Feature f’c (lb/in2

) 

71Max 

w/c* 

72NMSA 

** 

Percent 

SCM*** 

A: Class F 

Pozzolan 

B: Slag Cement 

C: Silica Fume 

Slump

73[or 

Slump 

flow] 

(in) 

74Air 

Content 

(%) 

Notes 

3 High 

Slump 

Structural 

Concrete 

4500 at 

28 days 

0.45 [No. 

457, 57, 

467, or 

67] 

A or B: 20 ± 5 4 to 7 4.5 to 

7.5 

[1, 2, 5] 

4 Interior 

Slabs 

4500 at 

28 days 

[No. 

457, 57, 

467, or 

67] 

A or B: 20 ± 5 2 to 4 [1,5] 

5 RSMC 4500 at 

56 days 

[No. 

467] 

A: 35 ± 10 

or B: 50 to 80 

1 to 3 [1,3,5] 

6 Drilled 

Shafts 

4500 at 

28 days 

[No. 57 

or 67] 

A or B: 20 ± 5 5 to 7 

7 Lean 

Concrete 

2500 at 

28 days 

[No. 57 

or 67] 

A or B: 20±5 

8 Colored 

Concrete 

4500 at 

28 days 

0.45 [No. 

457, 57, 

467, or 

67] 

A or B: 20±5 2 to 4 4.5 to 

7.5 

[5] 

9 SCC 4500 at 

28 days 

0.45 1/2 inch A: 20±10 

or 

B: 20 to 70 

Or 

A+B<70 

22 to 

24 

5.5 to 

8.5 

[1,2,6,7, 

8] 

10 High 

Strength 

8000 at 

28 days 

C: 5 to 10 [1,2,5] 

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70Table 03 30 00A – Concrete Mixes 

Mix 

No Feature f’c (lb/in2

) 

71Max 

w/c* 

72NMSA 

** 

Percent 

SCM*** 

A: Class F 

Pozzolan 

B: Slag Cement 

C: Silica Fume 

Slump

73[or 

Slump 

flow] 

(in) 

74Air 

Content 

(%) 

Notes 

75 *Maximum water/cementitious materials ratio.
	

**Nominal Maximum Size Aggregate. 

*** SCM as percent of total cementitious material, by weight.

76 [NOTES:
	

1. Ternary blended cementitious materials which meet the specifications may be 

submitted for approval. 

2. Concrete with ASTM C1017, Type I or II plasticizing admixtures, ASTM C494 

Type F high-range water-reducing admixtures, or Type G high-range water-reducing and 

retarding admixtures: 

i.		 Admixture shall be incorporated into trial batch or historical data. 

ii.		 Use slump appropriate for placing conditions. 

3. RSMC requires temperature control measures. 

4. Color admixture dosage rate as recommended by the manufacture 

5. CDSRA required. Shrinkage Test results shall be submitted with mix design. See 

Shrinkage Testing Procedure paragraph. 

6. SRA required. Shrinkage test results shall be submitted with mix design. Test 

mix in accordance with ASTM C157. 

7. Aggregate gradation for SCC concrete may deviate from ASTM C33. 

8. For SCC, deviating from the table may be acceptable provided resulting mixture 

meets performance targets for fresh and hardened SCC and deviations are approved by 

COR.] 

D.		 Submit design mixes for each type and strength of concrete substantiated by either 

laboratory trial batch or field performance methods as specified in ACI 301. For trial 

batch method, mix shall be proportioned and stamped by a professional engineer. 

E.		 Concrete trial mixes: 

1.		 77Average compressive strength of trial batch cylinders at design age: Design 

strength {plus 1,200 lbs/in2

 for concrete between 3,000 and 5,000 psi}, {1.10f’c + 

700 psi for concrete with specified design strength greater than 5,000 psi}. 

75	 Editing note: These asterisk notes and “NOTES” are contained within a single cell at the bottom of the 

table. 

76		 Revise, add, or delete notes to agree with table. Verify Shrinkage Testing Procedure article number when 

CDSRA specified. 

77		 Determine criteria for overdesign based on mixes listed in Table 03 30 00A – Concrete Mixes. 

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2.		 78[Average 28 day compressive strength of trial batch cylinders for lean concrete 

only: Design strength plus 500 lbs/in2, or field data meeting the over design 

requirements of ASTM 301.] 

3.		 Admixtures to be used in mix shall be incorporated into mix design submitted for 

approval. 

4.		 Air content: Within 1 percent of top of specified range. 

5.		 Slump: Within 1 inch of top of specified range. 

6.		 79[When CDSRA required: 

a.		 Mortar and concrete under restrained shrinkage test in accordance with 

ASTM C1581. 

b.		 Except, no cracking for minimum of 90 days.] 

7.		 80[When SRA required: 

a.		 Mortar and concrete tested in accordance with ASTM C157. 

b.		 Except: Length change shall not exceed 0.05 percent after 7 days of moist 

curing followed by 28 days of air drying.] 

F.		 81[Estimating concrete strength by maturity method: 

1.		 Prepare concrete maturity calibration mixture test specimens with same mixture 

proportions, materials sources, admixture dosages, and fresh properties for which 

maturity method will be applied. 

2.		 Cast test specimens cast for maturity calibration from same batch of concrete and 

cure in same conditions and temperature. 

a.		 Specimens for maturity calibration mixtures may be prepared from either 

laboratory trial batches or from field specimens cast and cured in 

conditions similar to project conditions. If the later method is used, 

maturity relationships cannot be used to predict strength until maturity 

report has been submitted and approved by the COR. 

3.		 Test compressive strength cylinders in pairs. Schedule tests such that at least 

three sets of tests yield results which are at or below 82 [2000 psi] and at least one 

set is above [2000 psi]. Perform testing is accordance with ASTM C39.] 

78 Include only when lean concrete specified.
	

79 Include only when CDSRA required.
	

80 Include only when SRA required.
	

81 Include only when use of estimating concrete strength by maturity method is appropriate for the job.
	

82 Strength appropriate for early form stripping, loading, backfill, traffic, etc.
	

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2.09		 BATCHING, MIXING, AND TRANSPORTING 

A.		 Batch plant: NRMCA certified with automatic digital recording of cementitious 

materials, aggregate, water, and chemical admixtures 

B.		 Manufacture and deliver in accordance with ASTM C94 and ACI C304R. 

1. Prepare batch ticket in accordance with ASTM C94 for every batch of concrete. 

C.		 83[Cold weather: When air temperature has fallen to or is expected to fall below 40 

degrees F, prepare ingredients and mix in accordance with ACI 306.1. 

1.		 Do not use frozen materials or materials containing ice or snow. 

2.		 Uniformly heat water and aggregates before mixing to obtain concrete mixture 

temperature of not less than 50 degrees.] 

D.		 84[Hot Weather: When precautions are necessary, prepare ingredients and mix in 

accordance with ACI 305.1. 

1.		 Cool ingredients before mixing to maintain specified maximum concrete 

temperature at time of placement 

2.		 Mixing water may be chilled or chopped ice may be used to control temperature, 

provided water equivalent of ice is calculated to total amount of mixing water. 

Ice replacing batch water shall be melted prior to discharge 

3.		 Using liquid nitrogen to cool concrete is Contractor’s option. 

E.		 Prevent appreciable segregation of ingredients. 

F.		 Place concrete within 90 minutes from introduction of cement to water or aggregates. 

1.		 85[For placing times exceeding 90 minutes, extended set control admixtures may 

be used when approved by COR.] 

2.10		 CONCRETE TEMPERATURE 

A.		 86[Concrete temperature at placing: 

1.		 Concrete other than RSMC: 50 to 90 degrees F (10 to 32 degrees C). 

83 Include when cold weather concreting is possibility.
	

84 Include when hot weather concreting is possibility.
	

85 Include only when expected haul distance or other factors will result in the Contractor not being able to
	

reasonable place concrete within the 90 minute window. When this statement is included, include extended 

set control admixture in Admixture article. 

86 When job does not include RSMC, include temperature range on first line. 

When job includes RSMC, include two subparagraphs. 

Revise temperature ranges when necessary. 

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2. RSMC: 50 to 70 degrees F (10 to 21 degrees C).] 

a. Maximum temperature may be lower according to the Temperature 

Control Plan. 

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2.11 87[CONTRACTOR QUALITY TESTING 

A. 88[{Contractor} {Independent testing agency}] shall perform sampling, testing, and 

reporting as required in Table 03 30 00B - Batch Plant Testing. 

Before editing the Contractor Quality Testing and Quality Assurance Articles, the specifications author 

should be aware how the office responsible for field inspection plans to have quality testing of concrete 

performed. This would best be accomplished by contacting that office. 

The major issue concerning quality testing of concrete is what party will perform testing that will be used 

to determine acceptability of work. Primary responsibility for quality testing for acceptance is anticipated 

to be one of the following scenarios. They are listed in preferred order of acceptance testing: 

Government personnel perform full Quality Assurance testing 

Government retains independent testing agency to perform full Quality Assurance testing 

Contractor required to retain independent testing agency to perform testing 

Include the Contractor Quality Testing Article when the Contractor is required to retain independent testing 

agency to perform quality testing that the Government plans to use for acceptance. The Contractor Quality 

Testing Article is optional when the Government or Government retained testing agency will be performing 

Quality Assurance testing. Quality testing by the Contractor would then be presumed to be part of the 

Contractor’s Quality Control program. 

Recommended practice for Reclamation is to have Government personnel perform full Quality Assurance 

testing of concrete. When Government personnel will not be performing full Quality Assurance testing of 

concrete, an option is for the Government to contract with a testing agency to perform Quality Assurance 

testing. The specifications would be the same for these two situations. Testing agency personnel would be 

acting on behalf of the Government when performing tests, so the relationship to the construction Contactor 

would be the same if Government personnel were performing the tests. 

When Government personnel or Government retained testing agency personnel will be performing Quality 

Assurance testing, the Contractor Quality Testing Article may be deleted. The clause at FAR 52.246-12, 

Inspection of Construction states “the Contractor shall maintain an adequate inspection system and perform 

such inspections as will ensure that the work performed under the contract conforms to contract 

requirements.” Tests specified in the Article should be part of the Contractors inspection system. 

Generally, Reclamation does not specify details of Contractor’s Quality Control. However, this article can 

be included when requested by the inspection office. In this situation, the Contractor would generally not 

be required to retain an independent testing agency to perform concrete quality tests. Contractor quality 

tests could be performed by qualified Contractor or batch plant personnel. 

When the inspection office plans to use Contractor performed testing in lieu of Government Quality 

Assurance testing for acceptance of work (i.e. Government personnel or Government retained testing 

agency personnel will not perform full Quality Assurance testing of concrete), the Contractor shall be 

required to retain an independent testing agency to perform quality testing of concrete. When independent 

testing agency is specified, include Section 01 46 20 - Testing Agency Services in specifications. Include 

Cast-In-Place Concrete in list of Sections requiring testing in Section 01 46 20. (Note: Having a testing 

agency hired by the Contractor to perform tests that are anticipated to be used for acceptance is less 

desirable than having the tests performed by Government personnel or a Government retained testing 

agency. Government contract personnel need to be aware that there is added risk of false reporting when 

the Contractor pays the testing agency that is performing tests that are anticipated to be used for 

acceptance.) 

When Contractor Quality Testing Article is included, see next two footnotes for recommended editing. 

See Section 01 46 00 - Quality Procedures for definitions of Quality Assurance, Quality Control, and 

Contractor Quality Testing. 

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1.		 89[Independent testing agency shall meet requirements specified in Section 

01 46 20 - Testing Agency Services.] 

2.		 Personnel conducting tests: Qualified as ACI Aggregate Testing Technician, 

Level 1; or equal. 

B.		 Perform tests at least as often as frequencies specified in Table 03 30 00B - Batch Plant 

Testing. 

C.		 Notify COR immediately of test results showing failure of materials to meet 

specifications. Provide passing test to COR within 24 hours. Submit reports of test 

results as specified. 

2.12		 GOVERNMENT CONTRACT QUALITY ASSURANCE - SOURCE 

A.		 90[The Government will perform, as a minimum, tests listed in Table 03 30 00B - Batch 

Plant Testing. This testing is in addition to the Contractor’s Quality Control program and 

does not relieve the Contractor of performing adequate Quality Control testing. The list 

of tests is provided to alert the Contractor to potential impacts to work scheduling. 

B.		 Government testing frequency is at the discretion of the COR. Greater frequency testing 

is normally performed at start of placing a mix design, when changing a mix design, 

when inconsistencies of materials is noticed, or when significant changes are made at 

batch plant. Testing frequency listed in Table 03 30 00B - Batch Plant Testing is 

provided only as approximation of Government testing.] 

C.		 91[In addition to specified Contractor Quality Testing, the Government may also perform 

the tests listed in Table 03 30 00B - Batch Plant Testing.] 

2.13		 BATCH PLANT TESTING 

88		 Select “Contractor” when Government will be performing Quality Assurance testing. Requiring the 

Contractor to hire an independent testing agency is usually not needed when the Government will perform 

full Quality Assurance testing. 

Select “Independent testing agency” when Government plans to perform little or no Quality Assurance 

testing and plans to use independent testing agency test results for evaluating acceptability of work. 

See previous footnote. 

89		 Include only when independent testing agency required to perform testing. 

90		 Include paragraphs A and B when the Government will be conducting full Quality Assurance testing of 

concrete. See footnote for Contractor Quality Testing article (2.11) for discussion of Reclamation practice. 

As noted in paragraph A, this information is provided to the Contractor for information as to potential 

impacts for scheduling his activities. 

91		 Include paragraph C only when the Government will be performing little or no Quality Assurance testing. 

The Contractor is required to retain independent testing agency to perform tests that the Government 

anticipates using for determining acceptability of work. See footnote for Contractor Quality Testing article 

(2.11) for discussion of Reclamation practice 

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Table 03 30 00B- Batch Plant Testing 

TESTS OF TEST 

STANDARD 

STANDARD TITLE REQUIREMENT 92TESTING FREQUENCY 

Aggregate 

Gradation 

ASTM C136 Sieve Analysis of Fine 

and Coarse Aggregates 

Fine and Coarse 

Aggregate meets 

sizing 

requirements per 

ASTM C33. 

At beginning of placing 

each mix. 

At change in mix design. 

At least every 500 yd3 of 

placing a mix. 

Aggregate 

Fines content 

ASTM C117 Materials Finer than 

75-μm (No. 200) Sieve 

in Mineral Aggregates 

by Washing 

Fine aggregate 

meet specified 

allowable fines 

content (material 

passing No. 200 

sieve) 

At beginning of placing 

each mix. 

At change in mix design. 

At least every 500 yd3 of 

placing a mix. 

Aggregate 

moisture 

content 

ASTM C566 Total Evaporable 

Moisture Content of 

Aggregate by Drying 

Verify that 

moisture meter at 

batch plant is 

accurate with the 

material batched. 

At beginning of placing 

each mix. 

At change in mix design. 

At least every 500 yd3 of 

placing a mix. 

PART 3 EXECUTION 

3.01		 PREPARATION 

A.		 Remove standing water, mud, and debris from foundation surfaces to be covered by 

concrete. 

B.		 Prepare rock surfaces free from oil, objectionable coatings, and loose, semidetached, and 

unsound fragments. Immediately before placement of concrete, wash rock surfaces with 

air-water jet and dry to uniform surface-dry condition. 

C.		 Prepare earth foundations free from frost or ice. 

D.		 Thoroughly moisten surfaces of absorptive foundations to be covered with concrete so 

that moisture will not be drawn from fresh concrete. Keep subgrade moisture uniform 

without puddles or dry areas. 

E.		 93[Vapor retarder: 

1.		 Place vapor retarder membrane over foundations to be covered with concrete {at 

locations shown on drawings}. 

92	 Revise testing frequencies as appropriate for job. 

93		 Typical use of vapor retarder is under building slabs. For discussion of use, see footnote for vapor retarder 

material in Accessories Article (2.07). Delete when vapor retarder not used. 

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a.		 Where vapor retarder is installed, moistening absorptive foundations 

specified above will not be required. 

2.		 Overlap sheets minimum of 6 inches and seal as recommended by manufacturer. 

3.		 Seal penetrations as recommended by membrane manufacturer.] 

F.		 Clean, roughen, and surface dry surfaces of construction joints 94[and existing concrete] 

to be covered with fresh concrete. 

1.		 Remove laitance, loose or defective concrete, coatings, sand, curing compound, 

and other foreign material. 

2.		 95Sandblast, steel shotblast, or high-pressure water jet surfaces, or use other 

method approved by COR to create a surface {equivalent to or larger than CSP 5 

in accordance with ICRI 310.2}{equivalent to or larger than CSP 8 in accordance 

with ACI 318}. 

3.		 Wash surface thoroughly, and surface dry immediately before placement of 

adjoining concrete. 

3.02		 96[TEMPERATURE CONTROL OF RSMC 

A.		 Design RSMC Temperature Control Plan for: 

1.		 Maximum temperature of 155 degrees F in concrete during curing and protection. 

2.		 Maximum temperature differential of 35 degrees F between center of thickest 

section and outside face. 

3.		 Installation and monitoring of at least 2 monitoring devices for every 150 cubic 

yards of concrete or each individual placement at each of the following locations: 

a.		 At center of thickest sections. 

b.		 Along coolest anticipated concrete face(s) at depth of 1-1/2 inches from 

surface. 

4.		 Monitoring ambient temperature for temperature control duration. 

B.		 Install temperature monitoring devices prior to placement according to approved RSMC 

Temperature Control Plan. 

C.		 Continually record temperature readings until temperature differentials are within 

requirements. Temperature information in digital format shall be available to COR daily. 

94		 Include when required. 

95		 Choose CSP 5 for most cases and CSP 8 if shear transfer is needed. For shear, Refer to ACI 318, Section 

11.6.9, (1⁄4” amplitude required). 

96		 Include this Article only when job includes RSMC. 

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D.		 Maintain specified temperature differential between temperature monitoring devices at 

center of thickest section and outside face. 

1.		 Insulate concrete with blankets or other approved insulation as necessary. 

2.		 Do not discontinue temperature monitoring or remove insulation until temperature 

at outside face is within 35 degrees F of lowest ambient temperature in 24 hour 

period. 

3.		 Internally cool concrete as necessary. 

4.		 Evaluate temperature records daily and adjustment temperature control methods 

as necessary. 

E.		 If internal concrete temperatures or concrete temperature differentials exceed specified 

limits, revise RSMC Temperature Control Plan and resubmit for approval prior to further 

placements.] 

3.03		 97[MONITORING FOR ESTIMATING CONCRETE STRENGTH BY 

MATURITY METHOD 

A.		 Monitor internal concrete temperature with a minimum of two (2) monitoring devices 

every 150 cubic yards of concrete or in each individual placement. 

B.		 Position maturity testing sensors throughout the placement. Locate at least one recording 

device within the final load of concrete from each placement and in areas of excess 

shade. 

C.		 Install temperature monitoring sensors prior to placement according to approved maturity 

meter plan. 

D.		 Do not pass wires through {unformed finished surfaces} {ogee crest} except as approved 

by the COR. 

E.		 Compliance with project specifications for design strength of concrete will continue to be 

based on standard laboratory cured 6- by 12-inch cylinders tested at design age.] 

3.04		 PLACING 

A.		 Notify COR at least 24 hours before placing concrete. 

B.		 Do not place concrete without approval of the COR. 

C.		 Place concrete in presence of COR. 

97		 Include this Article only when time available for construction is so limited that the Contractor will be 

required to impose loads on concrete placements before the time of design strength age has elapsed. 

Typical uses include determining strength for form stripping, backfilling, post tension stressing, and 

pavement early opening. 

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D.		 98[Placing concrete {for placement specified below} shall be performed under direct 

supervision of a Craftsman certified as ACI Concrete Flatwork Finisher. 

1.		 A minimum of one certified ACI Concrete Flatwork Finisher is required at each 

{specified} placing operation. 

2.		 {Placements requiring ACI Concrete Flatwork Finisher:} 

a.		 {list placements}] 

E.		 99[Allow at least 7 days between adjacent placements, or as approved by COR. 

1.		 100[For RSMC, COR may require more than 7 days between adjacent placements 

based on temperature control plan or actual temperature data of RSMC.] 

F.		 Do not use aluminum pipes and chutes for placing or pumping concrete. 

G.		 Adding water to concrete batch at site will be allowed only once and only when approved 

by the COR. 

1.		 Additional water shall be added before concrete is discharged. 

2.		 Do not exceed specified water to cement ratio. 

3.		 After water is added, concrete shall be mixed for at least 30 revolutions of mixer 

drum at mixing speed. 

4.		 Record added water on the batch ticket to nearest gallon. 

H.		 Adding air entraining admixtures to concrete batch at site will be allowed only once when 

approved by the COR. 

1.		 After air entraining admixture is added, concrete shall be mixed for minimum of 

30 revolutions of mixer drum at mixing speed. 

2.		 Take slump and air content after air-entraining admixture addition and additional 

revolutions. 

3.		 Record added air entraining admixture on batch ticket to nearest ounce. 

98		 Include only when determination is made that placing concrete shall be done under the supervision of 

certified ACI Concrete Flatwork Finishers. List structures when some, but not all, of the concrete 

placements require supervision by certified finisher. When all concrete placements require supervision by 

certified finisher, delete the list and “for the structures specified below”, and “specified” in subparagraphs 1 

and 2. 

Note: ACI Concrete Flatwork Finisher certification requires passing a written test plus successfully 

completing a performance examination and possessing actual on-the-job finishing experience (performance 

test plus 1,500 hours experience), or possessing a higher level of actual on-the-job experience (4500 hours 

experience). ACI also has certification for a Concrete Flatwork Technician. This certification has less 

rigorous qualification requirements and is not recommended. 

99		 Include when delay between placements is required. Consult with designer about including this 

requirement. When used, revise delay time as appropriate. 

100		 Include only when RSMC specified. 

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I.		 Do not use concrete which has become so stiff that concrete cannot be properly placed. 

J.		 Place formed concrete in continuous, approximately horizontal layers. Do not exceed 20 

inches in depth of layers. 

K.		 Vibrate concrete until concrete has been consolidated to maximum practical density, is 

free from pockets of coarse aggregate, and closes snugly against surfaces of forms and 

embedded materials. 

L.		 Hot Weather: 

1.		 Place concrete in accordance with ACI 305.1. 

2.		 Protect reinforcing steel so that steel temperature does not exceed ambient air 

temperature immediately before placing concrete. 

3.		 Fog spray forms, reinforcing steel, and subgrade just before placing concrete. 

Keep subgrade moisture uniform without puddles or dry areas. 

M.		 Cold weather: 

1.		 Place concrete in accordance with ACI 306.1. 

2.		 Do not place concrete on frozen subgrade or subgrade containing frozen 

materials. 

N.		 101[Colored Concrete: 

1.		 Schedule placement of cast-in-place colored architectural concrete so that 

adjacent placements of colored concrete are placed within 2 weeks time. 

2.		 Cast field cured test cylinders to determine compressive strength of concrete prior 

to application of light sand-blast finish. Schedule sand-blasting so surfaces of 

cast-in-place colored concrete are same strength. 

3.		 Perform light sand-blast finish to cast-in-place colored concrete in accordance 

with ACI 303. Surface of light sand-blast finish should expose fine aggregate and 

occasional coarse aggregate with a maximum reveal of approximately 1/16- inch.] 

3.05		 102[PLACING CONCRETE UNDERWATER 

A.		 As concrete is placed underwater, do not allow turbid water to discharge into Waterways. 

1.		 For discharge of turbid water, refer to Section 01 57 30 – Water Pollution Control. 

2.		 Placement operations shall not increase pH, turbidity, or temperature of water. 

B.		 Equipment: 

101		 Include only when colored concrete required. 

102		 Include only when concrete placing underwater is required. This article written for drilled shafts. It can be 

revised for other applications. 

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1.		 Not fabricated of aluminum. 

2.		 Provide suitable tremie delivery system or pump: 

a.		 Tremie system: 

1)		 Delivery system shall be watertight, fabricated of heavy-gauge 

steel pipe. 

2)		 Tremie pipe diameter: At least 6 times maximum size of 

aggregate but not less than 10-inches in diameter. 

3)		 A funnel or hopper shall facilitate transfer of concrete from 

delivery device to the tremie. 

4)		 Provide stable, stationary platform to support tremie during 

placement. 

b.		 Pump: 

1) Slickline shall be watertight. 

2) Slickline minimum diameter: 5 inches. 

3.		 Mark tremie pipe or pump slickline to allow quick and accurate determination of 

distance from surface of water to mouth of discharge pipe. 

4.		 Equip tremie pump or slickline with suitable power hoist to facilitate vertical 

movement during concrete placement. 

5.		 Air-lifts or pumps shall be available to remove unsuitable material which 

accumulates in low areas during placement. 

6.		 Depending upon method selected for sealing tremie or slickline at beginning of 

the placement, adequate supply of end closure devices or plugs shall be available. 

C.		 Placing: 

1.		 Ensure that concrete is delivered to point of placement without free-fall. 

2.		 Place concrete in continuous manner from bottom to top. Place by method which 

minimizes washout. 

3.		 Construction joint surfaces shall be jetted to remove mud, algae, laitance, and 

other unsuitable material prior to placing adjacent concrete. 

4.		 Start placements using a dry pipe technique and end closure device shall be filled 

with concrete before being raised off bottom. Discharge pipe shall then be raised 

maximum of 6 inches to initiate flow. 

5.		 Do not lift discharge pipe further until a mound is established around the 

discharge mouth. Initial lifting of discharge pipe shall be done slowly to 

minimize disturbance of material surrounding pipe mouth. 

6.		 Placements started using a plug shall be lifted 6 to 18 inches to allow water to 

escape. Concrete shall be added slowly to force the plug downward. Plugs shall 

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be removed, or made of a material approved by COR not to cause a defect in the 

concrete if not removed. 

7.		 Furnish uninterrupted concrete supply to discharge pipe at beginning of placement 

until a mound sufficient to seal tremie pipe or slickline has been established. 

8.		 Once established, maintain embedment of tremie pipe or slickline in fresh 

concrete at least 5 feet. Exact embedment depths shall depend upon placement 

rates and setting time of concrete. 

a.		 Control vertical movement of tremie pipe or slickline to prevent loss of 

seal. 

b.		 If loss of seal occurs, placement shall be halted immediately. 

c.		 Remove pipe, replace end closure device, and restart flow in presence of 

the COR. 

1)		 To prevent washout of already placed concrete, a plug shall not be 

allowed to restart after loss of seal. 

9.		 Clear blockages in discharge lines to prevent loss of seal. 

10.		 As temporary casing is withdrawn, maintain minimum head of 5 feet of concrete 

above bottom of casing.] 

3.06		 FINISHING 

A.		 Notify COR before finishing concrete. 

B.		 Finish concrete in presence of Government inspector unless inspection is waived in each 

specific case. 

C.		 103[Finishing {for the placements specified below} shall be performed under direct 

supervision of Craftsman certified as ACI Concrete Flatwork Finisher. 

1.		 A minimum of one certified ACI Concrete Flatwork Finisher is required at each 

{specified} finishing operation. 

2.		 {Placements requiring certified ACI Concrete Flatwork Finisher:} 

103		 Include only when determination is made that certified ACI Concrete Flatwork Finishers are required for 

job. List structures when some, but not all, of the concrete placements require supervision by certified 

finisher. When all concrete placements require supervision by certified finisher, delete the list and “for the 

structures specified below”, and “specified” in subparagraphs 1 and 2. Examples of concrete placements 

that could justify requiring a certified ACI Concrete Flatwork Finisher include low surface tolerances, 

surfaces that would have supercritical slow, and silica fume concrete. 

Note: ACI Concrete Flatwork Finisher certification requires passing a written test plus successfully 

completing a performance examination and possessing actual on-the-job finishing experience (performance 

test plus 1,500 hours experience), or possessing a higher level of actual on-the-job experience (4500 hours 

experience). ACI also has certification for a Concrete Flatwork Technician. This certification has less 

rigorous qualification requirements and is not recommended. 

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a.		 {list placements}] 

D.		 104[Finish surfaces as specified in Table 03 30 00F – Formed Surfaces and Table 

03 30 00G – Unformed Surfaces.] 

E.		 Where finishes are not specified or shown on drawings for a particular surface, finish 

concrete as specified for similar work. 

F.		 Formed surfaces: 

1.		 Finish class is designated by symbols 105[F1, F2, F3, and F4]. 

2.		 Finish F1: 

a.		 Applies to formed surfaces to be covered by fill material, grout, or 

concrete, and construction joint surfaces as specified in Table 03 30 00F – 

Formed Surfaces. 

b.		 Protect form tie rod ends on surfaces in contact with fill material from 

moisture where they will be below water table or waterline. 

1)		 Recess tie rod ends and fill recess with dry pack or other material 

approved by COR. 

c.		 Cut off flush with formed surface form tie rod ends on surfaces in contact 

with concrete or fill material and above maximum water table or waterline 

elevation. 

3.		 Finish F2: 

a.		 Applies to exposed formed surfaces not permanently concealed by fill 

material, grout, or concrete, and not required to receive finish F3 or F4, 

and to contraction joint surfaces and expansion joint surfaces as specified 

in Table 03 30 00F – Formed Surfaces. 

1)		 Recess tie rod ends and fill recess with dry pack or other material 

approved by COR. 

4.		 Finish F3: 

a.		 Applies to formed surfaces with special appearance requirements, such as 

surfaces exposed to view, and not required to receive finish F4, as 

specified in Table 03 30 00F - Formed Surfaces. 

b.		 After required patching and correction of imperfections has been 

completed, sack rub surface as follows: 

1)		 Thoroughly wet surface and sack rub while surface is still damp. 

104 Verify table numbers. When table numbers change, edit table numbers in following paragraphs. 

105 Select required formed finish class symbols and include following required paragraphs. 

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2)		 Use mortar consisting of 1 part cement; 2 parts, by volume, of sand 

passing No. 16 screen; and enough water so that mortar has 

consistency of thick cream. Blend standard cement with white 

cement as necessary to obtain color which will match surrounding 

concrete surface. 

3)		 Thoroughly rub mortar over area with clean burlap or sponge 

rubber float to fill pits, bugholes, and other defects. 

4)		 While mortar in pits is still plastic, rub surface with dry mix of 

above proportions and material to remove excess plastic material 

and place enough dry material in pits to stiffen and solidify mortar 

so that filling will be flush with surface. Remove material 

remaining on surface except material within pits. 

5)		 Continue curing surface as specified. 

5.		 Finish F4: 

a.		 Applies to formed surfaces with accurate alignment and evenness of 

surface requirements to eliminate destructive effects of water as specified 

in Table 03 30 00F – Formed Surfaces.] 

G.		 Unformed surfaces: 

1.		 Do not use dry portland cement or additional water during finishing. 

2.		 Do not use “jitterbugs” or other tools to force coarse aggregate away from 

surface. 

3.		 Finish class is designated by symbols U1, 106[U2, U3, or broom finish.] 

4.		 Finish U1 (Screeded Finish): 

a.		 Applies to unformed surfaces to be covered by fill material, grout, or 

concrete as specified in Table 03 30 00G - Unformed Surfaces. 

b.		 Use as first stage of finish U2 and U3. 

c.		 After concrete is placed and consolidated, strike off and level concrete to 

produce even uniform surface. 

5.		 Finish U2 (Floated Finish): 

a.		 Applies to unformed surfaces not permanently concealed by fill material, 

grout, or concrete, and not required to receive finish U3, as specified in 

Table 03 30 00G – Unformed Surfaces. 

b.		 Begin floating as soon as screeded surface has sufficiently stiffened and 

bleed water sheen has disappeared. 

Select required unformed finishes and include required paragraphs. When U2 or U3 finishes are specified, 

include U1 paragraphs even if there is no U1 finish in table (first stage of U2 and U3). When U3 finish is 

specified, include U2 paragraphs even if there is no U2 finish in table (second stage of U3). Delete last 

subparagraph (e) of U2 finish when there is no U3 finish. 

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c.		 Use hand- or power-driven equipment. 

d.		 Finish surface with minimum floating necessary to produce surface that is 

free of screed marks and is uniform in texture. 

e.		 107[Use as second stage of finish U3. Floating shall bring small amount of 

mortar without excess water to surface, so as to permit effective 

troweling.} 

6.		 Finish U3 (troweled finish): 

a.		 Applies to unformed surfaces where appearance and porosity is considered 

by Government to be of special importance as specified in Table 

03 30 00G – Unformed Surfaces. 

b.		 Begin steel troweling after bleed water has disappeared and floated surface 

has sufficiently hardened to prevent excess of fine material from being 

drawn to surface. 

c.		 Trowel with firm pressure to flatten sandy texture of floated surface. 

d.		 Trowel to a dense uniform surface free from blemishes and trowel marks. 

Do not excessively trowel surface.] 

7.		 Broomed finish: 

a.		 Apply broom finish immediately after concrete receives U2 finish. 

b.		 Edge transverse joints before brooming. 

c.		 Produce a scored surface by brooming with fiber-bristle brush in direction 

transverse to that of traffic with adjacent strokes slightly overlapping. 

d.		 Finished surface shall have uniform appearance and shall be free of abrupt 

corrugation exceeding 1/8-inch in depth. 

e.		 Brooming shall eliminate flat surface left by the surface face of the edger. 

8.		 Slope interior surfaces for drainage where shown on drawings or as directed by 

COR. Slope surfaces exposed to weather for drainage as directed by COR. 

9.		 Slope narrow surfaces, such as tops of walls and curbs, approximately 3/8-inch 

per foot of width, unless use of other slopes or level surface is indicated on 

drawings or is directed by the COR. 

10.		 Slope broader surfaces; such as walks, platform, and decks; approximately 

1/4-inch per foot unless use of other slopes or level surfaces is indicated on 

drawings or is directed by the COR 

3.07		 JOINTS AND EDGES 

A.		 Construction joints (CJ): 

107	 Delete when U3 finish not included. 

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1.		 Construction joints are joints which are purposely placed in concrete to facilitate 

construction, reduce initial shrinkage stresses and cracks, allow time for 

installation of embedded metalwork, or allow for subsequent placing of other 

concrete. 

2.		 Bond is required at construction joints regardless of whether or not reinforcement 

is continuous across joint. 

3.		 Locate construction joints where shown on drawings. Relocation, addition, or 

elimination of construction joints will be subject to approval by the COR. . 

4.		 Clean, roughen, and surface dry surfaces of construction joints to be covered with 

fresh concrete. See Preparation article. 

5.		 Do not use a mortar layer on construction joints. 

B.		 108[Control joints (Ct.J): 

1.		 Control joints are joints placed in concrete to provide for control of initial 

shrinkage stresses and cracks of monolithic units. 

2.		 Construct control joints so no bond exists between concrete surfaces forming the 

joint. 

a.		 Construct control joints by placing concrete on one side of joint and 

allowing it to set before concrete is placed on other side of joint. 

b.		 Coat surface of concrete first placed at control joint with curing compound 

that prevents bond before placing concrete on other side of joint. 

3.		 Reinforcement is continuous across tooled or saw cut control joints 

C.		 109[Partial Contraction Joints, (Partial Cr. J): 

1.		 Construct partial contraction joints so no bond exists between concrete surfaces 

forming the joint. 

a.		 Construct partial contraction joints by placing concrete on one side of joint 

and allowing it to set before concrete is placed on other side of joint. 

b.		 Coat surface of concrete first placed at partial contraction joint with curing 

compound that prevents bond before placing concrete on other side of 

joint. 

2.		 At partial contraction joints, discontinue every other reinforcement bar 

perpendicular to the joint; i.e. 1/2 of perpendicular reinforcement shall cross the 

joint. End discontinued bars 2 inches from face of joint.] 

108		 Include when control joints are required and the slab thickness will not allow for saw cut joints to be 

installed per ACI 302.1R. Control joints are joints placed in concrete to provide for control of initial 

shrinkage stresses and cracks of monolithic units. 

109		 Include only when partial contraction joints are required. 

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D.		 110[Contraction joints (Cr.J): 

1.		 Contraction joints are joints placed in concrete to provide for volumetric 

shrinkage of a monolithic unit or movement between monolithic units. 

2.		 Construct contraction joints so no bond exists between concrete surfaces forming 

the joint. 

a.		 Construct contraction joints by placing concrete on one side of joint and 

allowing it to set before concrete is placed on other side of joint. 

b.		 Coat surface of concrete first placed at contraction joint with curing 

compound that prevents bond before placing concrete on other side of 

joint. 

3.		 Except as provided for dowels, reinforcement is not continuous across a 

contraction joint.] 

E.		 111[{Expansion joints (EJ): 

1.		 Cut sponge rubber joint filler to size and shape of joint surface to receive filler. 

2.		 Adhere filler to concrete in accordance with adhesive manufacturer's 

recommendations. 

3.		 Butt sections of filler with tight-fitting butt joints to prevent mortar from seeping 

through joint.} 

F.		 {Expansion joints (EJ): 

1.		 Form joint in concrete. 

2.		 Fill joint with bituminous joint filler. 

3.		 Butt sections of filler with tight-fitting butt joints.}] 

G.		 112[Saw cut joints: 

1.		 Saw cut joints shall be completed within 24 hours following concrete placement. 

2.		 Joints shall have straight, sharp edges and cut to minimum width possible with 

type of saw used. 

3.		 Minimum depth of saw cuts shall be 1/4 of depth of concrete unless otherwise 

indicated on the drawings.] 

4.		 Early-entry, dry-cut saw cutting is not permitted. 

110		 Include when contraction joints required. 

111		 Include only when expansion joints required. Include applicable paragraphs. Generally only one set of 

paragraphs is necessary. First paragraphs are for expansion joints with sponge rubber joint filler. Second 

set of paragraphs are for expansion joints with bituminous joint filler. 

112		 Include only when saw cut joints are required as shown on drawings. Saw cut joints typically only used for 

flatwork where there will not be interference from reinforcing steel. 

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H.		 Edges: 

1.		 Permanently exposed concrete, except slabs and top edges of curbs: Chamfer 

edges with 45 degree bevel 3/4-inch by 3/4-inch; unless otherwise shown on 

drawings. 

2.		 Exposed edges of slabs and top edges of curbs: Tool to radius of 1/4 inch. 

I.		 Preformed joints consisting of plastic or metal strips not allowed. 

3.08		 STRUCTURAL DEVIATIONS AND SURFACE TOLERANCES 

A.		 Structural deviations are defined as allowable variations from specified lines, grades, and 

dimensions. 

B.		 Surface tolerances are defined as maximum allowable magnitude of surface irregularities. 

C.		 Specified structural deviations and surface tolerances are consistent with modern 

construction practice and governed by effects that permissible variations may have upon 

a structure. COR reserves the right to diminish specified structural deviations and surface 

tolerances where such variations impair structural action, operational function, or 

architectural appearance of a structure or portion of structure. 

D.		 Construct concrete within stated variations even though more than one may be specified. 

1.		 Specified variation for one element of a structure will not apply when it will 

permit another element of same structure to exceed its allowable variation. 

2.		 Where variations are not specified or shown on drawings for a particular 

structure, variations shall be those specified for similar work. As an exception to 

clause at FAR 52.236-21 “Specifications and Drawings for Construction,” 

specific tolerances shown on drawings in connection with dimension shall govern. 

E.		 Structural deviations: 

1.		 Check variations from specified lines, grades, and dimensions in hardened 

concrete to determine that structures are within tolerances specified in Table 

03 30 00C - Deviations from Specified Lines, Grades, and Dimensions. 

2.		 Variation is distance between actual position of structure or element of structure 

and specified position in plan for structure or particular element. 

a.		 Plus or minus variations, shown as (∀), indicate a permitted actual 

position up or down and in or out from specified position in plan. 

b.		 Variations not designated as (+) or (-) indicate maximum deviation 

permitted between designated successive points on completed element of 

construction. 

3.		 Specified position in plan is defined as lines, grades, and dimensions described in 

these specifications, shown on drawings, or prescribed by COR. 

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113[Insert table - see guide Section 03 30 00 - Concrete Deviations] 

F.		 Surface irregularities: 

1.		 Bulges, depressions, and offsets are defined as surface irregularities or roughness. 

2.		 Surface irregularities are classified as “abrupt” or “gradual” and allowable 

tolerances are specified in Table 03 30 00D - Surface Tolerances. 

a.		 A surface tolerance is designated by a capital “T” followed by a number 1 

through 5. 

b.		 Surface tolerance designations are separate from surface finishes and 

structural deviations. 

3.		 Abrupt surface irregularities: 

a.		 Abrupt surface irregularities are defined as offsets such as those caused by 

misplaced or loose forms in which maximum dimension of irregularity 

perpendicular to surface is greater than maximum dimension of 

irregularity in plane of surface. 

b.		 Abrupt surface irregularities include isolated surface irregularities which 

exceed specified gradual irregularities. 

4.		 Gradual surface irregularities: 

a.		 Gradual surface irregularities are defined as bulges and depressions 

resulting in gradual changes on surface. 

b.		 Gradual surface irregularities are further defined as isolated undulations 

on surface. Maximum dimension of undulation perpendicular to surface is 

small relative to maximum dimension of undulation in plane of surface. 

5.		 Check magnitude of surface irregularities of formwork and finished surfaces to 

ensure that surfaces are within specified tolerances. 

G.		 Surface tolerances: 

Table 03 30 00D - Surface Tolerances 

Concrete surface Maximum allowable surface 

irregularity tolerance 

Abrupt Gradual 

T1 1 inch 1/4 inch/inch 

T2 1/2 inch 1/8 inch/inch 

T3 1/4 inch 1/16 inch/inch 

Insert table for “Deviation from Specified Lines, Grades, and Dimensions”. See file 03 30 00 - Concrete 

Deviations.docx. Edit table to remove structure types that do not apply. Change table designation (letter) 

as needed. 

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Table 03 30 00D - Surface Tolerances 

Concrete surface Maximum allowable surface 

irregularity tolerance 

Abrupt Gradual 

T4 1/8 inch 1/32 inch/inch 

T5 1/32 inch 1/120 inch/inch 

H.		 Repair of hardened concrete not within specified tolerances: 

1.		 Repair hardened concrete which is not within specified tolerances to bring it 

within those tolerances. 

2.		 Perform repair after consultation with Government inspector regarding method of 

repair. Notify COR as to time when repair will be performed. 

3.		 Repair concrete which will be exposed to view in manner which will result in 

concrete surface with uniform appearance. 

a.		 When grinding surfaces exposed to view, limit depth of grinding such that 

no aggregate particles are exposed more than 1/16 inch in cross section at 

finished surface. 

b.		 Where grinding has caused or will cause exposure of aggregate particles 

greater than 1/16 inch in cross section at finished surface, repair concrete 

by excavating and replacing concrete. 

I.		 Field verification of surface tolerances: 

1.		 Determine compliance of surface with specified surface tolerances. 

2.		 Evaluate surface roughness. 

a.		 Measure roughness height or depth and check for compliance with values 

specified in Table 03 30 00D - Surface Tolerances and Table 03 30 00C -

Deviations from Specified Lines, Grades, and Dimensions. 

b.		 When measured height or depth of roughness is less than value in abrupt 

tolerance specification and height or depth of roughness does not cause 

structure to exceed applicable value specified in Table 03 30 00C -

Deviations from Specified Lines, Grades, and Dimensions, surface 

roughness is acceptable. 

c.		 When roughness height or depth exceeds abrupt tolerance specification, 

determine roughness slope for comparison to gradual tolerance 

specification. 

1)		 Measure roughness length and determine roughness slope by 

dividing roughness height or depth by roughness length (see Figure 

1). 

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2) When roughness slope is greater than slope specified by gradual 

tolerance specification, surface roughness is unacceptable. 

3) When roughness slope is less than gradual slope specified and 

gradual roughness does not cause structure to exceed allowable 

structural deviations, surface roughness is acceptable. 

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J.		 Measuring surface roughness: 

1.		 Examples below illustrate how to make necessary surface measurements for 

typical roughness. 

2.		 Case 1 - Roughness Protruding above Surface: 

a.		 Measure roughness protruding above surface with straightedge that is at 

least 20 times longer than roughness height being measured. 

b.		 Position straightedge with one end resting on top of roughness, as shown 

in Figure 2 (case 1). 

c.		 Determine roughness height by measuring maximum gap that occurs 

normal to straight edge. 

d.		 Note position on the straightedge from which normal distance is 

measured. 

e.		 To determine roughness length, measure distance along straightedge from 

point where the height was measured to point of contact between 

straightedge and top of roughness. 

f.		 Roughness slope is defined as ratio of roughness height to roughness 

length. 

g.		 As roughness is seldom symmetric, moving position of straightedge about 

roughness may be necessary to locate point where maximum height and 

slope exists. 

3.		 Case 2 - Roughness Extending below the Surface: 

a.		 A roughness occurring as an indentation to surface is measured by placing 

straightedge across indentation, as shown in Figure 2 (case 2). 

b.		 Measure maximum gap between straightedge and surface and note 

location of measurement on straightedge. 

c.		 From point of depth measurement, measure along straightedge in both 

directions to point of contact with surface. 

d.		 Use shortest length measured as roughness length. 

e.		 Divide roughness depth by roughness length to determine roughness slope. 

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K.		 Prevention of repeated failure to meet tolerances: 

1.		 When concrete placements result in hardened concrete which does not meet 

specified tolerances, submit to COR an outline of preventive actions such as 

modifications to forms, modified procedure for setting screeds, and different 

finishing techniques to be implemented to avoid repeated failures. Submit when 

requested by COR. 

2.		 Government reserves the right to delay concrete placements until preventive 

actions which have been approved by COR are implemented. 

3.09		 CURING 

A.		 Water curing: 

1.		 Keep concrete surface wet for 14 days, minimum, from time concrete has attained 

sufficient set to prevent detrimental effects to surface. 

2.		 Cure methods: 

a.		 Water-saturated material. 

b.		 System of perforated pipes, mechanical sprinklers, or porous hose. 

c.		 Other methods which will keep surfaces wet. 

d.		 Subject to approval by COR. 

3.		 114[When water curing is anticipated for RSMC, include water curing methods for 

RSMC in RSMC Temperature Control Plan. Provisions may be necessary to 

prevent rapid cooling of concrete surfaces.] 

B.		 Curing with curing compound: 

1.		 Apply to concrete surface to provide water-retaining film. Reapply as necessary 

to maintain continuous, water-retaining film on surface for 28 days. 

2.		 Thoroughly mix compound and spray apply in one coat to provide continuous, 

uniform film over surface. 

3.		 Do not exceed coverage rate recommended by curing compound manufacturer. 

Decrease coverage rate on rough surfaces as necessary to obtain required 

continuous film. 

4.		 Ensure ample coverage on edges, corners, and rough surfaces. 

5.		 Use spray equipment recommended by curing compound manufacturer. 

C.		 Sheet material curing: 

1.		 115[Includes curing with {polyethylene film} {or white burlap-polyethylene 

sheet}.] 

114		 Include only when RSMC specified. 

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2.		 Thoroughly moisten concrete surface by lightly spraying with water as soon as 

concrete has hardened sufficiently to prevent damage. 

3.		 Completely cover concrete surface with sheet material to provide airtight, 

water-retaining film over entire surface. 

4.		 Lap edges of sheet material to seal adjacent sheets. 

5.		 Place tightly against concrete surface at extreme edge of curing area. 

6.		 Secure sheet material to withstand wind and prevent circulation of air inside sheet 

material. 

7.		 Keep surface covered for 14 days, minimum. 

3.10		 116[CONTRACTOR FIELD QUALITY TESTING 

A.		 117[{Contractor} {Independent testing agency}] shall perform sampling, testing, and 

reporting as required in Table 03 30 00E - Field Testing. 

1.		 118[Independent testing agency shall meet requirements specified in Section 

01 46 20 - Testing Agency Services.] 

2.		 Personnel conducting plastic concrete field tests: Qualified as ACI Concrete Field 

Testing Technician, Grade 1; or equal. 

3.		 Personnel conducting concrete specimen tests: Qualified as ACI Concrete 

Strength Testing Technician; or equal. 

B.		 Perform tests at least as often as frequencies specified in Table 03 30 00E - Field Testing. 

C.		 Notify COR immediately of test results showing failure of materials to meet 

specifications. Notify COR within 2 hours of test results showing materials meet 

specifications. Submit reports of test results as specified. 

115		 Revise for type(s) of sheet materials specified. Coordinate with Curing Materials article for materials 

specified. See footnotes for that article for discussion of appropriate sheet materials. 

116		 See footnote for Article “Batch Plant Quality Testing” (2.11) for discussion of Reclamation practice and 

recommendations for quality testing. Including Contractor Field Quality Testing is not necessary when the 

Government plans to perform full Quality Assurance testing, however 

117		 Select “Contractor” when Government will be performing Quality Assurance testing. Requiring the 

Contractor to hire an independent testing agency is usually not needed when the Government will perform 

full Quality Assurance testing. 

Select “Independent testing agency” when Government plans to perform little or no Quality Assurance 

testing and plans to use independent testing agency test results for evaluating acceptability of work. 

See previous footnote. 

118		 Include only when independent testing agency required to perform testing. 

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3.11		 GOVERNMENT CONTRACT QUALITY ASSURANCE - FIELD 

A.		 119[The Government will perform, as a minimum, tests listed in Table 03 30 00E - Field 

Testing. This testing is in addition to the Contractors Quality Assurance/Quality Control 

(QA/QC) program and does not relieve the Contractor of performing adequate QA/QC 

testing. The list of tests is provided only to alert the Contractor to potential impacts to 

work scheduling. 

B.		 Government testing frequency is at discretion of the COR. Greater frequency testing is 

normally performed at beginning of new work, new crew, or new equipment. Testing 

frequency listed in Table 03 30 00E - Field Testing is provided only as approximation of 

Government testing.] 

C.		 120[In addition to specified Contractor Quality Field Testing, the Government may also 

perform tests listed in Table 03 30 00E - Field Testing.] 

3.12		 FIELD TESTING 

Table 03 30 00E- Field Testing 

TESTS OF TEST 

STANDARD 

STANDARD TITLE TESTING FREQUENCY 

Fresh Concrete 

Properties -

tests performed 

at site 

ASTM C143 Slump of HydraulicCement Concrete 1 set of tests per load for first two loads. 

When tested concrete meets specifications, 1 

set of tests each day of placement for each 

mixture for first 50 or less cubic yards, and 1 

set of tests for each additional 100 cubic yards 

of concrete. Minimum of 1 set of tests per 

hour during placements. 

When concrete does not meet specifications, 

test each load until 2 consecutive loads meet 

specifications, then resume testing frequency 

specified above. 

ASTM C231 Air Content of Freshly 

Mixed Concrete by the 

Pressure Method 

(alternative to ASTM 

C138 gravimetric 

method) 

ASTM C1064 Temperature of 

Freshly Mixed 

Hydraulic-Cement 

Concrete 

119		 Include paragraphs A, B when the Government will be performing full Quality Assurance testing of 

concrete. See footnote for Contractor Quality Testing article (2.10) for discussion of Reclamation practice. 

As noted in paragraph A, this information is provided to the Contractor for information as to potential 

impacts for scheduling his activities 

120		 Include paragraph C when the Government will perform little or no quality testing. The Contractor shall 

retain independent testing agency to perform tests that the Government evaluate when determining 

acceptability of work. See footnote for Contractor Quality Testing article (2.10) for discussion of 

Reclamation practice. 

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Table 03 30 00E- Field Testing
	

TESTS OF TEST 

STANDARD 

STANDARD TITLE TESTING FREQUENCY 

ASTM C138 Density (Unit 

Weight), Yield, and 

Air Content 

(Gravimetric) of 

Concrete 

Compressive ASTM C31 Making and Curing 1 set of samples (6-inch by 12 inch for each 

Strength, Concrete Test 

Specimens in the Field 

day of placement for each mixture for the first 

50 or less cubic yards, and 1 set of samples for 

each additional 100 cubic yards of concrete. 

ASTM C39 Compressive Strength 

of Cylindrical 

Concrete Specimens 

A minimum of 5 samples for strength testing 

shall be made each time strength samples are 

collected. 

2 additional field cured test cylinders during 

placement in adverse (hot or cold) weather. 

Cure these samples on jobsite under same 

conditions as concrete the cylinders represent 

for minimum of 7 days, then transfer to testing 

laboratory until testing at strength design days. 

Test 2 cylinders each at 7 days age and 2 

cylinders at strength design age. Maintain last 

cylinder for testing in event that the strength 

design age test results fall below the required 

strength. 

Concrete Cores ASTM C42 Obtaining and Testing 

Drilled Cores and 

Sawed Beams of 

Concrete 

At discretion of the Government when 

cylinder strengths fail to meet minimum 

requirements. 

The Contractor shall obtain core specimens in 

accordance with ASTM C42 at locations 

directed by COR, at no additional cost to the 

Government. The Contractor shall repair the 

core holes in accordance with USBR M-47 as 

directed by COR 

A.		 Acceptance criteria: 

1.		 Cylinder compressive strength: 

a.		 In accordance with ASTM C94, except as follows: 

1)		 90 Percent of test cylinders exceed specified compressive strength 

at design age. 

2)		 Average compressive strength of six consecutive test cylinders 

exceeds specified compressive strength at design age. 

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3)		 No individual strength test falls below specified compressive 

strength by more than 500 lb/in2 . 

2.		 Drilled concrete cores: 

a.		 121[{Concrete in placement represented by core tests will be considered 

structurally adequate when average compressive strength of three cores is 

equal to at least 85 percent of specified compressive strength and no single 

core has a compressive strength of less than 75 percent of specified 

compressive strength. 

b.		 Concrete in placement represented by core tests will be considered 

adequate for durability when average compressive strength of three cores 

is equal to at least 100 percent of specified compressive strength at design 

age. 

3.13		 PROTECTION 

A.		 Protect concrete from damage until final acceptance by Government. 

1.		 Do not load, remove forms or shoring, or backfill against concrete until concrete 

has gained sufficient strength to safely support its weight and imposed loads. 

2.		 Protect fresh concrete against erosion from rain, hail, sleet, or snow; 

contamination from foreign materials; and damage from foot traffic until the 

concrete has hardened. 

3.		 Protect concrete from heavy foot traffic and other construction activities by 

covering with plywood or other suitable material. Remove and dispose of 

temporary covering when no longer required. 

B.		 122[Protect concrete when freezing temperatures are imminent: 

1.		 Maintain concrete at a temperature of 50 degrees F (10 degrees C) or greater for 

72 hours, minimum, after placement. Vent heater and prevent concrete from 

drying where artificial heat is employed. 

2.		 Protect concrete from freezing during water curing. After discontinuance of water 

curing, maintain at a temperature of 50 degrees F (10 degrees C) or greater for 

next 72 hours. 

3.		 Discontinue protection against cold weather such that the drop in temperature of 

the concrete will be gradual and will not exceed 5 degrees F per hour and 40 

121		 Select subparagraph a or b. If a job has concrete placements where the different criteria would apply, need 

to list the placements that the different criteria would apply. 

Paragraph b is appropriate for concrete exposure classes requiring 4500 psi or above concrete in accordance 

with ACI 318. 

122		 Include when there could be the possibility of placing concrete in freezing weather. 

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degrees F in 24 hours 123[for thin sections and 5 degrees F per hour and 20 

degrees F in 24 hours for massive sections greater than 36 inches]. 

3.14		 REPAIR 

A.		 Repair concrete in accordance with USBR M-47. 

B.		 Use repair or replacement method directed by COR. 

3.15		 FINISH, SURFACE TOLERANCES, AND CURING SCHEDULES 

124[Insert tables} 

END OF SECTION 

123		 Include when there will be concrete placement over 36 inches in all directions. 

124	 Insert schedule tables for formed and unformed surface finish, tolerance, and curing method. See guide 

spec 03 30 00 - Concrete Schedule.docx. Edit tables to delete surfaces that do not apply. 

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SECTION 03 37 10 

SHOTCRETE 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 7/13/15 

Content Revisions: 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

Shotcrete 

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SECTION 03 37 10
	

SHOTCRETE
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 1[Shotcrete: 

1.		 Measurement: Volume discharged at nozzle. 

2.		 Payment: Cubic yard unit price offered in the schedule. Does not include 

cementitious materials. 

B.		 Cementitious materials in shotcrete: 

1.		 Measurement: Weight based on batch weight. 

2.		 Payment: Tons unit price offered in the schedule.] 

C.		 2[Cost: Include cost of shotcrete in linear foot price offered in the schedule for tunnel 

lining.] 

1.02		 REFERENCE STANDARDS 

A.		 American Concrete Institute 

1.		 ACI 506R-05 Guide to Shotcrete 

B.		 ASTM International (ASTM) 

1.		 ASTM C 33/C 33M-13 Concrete Aggregates 

2.		 ASTM C 42/C 42M-13 Obtaining and Testing Drilled Concrete 

Cores and Sawed Beams of Concrete 

3.		 ASTM C 94/C 94M-15 Ready-Mixed Concrete 

4.		 3

[ASTM C 150-15 Portland Cement] 

5.		 ASTM C 171-07 Sheet Materials for Curing Concrete 

6.		 ASTM C 309-11 Liquid Membrane-Forming Compounds for 

Curing Concrete 

7.		 ASTM C 1140/C 1140M-11 Preparing and Testing Specimens from 

Shotcrete Test Panels 

1 Include when shotcrete paid by volume. Revise if cementitious material to be included in payment 

for volume price offered for shotcrete. 

2 Include when tunnel lining paid by linear foot. 

3 Delete when there is a Section 03 30 00 

Shotcrete 

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8. ASTM C 1141-08 Admixtures for Shotcrete 

9. ASTM C 1436-13 Materials for Shotcrete 

10.		 ASTM C 1583/ C 1583M-13 Tensile Strength of Concrete Surfaces and 

the Bond Strength or Tensile Strength of 

Concrete Repair and Overlay Materials by 

Direct Tension 

11.		 4[ASTM C 618-12a Coal Fly Ash and Raw or Calcined Natural 

Pozzolan for Use as a Mineral Admixture in 

Concrete] 

12.		 ASTM C 1602/C 1602M-12 Mixing Water Used in the Production of 

Hydraulic Cement Concrete 

C.		 Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

D.		 NSF International 

1.		 NSF 61-2013 Drinking Water System ComponentsHealth Effects 

1.03		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 37 10-1, Shotcrete Mix Design: 

1.		 Material proportions. 

2.		 Manufacturer’s certification and test reports for each cementitious material, 

aggregate source, and admixture 

3.		 Prepare a test panel for each proposed mix, shooting orientation, and nozzleman 

prior to construction. 

a.		 Prepare and test panels in accordance with ASTM C1140. 

1) Minimum panel size: 18-inches by 18-inches by 4-inches thick. 

2) Provide reinforcement of the same size and grade specified. 

3) Extract cores in accordance with ASTM C42. 

4) Test three cores each at 5[8 hours, 24 hours, 7 and 28 days] for 

compressive strength. 

Delete when there is a Section 03 30 00 

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5)		 Provide three cores containing reinforcing steel for bar 

encapsulation verification. 

C.		 RSN 03 37 10-2, Specific Operating Procedure: 

1.		 Include engineering controls, protective clothing, eye protection, respiratory 

protection and air sampling as necessary to check control program effectiveness. 

2.		 List of personnel and certification of Nozzlemen. 

D.		 RSN 03 37 10-3,Test Panel Results. 

1.04		 DEFINITIONS 

A.		 Dry-mix process: 

1.		 Mix solid materials to a uniform color with no sand streaks, feed materials into a 

mechanical feeder or gun, carry materials by compressed air through a hose to a 

special nozzle, introduce water and mix with other ingredients at the nozzle, jet 

mixture from nozzle at high velocity onto surface. 

2.		 Add liquid accelerator to mixture at nozzle. 

3.		 Add powder accelerator to mixture as mixture enters mechanical feeder or gun. 

B.		 Wet-mix process: 

1.		 Mix ingredients, feed mixture into delivery equipment, deliver mixture by 

positive displacement or compressed air to nozzle, and then jet mixture from the 

nozzle at high velocity onto surface. 

2.		 Add accelerator to mixture at nozzle. 

1.05		 QUALIFICATION 

A.		 Certified nozzleman, ACI Shotcrete Nozzleman Certification. 

PART 2 PRODUCTS 

2.01		 SHOTCRETE MATERIALS 

A.		 In accordance with ASTM C 1436, except as detailed below. 

2.02		 CEMENTITIOUS MATERIALS 

A.		 6

[In accordance with Section 03 30 00 – Cast-In- Place Concrete.] 

Delete if there is no Section 03 30 00 

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B.		 7[Cementitious Materials Options: 

1.		 Specified portland cement only. 

2.		 Specified portland cement plus specified pozzolan. 

C.		 Portland Cement: 

1.		 ASTM C 150, Type 8[____]. 

2.		 Meet equivalent alkalies requirements of ASTM C 150 - Table 2. 

3.		 Meet false-set requirements of ASTM C 150 - Table 4. 

D.		 Pozzolan: 

1.		 ASTM C 618, Class F. 

2.		 Sulfur trioxide for Class F, maximum: 5.0 percent. 

3.		 Loss on ignition, maximum: 6.0 percent. 

4.		 Use pozzolan tested for effectiveness in controlling alkali-silica reaction under 

optional physical requirements in Table 2 of ASTM C 618. Use low-alkali 

cement for test. 

5.		 Do not decrease sulfate resistance of concrete by use of pozzolan. 

a.		 Demonstrate pozzolan shall have an “R” factor less than 2.5. 

1) R = (C-5)/F 

2) C: Calcium oxide content of pozzolan in percent determined in 

accordance with ASTM C 114. 

3) F: Ferric oxide content of pozzolan in percent determined in 

accordance with ASTM C 114.] 

E.		 9

[Low-alkali limitation for portland cement and mortar expansion limit for pozzolan may 

be waived by Government when concrete aggregate source has previously been tested by 

Bureau of Reclamation and aggregate source does not contain potentially deleterious 

amounts of particles which may react with alkalis in cementitious materials as evidenced 

by petrographic examination or mortar bar tests, or both.] 

2.03		 WATER 

A.		 ASTM C 1602, including optional requirements of Table 2. 

7 Delete if there is no Section 03 30 00
	

8 Specify Type (I, II, III, or V) if there is no Section 03 30 00.
	

9 Delete if aggregate sources have not been tested.
	

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2.04		 AGGREGATE MATERIALS 

A.		 Fine aggregate: ASTM C 33. 

B.		 Coarse Aggregate: ACI 506R, Grading No.10[1 or 2] from Table 1.1. 

2.05		 ADMIXTURES 

A.		 Air-Entraining Admixture: 

1.		 ASTM C1141 Type II, Grade 8. 

B.		 Chemical Admixtures: 

1.		 Allowable Chemical Admixtures: 

a.		 ASTM C1141 Type I or II, Grade 2. 

b.		 ASTM C 1141 Type II, Grade 7. 

c.		 11[ASTM C 1141 Type I or II, Grade 1, provided they do not contain 

chlorides.] 

2.		 Admixtures: Compatible with each other. 

3.		 Do not use chemical admixtures which introduce more than 1/10 of 1 percent 

chloride, by weight of cementitious materials. 

4.		 Class B accelerator may be used for dry-mix process 

5.		 Do not use Class B accelerator in wet-mix process 

6.		 Water-reducing, set-controlling admixture may be used. Meets ASTM C 494. 

2.06		 CURING MATERIALS 

A.		 Water: ASTM C 1602, including optional requirements of Table 2. 

B.		 Curing Compound: ASTM C 309. 

C.		 Polyethylene Film: ASTM C 171, white opaque. 

2.07		 BATCHING AND MIXING 

A.		 Mix: 

1.		 12[Compressive strength:600 psi at 8 hours age and 4,000 psi at 28 days based on 

3- by 3-inch cores.] 

10 Specify aggregate grading necessary for the project.
	

11 Include for cold weather use only.
	

12 Edit to specify specific project requirements
	

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2.		 Consistency: 

a.		 Dry mix process: Introduce water at nozzle and adjust so in-place 

shotcrete is compacted and shows no sags or excessive rebound. 

b.		 Wet-mix process: Maximum 3-inch slump. 

B.		 Batching 

1.		 Dry-mix process: 

a.		 Obtain uniform proportions of water, cementitious materials, sand, coarse 

aggregate, and admixture. Use equipment capable of controlling material 

delivery so inaccuracies do not exceed: 

1) 1 percent for water.
	

2) 1-1/2 percent for cementitious materials.
	

3) 2 percent for sand and coarse aggregate.
	

4) 3 percent for admixture.
	

b.		 Recalibrate auger feed as necessary to keep them within prescribed 

batching accuracy. 

c.		 Percent surface moisture in sand, by weight, ASTM C 128 and ASTM C 

566: 3 to 6 percent. 

d.		 Waste shotcrete batches when cementitious materials have been in contact 

with wet aggregate or other moisture for more than 2 hours. 

2.		 Wet-mix process: Manufacture in accordance with ASTM C 94. 

2.08		 MIXING 

A.		 Dry-mix process: 

1.		 Uniformly add cementitious materials, sand, coarse aggregate, and admixture and 

thoroughly mix before feeding into delivery equipment. Add liquid accelerator if 

used at nozzle. 

2.		 Machine mix dry ingredients. 

3.		 If mixers are used to mix dry ingredients without full amount of mix water added, 

discharge batch without segregation. 

4.		 Test mixers for uniformity of coarse aggregate content from front to back of 

mixer. 

5.		 Maximum permissible difference in percentage of coarse aggregate by weight 

sample shall not exceed 6 percent within a batch. 

6.		 Equip discharge nozzle with a manually operated water injection system of 

sufficient pressure to provide an even distribution of water into dry shotcrete 

mixture at nozzle. 

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B.		 Wet-mix process: Manufacture in accordance with ASTM C 94. 

PART 3 EXECUTION 

3.01		 PLACING 

A.		 Use an air compressor of ample capacity to maintain a supply of clean, dry air adequate 

for maintaining a uniform nozzle velocity. 

B.		 Place shotcrete by pneumatic pressure from discharge nozzle held about 2 to 5 feet from 

the surface in a stream as nearly normal as possible to surface being covered. 

C.		 Rapidly gyrate nozzle while placing. 

D.		 Place in layers having a thickness that assure complete adherence of shotcrete to the 

surface. Assure adequate bond is achieved between successive layers. 

E.		 Remove and replace any shotcrete which sloughs or separates as determined by COR. 

F.		 Prevent formation of sand pockets in shotcrete. If sand pockets form, remove 

immediately and replace with suitable shotcrete at Contractor’s expense. 

G.		 Do not use rebound as shotcrete aggregate. Remove and dispose of rebound 

accumulations. 

H.		 Placing shotcrete temperature: Between 50 and 90 degrees F. 

I.		 Do not place on frozen surfaces. 

J.		 Keep applied shotcrete at temperature greater than 50 degrees for a minimum of 3 days 

immediately following application. 

K.		 If using accelerating hardener, do not exceed shotcrete temperature of 80 degrees F. 

3.02		 CURING 

A.		 Water Curing: 

1.		 Keep concrete surface wet for 14 days, minimum, from time concrete has attained 

sufficient set to prevent detrimental effects to surface at a temperature above 40 

degrees F. 

2.		 Cure methods: 

a.		 Water-saturated material. 

b.		 System of perforated pipes, mechanical sprinklers, or porous hose. 

c.		 Other methods which keep surfaces wet. 

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d.		 Subject to approval by COR 

B.		 Curing with Curing Compound: 

1.		 Apply to concrete surface to provide a water-retaining film. Reapply as necessary 

to maintain a continuous, water-retaining film on surface for 28 days. 

2.		 Thoroughly mix compound and spray apply in one coat to provide a continuous, 

uniform film over surface. 

3.		 Do not exceed coverage rate of 150 square feet per gallon. Decrease coverage 

rate on rough surfaces as necessary to obtain required continuous film. 

4.		 Ensure ample coverage on edges, corners, and rough surfaces. 

5.		 Spray equipment and equipment performance subject to approval by the COR. 

Repair or replace equipment when directed by the COR. 

6.		 Use personnel qualified in using specified spray technique, as determined by the 

COR, to perform application 

C.		 Polyethylene Film Curing: 

1.		 Thoroughly moisten concrete surface by lightly spraying with water as soon as 

concrete has hardened sufficiently to prevent damage. 

2.		 Completely cover concrete surface with polyethylene film to provide an airtight, 

water-retaining film over entire surface. 

3.		 Lap edges of polyethylene sheets to seal adjacent sheets. 

4.		 Place tightly against concrete surface at extreme edge of curing area. 

5.		 Secure film to withstand wind and prevent circulation of air inside curing film. 

6.		 Keep surface covered for 14 days, minimum. 

3.03		 GOVERNMENT QUALITY ASSURANCE 

A.		 If selected shotcreting system fails to provide satisfactory in-place shotcrete as 

determined by the COR, Contractor shall change to another system of either of the two 

processes, provide a redemonstration of the nozzleman’s proficiency, or provide a new 

certified nozzleman. 

3.04		 CONTRACTOR QUALITY CONTROL 

A.		 Field test panels: Prepare three test panels during shotcreting operations at locations 

requested by the COR. Prepare one set of three test panels for every 5,000 sf of shotcrete 

or one set per day, whichever is greater. 

1.		 Prepare and test panels in accordance with ASTM C 1140. 

2.		 Minimum panel size: 18-inches by 18-inches by 4-inches thick. 

3.		 Provide reinforcement of the same size and grade specified. 

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4.		 Extract cores in accordance with ASTM C 42. 

5.		 Test three cores each at 13[8 hours, 24 hours, 7 and 28] days for compressive 

strength. 

6.		 Provide three cores containing reinforcing steel to the COR for bar encapsulation 

verification. 

B.		 For shotcrete bonded to concrete: 

1.		 Measure bond strength according to ASTM C 1583 at locations directed by COR. 

2.		 Minimum bond strength: 100 psi. 

END OF SECTION 

Edit to specify specific project requirements. 

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SECTION 03 81 10 

CONCRETE REMOVAL 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 5/11/15 

Content Revisions: 

5/11/15 Changed “schedule” to “Price Schedule”. 

12/22/14 Added hydrodemolition and formatted. 

1/17/13 Added Note. Added lump sum payment option. Added subparagraph that actual 

compressive strength may be higher than design compressive strength. 

Corrected reference to Section 01 74 00. 

4/7/09 Changed Section number. 

Editorial/Format Revisions: 

5/11/15 Changed template 

4/7/09 Changed template. 

3/18/08 Changed template and added blank page code at end. 

Template: CSI_15a.dotx 

NOTES 

This Section covers selective, partial removal of existing concrete required for modification to 

an existing structure. Removal of an entire concrete structure should be addressed with a 

Section number of 03 04 XX or 02 41 XX. See discussion of Section numbers in 

Reclamation Master. Also, this Section does not cover requirements for removing 

deteriorated concrete for repair of concrete. This activity should be covered in a Section with 

a number of 03 01 XX. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

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SECTION 03 81 10
	

CONCRETE REMOVAL
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 1[Concrete Removal: 

1.		 Payment: Lump sum price offered in the Price Schedule.] 

B.		 2[Core Drilling X-inch Holes in Existing Concrete: 

1.		 Measurement: Length of holes drilled in existing concrete. 

a.		 Holes drilled in concrete placed under this contract will not be included in 

measurement. 

2.		 Payment: Foot price offered in the Price Schedule. 

a.		 {Includes core drilling used to round corners after hydrodemolition}3] 

C.		 4[Saw Cutting Existing Concrete: 

1.		 Measurement: Length of saw cuts made for removal as shown on the drawings or 

directed by the COR. 

a.		 Saw cuts made in concrete place under this contract will not be included in 

measurement. 

2.		 Payment: Linear foot price offered in the Price Schedule. 

a. {Includes saw cutting to square edges after hydrodemolition}5

] 

D.		 6[Saw Cutting Existing Concrete: 

1.		 Measurement: Area of existing concrete saw cut for removal. 

1		 Include when concrete removal will be paid by lump sum price. 

2		 Include when core drilling of concrete required – for instance if rounded surfaces are required at corners. 

3		 Delete if hydrodemolition is not proposed. 

4		 Include when saw cutting will be paid for by the linear foot. Typical method of payment when full depth 

saw cutting is not required. Include similar language for edge grinding if that is permissible. Edge 

grinding is for special circumstances when shallow repairs are planned. The minimum depth for edge 

grinding is 1⁄4 inch. Consult with CGSL staff if edge grinding is anticipated. 

5		 Delete if hydrodemolition is not proposed. 

6		 Include when saw cutting will be made by the area of concrete cut. Can be used when full depth concrete 

cuts are required. Include similar language for edge grinding if that is permissible. Edge grinding is for 

special circumstanced when shallow repairs are planned. The minimum depth for edge grinding is 1⁄4 inch. 

Consult with CGSL staff if this is anticipated. 

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a.		 Saw cuts made in concrete place under this contract will not be included in 

measurement. 

2.		 Payment: Square foot price offered in the Price Schedule. 

a. {Includes saw cutting to square edges after hydrodemolition}7] 

E.		 8[Concrete Removal: 

1.		 Measurement: Volume of concrete removed. 

2.		 Payment: Cubic yard price offered in the Price Schedule.] 

F.		 [Concrete Removal, Hydrodemolition, 9

[_]-Inch Calibration Settings: 

1.		 Measurement: Area of concrete removed as shown on the drawings or as directed 

by COR. 

2.		 Payment: Square yard price offered in the Price Schedule.]10 

1.02		 11[DEFINTIONS 

A.		 Water jetting nose pressures for concrete removal and surface preparation: 

1.		 Low: Up to 5,000 psi. 

2.		 High: Between 5,000 and 20,000 psi. 

3.		 Ultra high: Between 20,000 and 40,000 psi.] 

1.03		 REFERENCE STANDARDS 

A.		 American Concrete Institute 

1.		 ACI 318-11 Code Requirements for Structural Concrete 

and Commentary 

B.		 Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

C.		 International Concrete Repair Institute (ICRI) 

7 Delete if hydrodemolition is not proposed.
	

8 Used in conjunction with saw cutting pay items.
	

9 Indicate desired depth of removal, i.e 6. This depth is also used to calibrate the equipment. If more than
	

one removal depth is anticipated, for example at joints, repeat this section for each depth. 

10		 Delete if hydrodemolition is not proposed. 

11		 Delete if hydrodemolition not used. 

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1.		 ICRI 310.2R-2013 Selecting and Specifying Concrete Surface 

Preparation for Sealers, Coatings, Polymer 

Overlays and Concrete Repair 

1.04		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 81 10-1, Concrete Removal Plan: 

1.		 Methods and equipment used to locate embedded metalwork and reinforcement 

within concrete to be removed. 

2.		 Methods, equipment, and sequence used for cutting and removing concrete. 

3.		 12[Hydrodemolition equipment, plans, methods, and sequence including handling 

and disposing of solid waste and wastewater from hydrodemolition and other 

waste resulting from concrete removal. 

a.		 Describe calibration plan for each pass, if multiple passes are required. 

b.		 If mechanical methods are proposed for use in small areas or to finish 

removal after hydrodemolition, describe equipment, plans, and methods.] 

4.		 Describe cleanup operations, equipment and equipment locations. 

5.		 Plans to prevent damage to remaining concrete. 

6.		 Temporary barriers and enclosures to protect building occupants and contain dust 

during work. 

C.		 13[RSN 03 81 10-2, Hydrodemolition Calibration Test Data. 

D.		 RSN 03 81 10-3, Changes to Removal Equipment Settings (if changes are made).] 

1.05		 EXISTING CONDITIONS 

A.		 Existing concrete consists of cement, sand, and broken rock or gravel. 

1.		 14[Maximum aggregate size: ___-inch. 

2.		 Design strength: _____ psi. Actual compressive strength of existing concrete 

may be significantly higher]. 

B.		 Information drawings provide general locations of embedded reinforcement, pipe, 

conduit, and metalwork. Actual locations may vary. 

12 Delete if hydrodemolition is not proposed.
	

13 Delete if hydrodemolition not used.
	

14 Insert maximum size aggregate and design compressive strength, if known, otherwise delete statements.
	

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PART 2 PRODUCTS 

Not Used 

PART 3 EXECUTION 

3.01		 GENERAL 

A.		 Cease operations and notify COR if concrete removal operations: 

1.		 Contact electrical conduit containing energized circuits. 

2.		 Crack concrete to remain in place. 

B.		 Do not resume operations until directed by COR. 

C.		 Coordinate performance of noisy, malodorous, or dusty work with the COR. 

D.		 Control waste water in accordance with: 

1.		 Approved plan. 

2.		 Section 01 57 30 - Water Pollution Control. 

3.02		 EXAMINATION 

A.		 Locate and mark embedded reinforcement, pipe, conduit and metalwork within concrete 

removal areas before beginning concrete removal. 

3.03		 15[PREPARATION 

A.		 Provide temporary barriers and enclosures to protect building occupants and equipment. 

B.		 Erect and maintain weatherproof closures for exterior openings. 

C.		 16[Abate paint containing heavy metals in accordance with Section 02 83 30 - Removal 

and Disposal of Coatings Containing Heavy Metals.] 

D.		 Location of concrete removal on drawings is approximate. Verify and adjust concrete 

removal areas with COR in the field. 

E.		 Prior to starting removal work, obtain written permission from COR. 

15		 Include preparation requirements that are appropriate for the job. Most jobs will not need all the 

preparation requirements listed. 

16		 Delete if paint with heavy metals not present. 

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3.04		 REMOVAL 

A.		 Remove concrete such that minimum repair thickness is 17___-inch. 

B.		 Initially remove damaged, deteriorated, loosened, or unbonded portions of existing 

concrete by high and ultra-high pressure water blasting, jetting, hydrodemolition, jack 

hammering, or other approved method. Follow with approved mechanical means if 

necessary. 

C.		 Produce rounded 1-inch radius corners. 

D.		 Produce surfaces and edges suitable for required construction. 

E.		 Use methods which will not damage concrete or reinforcement to remain in place. 

F.		 18[If damage to concrete is caused by intrusion of a contaminant, remove additional 

concrete until contaminant concentration is below acceptable threshold values.] 

G.		 Do not use jackhammers in excess of 30 pounds or, dry sandblasting, without COR 

approval. 

1.		 Points on jackhammer bits shall cleanly break the concrete. 

2.		 Replace or sharpen jackhammer bits without points. 

H.		 Do not line drill perimeters of large openings. 

I.		 Do not pry on concrete to be removed or existing reinforcement. 

J.		 Blasting not permitted. 

K.		 Do not use bush hammers or scabblers. 

L.		 19[Hydrodemolition: 

1.		 Calibration Test: 

a.		 20

___-inch Calibration 

1)		 COR will designate approximately 30 square foot representative 

area of damaged concrete for hydrodemolition equipment 

calibrations. 

17 Select minimum repair thickness according to repair materials requirements.
	

18 Use if chlorides or another contaminant is causing deterioration.
	

19 Delete if hydrodemolition is not proposed.
	

20 Specify depth. If more than one depth will be specified repeat section for each depth.
	

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2)		 Contractor shall calibrate hydrodemolition equipment to achieve 

removal of21 ___-inches of sound concrete, as measured from the 

original elevation. 

3)		 Record nozzle pressure, speed of travel, flow rates, application 

heights and other parameters required for each calibration. 

2.		 22[For repair areas at 23[{___-inch}{location}]. 

a.		 Use hydrodemolition equipment at the ___-inch calibration settings to 

remove concrete as shown on the drawings and as verified by the COR. 

b.		 Make one ___-inch pass in areas to minimum dimensions as shown on 

drawings.] 

3.		 Continually monitor hydrodemolition effectiveness. Make calibration 

adjustments as required. 

4.		 Remove deteriorated concrete in areas not accessible by hydrodemolition with 

other methods approved by COR. 

5.		 After hydrodemolition, wash concrete surfaces with 2,000 psi water to remove 

loose and fragmented concrete debris and other contaminants. Remove cuttings 

from prepared surfaces before drying.] 

M.		 24[Drilling: 

1.		 Drill cores at concrete removal corners as approved. 

2.		 Drill holes through concrete where indicated on drawings. 

3.		 Drill holes passing through concrete walls and floors with rotary diamond core 

bit. 

4.		 Make cut edges clean and sharp.] 

N.		 25[Saw cutting: 

1.		 26[Perform after: 

a.		 Hydrodemolition. 

b.		 Removal of concrete damage resulting from reinforcing steel corrosion.] 

21 Specify depth.
	

22 Repeat as necessary for more than one concrete removal depth.
	

23 Indicate concrete removal depth or area or both.
	

24 Use if drilling is allowed or required.
	

25 In special circumstances, edge grinding can be substituted for saw cutting. This is appropriate when repairs
	

will be thin. The minimum depth should be no less than 1/4 inch. Consult with Concrete, Geotechnical, 

and Structural Lab staff if this is anticipated. 

26		 Delete if hydrodemolition not proposed or damage is not from reinforcing steel corrosion. 

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2.		 Fully encompass removal area. 

3.		 Produce clean, sharp edges. 

4.		 Saw cut depth: 27[{Shown on drawings}{___-inches}{full depth of concrete}.] 

a.		 Do not damage reinforcing steel. 

b.		 If embedment or other conditions prevent a minimum 1-inch saw cut 

depth, use a grinder to create a minimum 1/4-inch perpendicular face. 

5.		 Limit number of corners. 

6.		 Acute angels: Greater than approximately 70 degrees. Do not produce sharp 

corners. 

7.		 Use diamond blade or diamond wire saws. 

8.		 Make cuts normal to exposed concrete surface except as indicated on drawings. 

9.		 Prevent kerfs from crossing. 

10.		 Do not extend saw kerfs beyond specified limits of removal. 

11.		 28[Chamfer permanently exposed cut 3/4-inch.] 

O.		 Reinforcement: 

1.		 [Replace reinforcing steel bar or section of bar that has lost more than 25 percent 

of its cross-sectional area. 

a.		 If adjacent bars are damaged, replace adjacent bars with 20 percent or 

more loss in cross sectional area. 

b.		 Replace bars to match original bar size to according to ACI 318, Section 

12.14 and 12.15 as appropriate or as approved by the COR.]29 

2.		 If epoxy coating on steel reinforcement is damaged, repair using a coating 

approved by the rebar manufacturer. Do not coat previously uncoated reinforcing 

steel. 

3.		 Remove concrete shadows around circumferences of reinforcing bars. 

4.		 When corroded reinforcement steel bars are exposed, remove additional concrete 

along corroded bars until a continuous length of 2-in of bar free from corrosion is 

exposed. 

a.		 Asses limit of active corrosion on a visual basis. 

b.		 Edges of additional areas removed shall be cut square as specified below. 

27 Select appropriate depth for saw cutting. Insert number of inches when that option selected.
	

28 Include when permanently exposed saw cut edges require chamfer.
	

29 Adjust acceptable losses based on design requirements.
	

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c.		 Remove additional concrete along bar to accommodate couplers or lap 

splices for replacement reinforcement. 

d.		 Obtain approval from COR prior to additional concrete removal. 

5.		 30[Where more than 1/3 of the diameter of a reinforcing bar is exposed by 

removal of concrete to required depth, remove additional concrete to minimum 

depth of ___ inches below the bar.] 

6.		 When removing concrete in and around reinforcing steel to remain in place, use 

15-pound or smaller chipping hammers, high or ultra-high pressure water jetting. 

a.		 For removal away from saw cut edges, cleanly break concrete with 

pointed jackhammer bits. Replace or sharpen jackhammer bits that are not 

pointed. 

b.		 Complete removal near repair boundaries with hammers fitted with spade 

bits. 

P.		 Cleaning and Surface Preparation: 

1. Primary Cleaning - Remove dust and debris resulting from concrete removal. 

a.		 Use contained shotblasting, wet sandblasting, or water blasting to remove 

weakened or damaged concrete microfractured surfaces. 

b.		 If water blasting, use pressure sufficiently high to prepare surface. 

Pressures up to 15,000 psi may be necessary. 

c.		 Remove materials that weaken the bond between remaining concrete and 

repair material. 

d.		 Include saw cut or ground faces. 

e.		 After primary cleaning, protect surface from contaminants. 

2.		 Secondary Cleaning - Within 48 hours prior to placement of repair material, use 

low pressure water jetting to remove materials that may impair bond. 

3.		 Concrete substrate surface roughness: Equivalent to or larger than CSP31[ ___] in 

accordance with ICRI 310.2R. 

4.		 Clean and allow surfaces to dry thoroughly, unless specific repair technique 

requires application of materials to a saturated surface. 

5.		 Do not use acids for cleaning or preparing concrete surfaces for repair. 

30		 Can be adjusted to “excavate around exposed reinforcing bars”. Consult with CGSL staff. 

31		 Select appropriate CSP number. 5 is typically used. Hydrodemolition will usually result in a much rougher 

surface. Choose CSP number 8 if shear transfer is needed. For shear refer to ACI 318, Section 11.6.9, 

(1/4-inch amplitude required). 

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3.05		 REPAIR 

A.		 Repair concrete and reinforcement outside of prescribed removal lines damaged or 

loosened during cutting and removal operations. Repair or replace: 

1.		 As directed by COR. 

2.		 In accordance with 32[{Section 03 01 36 - Concrete Repair}{Section 03 33 00 -

Cast-in-Place Concrete}]. 

3.06		 DISPOSAL 

A.		 Dispose of removed materials in accordance with Section 01 74 00 - Cleaning and Waste 

Management. 

END OF SECTION 

Select section, modify if necessary. 

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SECTION 03 81 14 

CONCRETE REPAIR 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: N/A 

Content Revisions: 

02/03/15 New Section 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

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SECTION 03 81 14
	

CONCRETE REPAIR
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 1[Concrete Preparation: 

1.		 Measurement: Area of concrete prepared. 

2.		 Payment: Price offered in the Price Schedule. 

B.		 Concrete Repair: 

1.		 Measurement: Volume of concrete replaced. 

2.		 Payment: Cubic foot price offered in the Price Schedule.] 

C.		 Cost: Costs for repair of concrete damaged by the Contractor's operations are the 

Contractor's responsibility. 

1.02		 2

[DEFINTIONS 

A.		 3

{Refer to Section 03 81 10 - Concrete Removal.} 

B.		 {Water jetting nose pressures for concrete removal and surface preparation: 

1.		 Low: Up to 5,000 psi. 

2.		 High: Between 5,000 and 20,000 psi. 

3.		 Ultra high: Between 20,000 and 40,000 psi.}] 

1.03		 4REFERENCE STANDARDS 

A.		 American Concrete Institute 

1.		 ACI 318-11 Building Code Requirements for Structural 

Concrete and Commentary 

2.		 ACI 364.3R-09 Guide for Cementitious Repair Material 

Data Sheet 

1		 Include if concrete repair is part of the project. Delete if repair is due to contractor mistakes while placing 

new concrete. 

2		 Delete if hydrodemolition not used. 

3		 Use A. if defined Section 03 81 10 - Concrete Removal. Use B and C if not defined in Section 03 81 10 -

Concrete Removal. 

4		 Adjust according to actual repair materials specified. 

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B. ASTM International (ASTM) 

1. ASTM C 33/C 33M-13 

2. ASTM C 109/C 109M-13 

3. ASTM C 157/C 157M-08(2014) 

4. ASTM C 171-07 

5. ASTM C 309-11 

6. ASTM C469/C469M-14 

7. ASTM C496/C496M-11 

8. ASTM C 666/C 666M-03(2008) 

9. ASTM C 881/C 881M-14 

10. ASTM C 882/C 882M-13a 

11. ASTM C 928/C 928M-13 

12. ASTM C 1315-11 

13. ASTM C 1581/C 1581M-09a 

14. ASTM C 1602/C 1602M-12 

Concrete Aggregates 

Compressive Strength of Hydraulic Cement 

Mortars (Using 2-in. or [50-mm] Cube 

Specimens) 

Length Change of Hardened HydraulicCement Mortar and Concrete 

Sheet Materials for Curing Concrete 

Liquid Membrane-Forming Compounds for 

Curing Concrete 

Static Modulus of Elasticity and Poisson’s 

Ratio of Concrete in Compression 

Splitting Tensile Strength of Cylindrical 

Concrete Specimens 

Resistance of Concrete to Rapid Freezing 

and Thawing 

Epoxy-Resin-Base Bonding Systems for 

Concrete 

Bond Strength of Epoxy-Resin Systems 

Used With Concrete By Slant Shear 

Packaged, Dry, Rapid-Hardening 

Cementitious Materials for Concrete Repairs 

Liquid Membrane-Forming Compounds 

Having Special Properties for Curing and 

Sealing Concrete 

Determining Age at Cracking and Induced 

Tensile Stress Characteristics of Mortar and 

Concrete under Restrained Shrinkage 

Mixing Water Used in the Production of 

Hydraulic Cement Concrete 

C. Army Corps of Engineers, Concrete Research Division (CRD) 

1.		 CRD C 39-81 Test Method for Coefficient of Linear 

Thermal Expansion of Concrete 

2.		 CRD C 164-92 Direct Tensile Strength of Cylindrical 

Concrete or Mortar Specimens 

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D.		 International Concrete Repair Institute (ICRI) 

1.		 ICRI 320.3R-2012 Guide for Inorganic Repair Material Data 

Sheet Protocol 

E.		 Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

1.04		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 81 14-1, Concrete Preparation Plan: 

1.		 Methods, equipment, and sequence used to cut and remove concrete and prepare 

the surface for repair. Include: 

a.		 Methods and equipment used to locate embedded reinforcement within 

concrete to be removed. 

b.		 Temporary barriers and enclosures to be provided for workers and 

containing dust during work. 

C.		 RSN 03 81 14-2, Approval Data: 

1.		 For packaged repair materials 

a.		 Manufacturer’s material data sheets for repair material in accordance with 

data sheet protocol for testing and reporting of data in ACI 364.3R and 

ICRI 320.3R including surface preparation, mixing, application, and 

curing instructions. 

b.		 Manufacturer’s certification that materials comply with specified 

requirements and is suitable for intended application. 

2.		 For concrete, supply approval data according to Section 03 30 00 Cast in Place 

Concrete. Include mixing, transporting, application, and curing plan. 

3.		 Method(s) used to place repair material. 

D.		 RSN 03 81 14-3 Applicator’s References and Qualifications: 

1.		 Include project names and locations, name of engineer/architect, and type and 

quantity of repair material applied. 

E.		 RSN 03 81 14-4, Placement Plan: 

1.		 Describe method(s) to be used to place repair material. 

a. Type and placement of formwork and sequence of installation. 

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b.		 Show location of chimney(s) to place concrete for repairs to holes. 

Method(s) for removing material in chimneys after formwork is removed. 

1.05		 QUALIFICATIONS 

A.		 Employ persons trained for application of repair materials. Minimum of 3 similar repair 

projects within past 5 years. 

1.06		 DELIVERY, STORAGE, AND HANDLING 

A.		 In accordance with manufacturer’s instructions. 

B.		 Keep materials in manufacturer’s original, weatherproof, unopened containers and 

packaging until installation. Clearly label with product name and manufacturer. 

C.		 Store materials in clean, dry conditions. 

D.		 Protect materials to prevent contamination or damage. 

E.		 5[For site mixed or ready mixed concrete, meet requirements for Section 03 30 00 - Castin-Place Concrete.] 

1.07		 EXISTING CONDITIONS 

A.		 6{Refer to Section 03 81 10 - Concrete Removal.} 

B.		 {Existing concrete consists of cement, sand, and broken rock or gravel. 

1.		 7[Maximum aggregate size: ___-inch. 

2.		 Design strength: _____ psi. Actual compressive strength of existing concrete 

may be significantly higher]. 

C.		 Information drawings provide general locations of embedded reinforcement, pipe, 

conduit, and metalwork. Actual locations may vary.} 

1.08		 AMBIENT CONDITIONS 

A.		 Ambient and Surface Temperatures: 8

[__ to __] degrees F at time of application. 

B.		 Exterior Applications: If rain, snow, or excessive moisture is expected during application 

or within 24 hours after application, protect repairs from freezing and moisture. 

5 Delete in not using Section 03 30 00 - Cast-in-Place Concrete.
	

6 Use A. if defined Section 03 81 10 - Concrete Removal. Use B and C if not defined in Section 03 81 10 -

Concrete Removal. 

7 Insert maximum size aggregate and design compressive strength, if known, otherwise delete statements. 

8 Insert if known, otherwise indicate unknown. 

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PART 2 PRODUCTS 

2.01		 NEW CONCRETE REPAIR MATERIALS 

A.		 Concrete Age: Between 24 and 72 hours. 

B.		 Packaged Repair Material. 

1.		 Depth: Between 1/4-inch and the bottom of the nearest reinforcing steel. 

2.		 Too small for concrete. 

3.		 Suitable for repair thickness. 

4.		 9

[__], or equal with the following10 essential characteristics 

a.		 Formulated for low shrinkage. 

b.		 Durable in exposure conditions. 

c.		 Compressive Strength, ASTM C109, 73 degrees Fahrenheit: 

1) 1 Day: Minimum 1,000 psi. 

2) 7 Days: Minimum 3,000 psi. 

3) 28 Days: Minimum 5,000 psi. 

d.		 28 Day Drying Shrinkage, ASTM C157: Less than 0.050 percent. 

e.		 Static Modulus of Elasticity, ASTM C469, 28 Days: 3.0 to 3.5 x 106

 psi. 

f.		 Coefficient of Thermal Expansion, CRD C 39: 7.5 to 8.5 x 10-6 

in/in/degree F. 

g.		 Freezing and Thawing Resistance, ASTM C666, Procedure A: Average 

Durability Factor, 300 Cycles, greater than 90. 

h.		 Average age at cracking, ASTM C1581: Greater than 60 days. 

i.		 Direct Tensile Strength, CRD C 164, 2-inch by 4-inch specimens, Average 

Tensile Strength: 

1) 7 Days: Minimum 300 psi. 

2) 28 Days: Minimum 400 psi. 

j.		 Bond Strength, ASTM C882, Modified per ASTM C928, 3-inch by 6-inch 

slant-shear specimens, Average Slant-Shear Bond Strength: 

1) 7 Days: Minimum 1,000 psi. 

2) 28 Days: Minimum 2,000 psi. 

9		 List name and manufacturer for repair materials. Repeat for each repair material option. Consult with 

CGSL for recommendations 

10		 Consult with CGSL to select characteristics 

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k. Mix components in accordance with manufacturer’s instructions. 

C.		 Portland Cement Mortar 

1.		 Depth: No deeper than the bottom of the nearest reinforcing steel. 

2.		 Less than about 6-inches across. 

3.		 Too small for concrete. 

4.		 Portland cement: As specified in Section 03 30 00 – Cast-In-Place Concrete. 

5.		 Sand: ASTM C33 fine aggregate, except 100 percent passing No. 16 sieve. 

6.		 Clean water: ASTM C1602 including optional requirements of Table 2. 

7.		 Consistency - 1 part cement; 2 parts, by volume, of sand; and enough water so 

that mortar has consistency of thick cream. 

D.		 Dry Pack Mortar 

1.		 For repairs deeper than opening (holes). 

2.		 Minimum depth – one inch. 

3.		 Depth equal to or greater than width. 

4.		 Does not extend through section 

5.		 Does not extend behind or under reinforcing steel. 

6.		 Less than 1 square foot in surface area. 

7.		 Portland cement: As specified in Section 03 30 00 – Cast-In-Place Concrete. 

8.		 Sand: ASTM C33 fine aggregate, except 100 percent passing No. 16 sieve. 

9.		 Clean water: ASTM C1602 including optional requirements of Table 2. 

10.		 Consistency - 1 part cement to 2.5 parts sand with sufficient water so that the 

mortar will stick together when squeezed by hand but not exude water. 

11.		 [

11{Bond Coat: 1 part cement to 1 parts and mixed with sufficient water to create 

a fluid paste} {Epoxy bond coat: ASTM C881 type II, grade 2, [class B] [C 

resin]}]. 

2.02		 OLD CONCRETE REPAIR MATERIALS 

A.		 Concrete Age: Greater than 72 hours. 

B.		 12[Packaged Repair Material. 

1.		 Used on both new and old concrete. 

11 Select type of bond coat if needed. Consult with Part 1 of M47 and CGSL staff. 

12 Use this paragraph if Packaged Repair Material used. 

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2. Refer to Packaged Repair Material in New Concrete Repair Materials above.] 

C.		 13[{Concrete meeting the requirements of Section 03 30 00 - Cast- in-Place Concrete} 

{Silica fume concrete meeting the requirements of Section 03 30 00 - Cast- in-Place 

Concrete } {Shotcrete meeting the requirements of Section 03 37 02 - Shotcrete} 

proportioned to be shrinkage compensating with: 

1.		 PREVent C, as manufactured by Premier Magnesia, www.premiercpg.com, or 

equal with the following essential characteristics: 

a.		 Facilitate expansion of concrete at essentially the same rate as shrinkage 

during the curing period. 

b.		 Reduce the capillary surface tension of pore water. 

c.		 Provides at least 60 percent shrinkage reduction. 

d.		 Formulated for use in freezing weather. 

e.		 ASTM C1581: No cracking for a minimum of 90 days.] 

D.		 Dry Pack Mortar: 

1.		 Used on both new and old concrete. 

2.		 Refer to Dry Pack Mortar in New Concrete Repair Materials above. 

2.03		 CURING MATERIALS 

A.		 14{Refer to Section 03 30 00 - Cast-in-Place Concrete} 

B.		 {Water: ASTM C1602, including optional requirements of Table 2. 

C.		 Curing compound: 

1.		 ASTM C309, type 1-D. 

2.		 ASTM C1315, type I-A 

D.		 Polyethylene film: ASTM C171, white opaque.} 

PART 3 EXECUTION 

3.01		 GENERAL 

A.		 Cease operations and notify COR if concrete repair operations: 

13		 Use this paragraph if concrete, shotcrete, silica fume concrete or other special concrete will be used for 

repair. 

14		 Delete A if Section 03 30 00 - Cast-in-Place is not included in the project. Delete B, C and D if Section 03 

30 00 - Cast-in-Place Concrete is included with project. 

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1.		 Contact electrical conduit containing energized circuits. 

2.		 Crack concrete to remain in place. 

3.		 Do not resume operations until directed by COR. 

B.		 Coordinate performance of noisy, malodorous, or dusty work with the COR. 

C.		 Prior to starting removal work, obtain written permission from COR. 

D.		 Do not place repair material until approved by COR. 

E.		 Remove repair material outside of repair area. 

F.		 Clean so repair material is flush with the surface. 

G.		 Repair concrete and reinforcement outside of prescribed removal lines damaged or 

loosened during cutting and removal operations. Repair or replace as directed by COR. 

3.02		 NEW CONCRETE REPAIR 

A.		 Grinding 

1.		 To correct surface bulges, offsets, and other irregularities. 

2.		 Concrete surfaces subjected to potential cavitation erosion – Limit grinding depth 

so that no more than 1/4-inch cross-section of aggregate particle is exposed. 

3.		 Concrete surfaces exposed to public view - Limit grinding depth so that no more 

than 1/2-inch cross-section of aggregate particle is exposed. 

4.		 Limit grinding depth so that no more than 1⁄2 the diameter of the largest aggregate 

particle is exposed. 

5.		 If limits cannot be met, remove and replace concrete. 

B.		 Preparation 

1.		 Remove abrupt protrusions (i.e. form fins) flush with the concrete surface. 

2.		 Remove surface contaminants such as latencies by pressure washing, or by other 

methods as approved by the COR. Adjust pressure to remove contaminants and 

limit concrete excavation, unless excavation is required. 

3.		 Do not interrupt curing of adjacent concrete. Keep concrete surfaces moist until 

repairs are completed. 

C.		 Portland Cement Mortar 

1.		 Moisten surface and place mortar on damp surface. 

2.		 For small repairs, use sponge rubber float to fill surface defects with mortar. 

3.		 For larger repairs, spray apply mortar. 

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4.		 If repairs are more than 1 inch deep, apply mortar in layers not more than 3/4 of 

an inch thick. Allow sufficient time between layers so material does not sag. 

5.		 Rub dry mix of same proportions to stiffen and solidify plastic material. 

6.		 Curing 

a.		 Immediately after placement, bring concrete surface and surface of repair 

material to saturated surface dry (SSD) by misting. 

b.		 Maintain moist curing for 14 days 

c.		 Apply curing compound immediately after surface appears dry. Use 

curing similar to adjacent concrete. 

D.		 Packaged Repair Material 

1.		 Bring surface and surrounding area to 15[_]. 

2.		 For small repairs, use sponge rubber float to fill surface defects with mortar. 

3.		 For larger repairs, spray apply mortar. 

4.		 Follow manufacturer’s curing requirements. 

E.		 Dry Pack Mortar 

1.		 Roughen surfaces using grinding wheel, grinding bit or other approved tools. Do 

not use metal. 

2.		 Remove unconsolidated concrete, latencies, and other contaminants from hole 

3.		 Remove abrupt protrusions (i.e. form fins) flush with the concrete surface. 

4.		 16[{Thoroughly moisten surface using damp rags placed in holes for a minimum 

24 hours.} {Coat interior of the hole with a mortar bond coat consisting of 1 part 

cement to 1 part sand and sufficient water to produce a fluid past.} {Apply epoxy 

bond coat to interior surfaces of hole.}] 

5.		 17[{Immediately after removing rags, blow oil-free compressed air into the hole to 

dry the surfaces.} {Immediately after applying bond coat pack the hole with dry 

pack mortar.} 

6.		 Pack in hole in lifts small enough to compact using a hardwood dowel and 

hammer. Lifts should be no more than 2-inches for large diameter holes, and may 

be as small as 3/8 inch for small diameter holes. 

7.		 Pack the top by laying the flat side of a hardwood board against the fill and 

striking the board with a hammer. 

15		 List required moisture content of surface. For cementitious repair materials, that is usually SSD. Other 

special repair materials may require different moisture conditions. 

16		 Consult CGSL and M-47. 

17		 Consult CGSL and M-47. 

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8.		 Thoroughly rub mortar over area with a sponge rubber float or steel trowel to 

finish surface. 

9.		 Curing 

a.		 Immediately after placement of material, bring concrete surface and 

surface of repair material to SSD by misting. 

b.		 Once surface appears damp, discontinue misting and apply curing 

compound immediately after surface appears to dry. 

3.03		 OLD CONCRETE REPAIR 

A.		 Shallow Repairs 

1.		 For defects where less than 1/3 circumference of reinforcing steel. 

2.		 Where needed, shape repair area to prevent trapping air in placement. 

3.		 Use materials suitable for thickness of repair and as approved. 

4.		 Contain materials with formwork as needed. 

5.		 For stiff repair materials, thoroughly pack material into void and rub over area 

with a sponge rubber float or steel trowel to fill defects. 

B.		 Remove and prepare concrete in accordance with Section 03 -81 10 - Concrete Removal. 

C.		 Bring concrete to 18[_] moisture condition before placement of repair material. Ensure 

surface moisture conditions meet repair material requirements. 

D.		 Apply repair materials. 

1.		 Remove standing water. 

2.		 Mix components as approved. 

3.		 At locations indicated on drawings, or as directed by COR. 

4.		 Follow approved application instructions: 

5.		 For vertical and overhead repair (stiff) material, apply repair material with 

sufficient pressure to ensure intimate contact with substrate. 

6.		 For horizontal repair materials or repair materials contained by formwork, use 

placement methods to ensure intimate contact of repair material with substrate. 

Remove forms when repair mortar has reached sufficient strength so it is not 

damaged by form removal. 

For cementitious repair materials, use saturated-surface-dry (SSD). Presoak prepared concrete surface to 

SSD condition and surface dry immediately. Other repair materials may require different moisture 

conditions. 

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E.		 Curing: 19[{Follow manufacturer’s instructions} {According to Section 03 30 00 Cast in 

Place Concrete} {Curing Compound: Apply curing compound in accordance with 

product instructions.} {Moist Curing: 

1.		 Moist cure for [_] days, depending on drying conditions. 

2.		 Include time in form. 

3.		 Moist cure for [_] days in hot, dry, or windy conditions.}] 

3.04		 PROTECTION 

A.		 Protect from direct sunlight, wind, and other conditions that could cause rapid drying. 

B.		 Protect from damage or deterioration during project. 

3.05		 REINFORCING STEEL 

A.		 20[Replace any single reinforcing steel bar or section of bar that has lost more than 25 

percent of its cross-sectional area. 

1.		 If adjacent bars are damaged, replace adjacent bars with 20 percent or more loss 

in cross sectional area. 

2.		 Replace bars to match original bar size according to ACI 318, section 12.14 and 

12.15 as appropriate, or as approved by the COR.] 

B.		 If epoxy coating on epoxy coated steel reinforcement is damaged, repair damaged coating 

using an epoxy coating approved by the rebar manufacturer. Do not coat previously 

uncoated reinforcing steel. 

3.06		 FORMING 

A.		 21[Use formwork to protect, prevent movement and leakage of repair material. Construct 

formwork in accordance with Section 03 11 10 - Concrete Forming for specified finish. 

1.		 Repairs to holes: 

a.		 Construct formwork in sections to allow for concrete lift placement. 

Maximum placement height – 22[_ inches] 

b.		 Use form chimneys to allow for concrete consolidation and observe 

placement. 

1)		 Multiple chimneys may be needed. 

19 Select the appropriate curing method.
	

20 As appropriate, adjust acceptable losses based on design requirements.
	

21 For formwork to repair holes in wall and other vertical or nearly vertical surfaces, refer to Chapter 4 of Part
	

1 of the Guide and CGSL staff for guidance. 

22 Select maximum lift height. Refer to Chapter 4 of Part 1 of this Guide and CGSL staff for guidance 

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2)		 After form removal, remove chimney concrete and smooth to 

match adjacent surfaces. Depending on repair material, chimney 

concrete can be removed about 24 hours after placement.] 

3.07		 FINISHING 

A.		 Tooled Edges: Tool exposed edges to a radius of 1⁄4 inch. 

B.		 Where finishes are not specified or shown on drawings for a particular surface, finish 

concrete as specified for similar work. 

C.		 Finish concrete in presence of COR unless inspection is waived. 

D.		 23{Formed surfaces: 

1.		 Finish F2: 

a.		 Applies to exposed formed surfaces as specified in Table 03 81 14A -

Formed Surfaces. 

b.		 Recess tie rod ends and fill recess with dry pack or other material 

approved by COR. 

E.		 Unformed surfaces: 

1.		 Finish class is designated by symbol U1. 

2.		 Finish U1 (Screeded Finish): 

a.		 Applies to unformed surfaces as specified in Table 03 81 14B - Unformed 

Surfaces. 

b.		 Level and screed concrete to produce even uniform surfaces.} 

F.		 {Refer to Section 03 30 00 - Cast-in-Place Concrete.} 

3.08		 24FINISH, SURFACE TOLERANCES, AND CURING SCHEDULES 

A.		 {Meet requirements of Section 03 30 00 - Cast-in-Place Concrete for surface tolerances.} 

23		 Select the appropriate finish and tolerance. The listed items are for example only. Different work may 

require different finished and different tolerances. If specification has Section 03 30 00 - Cast-in-Place 

delete D and E. If specification doesn’t have Section 03 30 00 - Cast-in-Place use D and E, modified for 

project. 

24		 Delete Table if specifications have Section 03 30 00- Cast-in-Place Concrete. If specifications do not have 

Section 03 30 00 - Cast-in-Place section, update table with required finishes and tolerances. 

Concrete Repair 

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Table 03 81 14A - Formed Surfaces 

Surface Finish Maximum 

Allowable 

Tolerances 

Acceptable Curing 

Methods 

All repair surfaces F2 T3 Water 

White wax-base, or white 

water-emulsified resinbase curing compound 

Table 03 81 14B - Unformed Surfaces
	

Surface Finish Maximum 

Allowable 

Tolerances 

Acceptable Curing 

Methods 

All repair surfaces U1 T3 Water 

White wax-base or white 

water-emulsified resinbase curing compound 

3.09		 DISPOSAL 

A.		 Dispose of removed materials in accordance with Section 01 74 00 - Cleaning and Waste 

Management. 

END OF SECTION 

Concrete Repair 

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SECTION 03 81 15 

POLYMER CONCRETE SURFACE REPAIR 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 6/16/15 

Content Revisions: 

05/04/15 New Section 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Refer to Part 1 of the Guide to Concrete Repair to determine if the repair method detailed in 

this specification is appropriate for the damaged concrete. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

Polymer Concrete Surface Repair 

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SECTION 03 81 15
	

POLYMER CONCRETE SURFACE REPAIR 

PART 1 GENERAL 

1.01 MEASUREMENT AND PAYMENT 

A. Concrete Surface Repair: 

1. Measurement: Surface area of repair as directed by COR. 

2. Payment: Square foot price offered in the Price Schedule. 

1.02 1

[REFERENCE STANDARDS 

A. ASTM International (ASTM) 

1.		 ASTM C307-03(2012) Tensile Strength of Chemical Resistant 

Mortar, Grouts, and Monolithic Surfacings 

2. ASTM D570-98(2010)		 Water Absorption of Plastics 

3.		 ASTM C579-01(2012) Compressive Strength of ChemicalResistant Mortars, Grouts, Monolithic 

Surfacings, and Polymer Concrete 

4.		 ASTM C881/C881M-14 Epoxy-Resin-Base Bonding Systems for 

Concrete 

5. ASTM D638-14 Tensile Properties of Plastics 

6. ASTM D695-10 Compressive Properties of Rigid Plastics 

7.		 ASTM D4541-09 Pull-Off Strength Using Portable Adhesion 

Testers 

B. International Concrete Repair Institute (ICRI) 

1.		 ICRI 210.3R-2013 Guide for Using In-Situ Tensile Pulloff 

Tests to Evaluate Bond of Concrete Surface 

Materials 

2.		 ICRI 310.2R-2014 Selecting and Specifying Concrete Surface 

Preparation for Sealers, Coatings, Polymer 

Overlays and Concrete Repair 

1.03 SUBMITTALS 

A. Submit the following in accordance with Section 01 33 00 - Submittals. 

1 Adjust references for specific polymer selected. 

Polymer Concrete Surface Repair 

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B.		 RSN 03 81 15-1, Approval data: 

1.		 Product Data: 

a.		 Manufacturer's technical data including recommendations for application 

and use. 

b.		 Test reports and certifications substantiating products comply with 

requirements. 

2.		 Describe methods, equipment, and sequence to be used for placing repair mortar. 

3.		 Certification of installer, if required by repair mortar manufacturer. 

4.		 Concrete surface preparation method. 

1.04		 PROJECT CONDITIONS 

A.		 Information drawings provide general locations of embedded reinforcement, pipe, 

conduit, and metalwork. Actual locations of these items may vary from what is shown on 

the drawings. 

B.		 Coordinate performance of noisy or dusty work with the COR. 

1.05		 AMBIENT CONDITIONS 

A.		 Ambient and Surface Temperatures: 2

[__ to __] degrees F at time of application. 

B.		 Exterior Applications: Do not apply repair mortar when rain, snow, or excessive 

moisture is expected during application or within 24 hours after application without 

protection. 

PART 2 PRODUCTS 

2.01		 REPAIR MORTAR 

A.		 Repair mortar: 3

[_] or equal with the following essential characteristics: 

1.		 100 percent solids. 

2.		 Low odor. 

3.		 Trowelable to a smooth finish. 

4.		 4[ASTM C881 Type III, Grade 3, Class B, D, or E as appropriate: 

a.		 Suitable for application to damp or wet concrete. 

2 Insert if known, otherwise indicate unknown.
	

3 List suitable products here. Consult with CGSL staff for recommendations.
	

4 List appropriate characteristics here. Values shown are for example only. Consult with CGSL staff for
	

recommendations. 

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b.		 3 component. 

c.		 Compressive Strength:
	

1) ASTM D695: 6170 psi
	

2) ASTM C579: Maximum 6200 psi
	

d.		 Adhesion:
	

1) ASTM D4541: 600 psi
	

2) ICRI 210.3R: 300 psi
	

B.		 Tensile Strength, ASTM C307: 1810 psi 

1.		 Tensile Elongation, unfilled, ASTM D638: 10 percent 

2.		 Volatile Organic Compounds: 0 grams/liter. 

3.		 Absorption, ASTM D570: 0.3 percent.] 

PART 3 EXECUTION 

3.01		 REPAIRS 

A.		 Repair concrete surfaces of 5

[_] 

3.02		 PREPARATION 

A.		 Prepare concrete according to 03 81 10-Concrete Removal. 

B.		 Prior to preparing surface, obtain written permission from COR. 

C.		 Wet sandblast, steel shotblast, or water jet surfaces, or other method approved by COR to 

create a surface profile equivalent to or larger than CSP [_]6 in accordance with ICRI 

310.2R. 

D.		 Concrete surface: Minimum 100 psi when tested in accordance with ICRI 210.3R. 

E.		 Clean and allow surfaces to dry thoroughly, unless specific repair technique requires 

application of materials to a saturated surface. 

F.		 Do not use of acids for cleaning or preparing concrete surfaces. 

5		 List concrete surfaces to be repaired. 

6		 Select appropriate CSP number. 5 is typically used. Hydrodemolition will usually result in a much rougher 

surface. 

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3.03		 INSTALLATION 

A.		 Follow manufacturer’s instructions and requirements for: 

1.		 Priming, mixing, placing and curing repair mortar. 

2.		 Surface temperature. 

3.		 Conditioning temperature of polymer compound components. 

B.		 Completely cover exposed aggregate and match existing surfaces. 

C.		 For thick repair areas place repair mortar in lifts or layers to limit heat generation during 

curing. 

D.		 Finished surface: Smooth within 7

[1/16] inch. 

3.04		 PROTECTION 

A.		 Protect repair from weather and other damaging conditions. 

B.		 8

Repair concrete and reinforcement outside of prescribed removal lines damaged or 

loosened during cutting and removal operations. Repair or replace as directed by COR. 

END OF SECTION 

7		 Select maximum depth or height of offsets. 

8		 Coordinate with Section 03 81 10 - Concrete Removal. Delete this paragraph in this Section if same 

paragraph is used Section 03 81 10 - Concrete Removal. 

Polymer Concrete Surface Repair 

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SECTION 03 81 16 

EPOXY GROUT CRACK REPAIR 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 07/25/15 

Content Revisions: 

07/25/15 New Section 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Refer to Part 1 of the Guide to Concrete Repair to determine if the repair method detailed in 

this specification is appropriate for the damaged concrete. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

Epoxy Grout Crack Repair 

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SECTION 03 81 16
	

EPOXY GROUT CRACK REPAIR
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 Prepare Cracks: 

1.		 Measurement: Length of prepared cracks. 

2.		 Payment: Applicable lineal foot offered in Price Schedule. 

B.		 Inject Cracks: 

1.		 Measurement: Length of injected cracks. 

2.		 Payment: Applicable lineal foot offered in Price Schedule. 

1.02		 REFERENCE STANDARDS 

A.		 ASTM International (ASTM) 

1.		 ASTM C 881/C 881M-14 Epoxy-Resin-Base Bonding Systems for 

Concrete 

B.		 Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

1.03		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 81 16-1, Epoxy Grout: 

1.		 Epoxy Grout Plan: Include work sequence, ports and/or packers to inject grout 

into cracks, method of drilling holes if using mechanical packers, grout 

equipment, crack capping compound, and disposal of debris. 

2.		 Manufacturer’s product data. 

3.		 Manufacturer’s Certification: Epoxy grout and capping compound meets 

specified requirements. 

4.		 Manufacturer’s Instructions: Environmental, storage, surface preparation, 

mixing, installation, and cleanup instructions. 

C.		 RSN 03 81 16-2, Qualifications. 

Epoxy Grout Crack Repair 

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1.		 Include project names and locations, type and quantity of grout applied, engineer 

or architect name, name of person applying grout. 

1.04		 QUALIFICATIONS 

A.		 Applicator : 

1.		 Minimum of 3 successfully completed epoxy grouting projects in the past 5 years. 

2.		 Trained for application of epoxy grout. 

B.		 Grout Manufacture’s Representative: 5 years of experience with manufacturer’s product 

used in similar applications. 

1.05		 DELIVERY, STORAGE, AND HANDLING 

A.		 Deliver materials to jobsite in manufacturer’s original unopened packaging with labels 

and seals intact. 

B.		 Store materials in accordance with manufacturer’s instructions. 

C.		 Store joint sealant at temperatures between 40 degrees Fahrenheit and 80 degrees 

Fahrenheit or per manufacturer’s instructions, whichever is more stringent. 

1.06		 ENVIRONMENTAL REQUIREMENTS 

A.		 Install materials within temperature limits specified by materials manufacturer. 

B.		 Maintain temperatures limits during curing as specified by materials manufacturer. 

C.		 Comply with material manufacturer’s environmental restrictions. 

1.07		 PROJECT CONDITIONS 

A.		 Concrete to be removed consists of cement, sand, and broken rock or gravel. 

1.		 Maximum aggregate size: ______-inch. 

2.		 Design compressive strength: _______ lb/in2 at 28 days. 

3.		 Actual compressive strength may be substantially higher or lower than the design 

compressive strength. 

B.		 Information drawings provide general locations of embedded reinforcement, pipe, 

conduit, and metalwork. Actual locations of these items may vary from what is shown on 

the drawings. 

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1.08		 AMBIENT CONDITIONS 

A.		 Exterior Applications: Do not apply repair mortar when rain, snow, or excessive 

moisture is expected during application or within 24 hours after application without 

protection. 

PART 2 PRODUCTS 

2.01		 EPOXY 

A.		 Injection epoxy: 1[_. 

1.		 ASTM C881. 

2.		 Viscosity: ___. 

3.		 Gel time: ____. 

4.		 Compressive Strength: ____. 

5.		 Tensile Strength: ____] 

B.		 Capping epoxy: As recommended by injection epoxy manufacturer 

2.02		 ACCESSORIES 

A.		 Ports and Packers – As recommended by epoxy grout manufacturer 

PART 3 EXECUTION 

3.01		 GENERAL 

A.		 Cease operations and notify COR if concrete repair operations: 

1.		 Contact electrical conduit containing energized circuits. 

2.		 Crack concrete to remain in place. 

3.		 Do not resume operations until directed by COR. 

B.		 Coordinate performance of noisy or dusty work with the COR. 

3.02		 PREPARATION 

A.		 Remove dirt and debris from within cracks prior to injection. If using water, dry as 

recommended by the grout manufacturer. 

B.		 Install grout ports: 

1	 List appropriate products and properties. 

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1.		 As recommended by grout manufacturer. 

2.		 On surface of crack or in injection holes as approved by COR. 

C.		 Seal crack openings as recommended by grout manufacturer. 

1.		 Prepare surfaces adjacent to cracks to expose clean, sound concrete. Remove 

mortar, laitance, dust, coatings, curing compounds, petroleum products, corrosion, 

and other foreign material 

2.		 Capture concrete debris. 

D.		 Repair concrete outside of prescribed injection area which is damaged or loosened during 

repair operations. Repair in accordance with USBR M-47 as approved by COR. 

E.		 Obtain approval of crack preparation from COR before installing epoxy in cracks. 

3.03		 EPOXY GROUTING 

A.		 Completely fill cracks. 

B.		 Multiple port injection allowed if approved by grout manufacturer. 

C.		 Start injection at lower ports. 

1.		 Attach injection lines to lowest injection port and proceed upward. 

2.		 When grout is visible at elevation of next higher port, close or cap injection port 

attached to injection lines. 

3.		 Proceed to next higher injection ports. 

D.		 Keep ports capped or closed and in-place until grout is cured. 

E.		 Pump: 

1.		 Motor driven grout pump, not hand operated, made to pump epoxy grout: 

2.		 Suitable for injecting approved grout at correct proportion. 

3.		 Output: At least 0.4 gpm. 

4.		 Output Pressure: 

a.		 Appropriate for grout plan and crack size. 

b.		 Pressures as high as 1,000 psi depending on crack characteristics. 

5.		 Record grout pressures at ports. 

F.		 Notify COR if quantity of injected grout is larger than expected. 

3.04		 FIELD QUALITY CONTROL 

A.		 At job startup, onsite grout manufacturer’s representative to approve:: : 

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1.		 Equipment and methods used for crack preparation, grout mixing, and grout 

installation before work begins. 

2.		 Crack preparation. 

3.		 Grout installation. 

3.05		 CLEANING 

A.		 Remove ports, capping epoxy, and soiling from adjacent surfaces. 

3.06		 DISPOSAL 

A.		 Dispose of removed materials in accordance with Section 01 74 00 - Cleaning and Waste 

Management. 

END OF SECTION 

Epoxy Grout Crack Repair 

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SECTION 03 81 17 

CHEMICAL GROUT CRACK REPAIR 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 06/25/15 

Content Revisions: 

05/19/15 New Section 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Refer to Part 1 of the Guide to Concrete Repair to determine if the repair method detailed in 

this specification is appropriate for the damaged concrete. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 
 

 

 

 

 

 


 


 


	


	

		

	 

	 

	 

	 

	 

	 

	 

		

	 

	 

		

	 

	 

	 

	 

	 

	 

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SECTION 03 81 17
	

CHEMICAL GROUT CRACK REPAIR
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.	 Holes: 

1.	 Measurement: Number of holes drilled and grouted. 

2.	 Payment: Hole price offered in the Price Schedule. 

a.	 Includes drilling hole, installing port, connection for injecting grout, and 

plugging hole after grouting. 

B.	 Chemical grout: 

1.	 Payment: Lump sum price offered in the Price Schedule. 

a.	 Price to include chemical grout material, dry oakum jute, curing, cleaning, 

any additives, and grouting. 

1.02		 1

[REFERENCE STANDARDS 

A.	 Bureau of Reclamation (USBR) 

1.	 USBR M-47 Standard Specifications for Repair of 

Concrete, August 2015 (Part 2, Appendix 1 

of “Guide to Concrete Repair” available at 

http://www.usbr.gov/ (insert URL _______) 

1.03		 SUBMITTALS 

A.	 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.	 RSN 03 81 17-1, Chemical Grout: 

a.	 Manufacturer’s product data for grout material and dry oakum jute. 

b.	 Manufacturer’s certification that grout is suitable for intended service 

conditions and exposure. 

c.	 Manufacturer’s environmental, storage, preparation, mixing, installation, 

and cleanup instructions for grout material. 

d.	 Grout plans to include method of drilling holes, equipment, ports and/or 

packers to inject grout into cracks and voids. 

Adjust according to actual chemical grout specified. 1
 

 

 

 

 

 

 


 


 

	 

	 

		

	 

		

	 

	 

	 

		

	 

	 

	 

	 

		

	 

		

	 

	 

		

	 

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C.	 RSN 03 81 17-2, Qualifications: 

a.	 Include project names and locations of past similar work, name of 

engineer/architect, and type and quantity of chemical grout applied. 

1.04		 QUALIFICATIONS 

A.	 3 similar projects within the past 5 years. 

1.05		 DELIVERY, STORAGE, AND HANDLING 

A.	 Deliver materials to jobsite in manufacturer’s original unopened packaging with labels 

and seals intact. 

B.	 Store materials in protected area in accordance with manufacturer’s instructions. 

C.	 Store sufficient quantities of components onsite to not delay grouting operations. 

1.06		 EXISTING CONDITIONS 

A.	 Existing concrete consists of cement, sand, and broken rock or gravel. 

1.	 2 [Maximum aggregate size: ___-inch. 

2.	 Design strength: _____ psi. Actual compressive strength of existing concrete 

may be significantly higher]. 

B.	 Information drawings provide general locations of embedded reinforcement, pipe, 

conduit, and metalwork. Actual locations may vary. 

1.07		 AMBIENT CONDITIONS 

A.	 Ambient and Surface Temperatures: 3

[__ to __] degrees F at time of application. 

1.08		 ENVIRONMENTAL REQUIREMENTS 

A.	 Install materials within temperature limits specified by materials manufacturer. 

B.	 Comply with material manufacturer’s environmental restrictions. 

PART 2 PRODUCTS 

2.01		 MATERIALS 

A.	 4

Chemical Grout: 

2 Insert maximum size aggregate and design compressive strength, if known, otherwise delete statements. 

3 Insert if known, otherwise indicate unknown. 
 

 

 

 


 


 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

		

	 

	 

	 

	 

	 

		

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1.	 _, manufactured by Avanti International, 822 Bay Star Blvd., Webster, TX, 

77598, 800-877-2570, www.avantigrout.com. 

2.	 _, manufactured by Strata-Tech, 3601 104th Street, Des Moines, IA, 50322, 515­

251-7770, www.strata-tech.com. 

3.	 _, manufactured by W.R. Grace, 62 Whittemore Ave., Cambirdge, MA 02140, 

Phone: 800-732-0166, www.grace.com/construction/en-us/injection-materials. 

4.	 _, manufactured by Resiplast US, PO Box 308, Cypress, TX 77410, 855-909­

1800,. www.spetec.com/producten.html 

5.	 5Use one of the above products or equal with the following essential 

characteristics: 

a.	 _____ polyurethane. 

b.	 Contains no solvents. 

c.	 Viscosity: ___ cps maximum. 

d.	 Expansion: ___ percent maximum. 

e.	 Specific gravity: _____. 

f.	 Cured Tensile Strength: ____psi +/- __psi. 

B.	 Oakum jute: __, manufactured by __; or equal, with the following essential 

characteristics: 

1.	 Minimum: 7 strand. 

2.	 1-1/4 to 1-1/2 turns per foot. 

3.	 2-inch diameter 

C.	 Accessories: Injection ports with valves or other back-flow preventer. 

PART 3 EXECUTION 

3.01		 GENERAL 

A.	 Cease operations and notify COR if concrete removal operations: 

1.	 Contact electrical conduit containing energized circuits. 

2.	 Crack concrete to remain in place. 

B.	 Do not resume operations until directed by COR. 

4	 Select at least 3 sources for grout and one for jute that are suitable for anticipated work. Consult with 

CGSL staff for recommendations. 

5		 Fill in blanks of essential characteristics. Consult with CGSL staff for recommendations. 
 

 

 

 

 

 

 

 


 


 

	 

		

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

		

	 

	 

	 

		

		

		

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C.	 Coordinate performance of noisy, malodorous, or dusty work with the COR. 

D. 

3.02		 PREPARATION 

A.	 Offset drill holes along leaks to intercept leaks at least 6[_]-inches from surface or as 

approved by COR. 

B.	 Space holes every 7[_]-inches or as approved by the COR. 

C.	 Drill holes 8{on alternating sides of cracks} {along joint} to ensure intersection. 

D.	 Diameter of hole appropriate for injection ports. 

E.	 If rebar is encountered, adjust location of hole to avoid rebar. 

F.	 Blow out holes to remove dust created by drilling prior to placing packers. 

G.	 Install ports. Use hammer-in, mechanical, or threaded ports or packers or other type as 

approved by COR in holes. 

1.	 Use ports that prevent backflow. 

H.	 Prior to injecting grout, flush water through ports to ensure connection of hole to voids 

and to clean debris from hole and voids. Alternating use of air pressure and water may be 

needed to clean void and crack. 

1.	 Flush until water is clean. 

2.	 9Do not exceed __ psi for flushing unless approved by COR. 

3.	 If the hole does not intersect with the crack or joint, drill new hole. 

I.	 Capture concrete debris, and drill cuttings. 

J.	 Obtain approval of grout preparation from COR before injecting grout. 

3.03		 INSTALLATION 

A.	 Equipment: 

1.	 Grout pump: 

6	 Typically, the intercept depth is half way through the section, or at least 12-inches deep for thick sections. 

Deeper is typically better. 

7		 As needed to ensure proper filling of leak. 

8		 Choose appropriate location 

9		 Insert acceptable pressure. 
 

 

 

 

 

 


 


 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

	 

		

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a.	 Mechanically driven, not hand operated, specifically for viscous materials: 

b.	 Capable of pumping grout component(s) at proper ratio. 

c.	 Output: At least 1.0 gpm. 

d.	 Output pressure: At least 1000 psi. 

2.	 Two component grouts: Place components in graduated containers to monitor 

proportioning throughout grouting operations. 

B.	 Chemical grouting: 

1.	 Mix and install grout according to manufacturer’s instructions. Use catalysts 

and/or accelerators as appropriate. 

2.	 Just prior to injection, pump grout through grout line(s), into a suitable container 

to confirm grout is proportioned to cure. Record grout pressures at each port. 

3.	 10Start injection at lowest area of leak and work across and up. 

a.	 Attach injection lines to lowest injection port. Proceed across and upward. 

b.	 When grout is visible at adjacent port(s), or at edge of leak, close injection 

port valve attached to injection lines 

c.	 If excessive grout leaks from leak, plug leaks with resin soaked oakum or 

other material as approved by COR. 

d.	 Proceed to next appropriate injection port. 

e.	 Keep grout contained and in place until grout is cured. 

C.	 Maximum injection pressure: 

1.	 Do not exceed maximum injection pressure unless approved by COR. 

2.	 Determine for each grout material just prior to injection. 

3.	 Measure pressure at pump or other suitable location as approved by the COR. 

4.	 Assemble grout, grout pump, grout lines, and grout injection gun as will be used 

during grouting operations and attach grout gun to injection port similar to those 

in drilled holes. 

5.	 Determine base pressure needed to move grout through grout lines, injection gun, 

and injection port at appropriate quantity. 

a.	 11Maximum pressure: Base pressure plus ___ psi. 

b.	 Higher pressures subject to approval by COR 

6.	 12[Do not warp or deflect liners and plates.] 

10	 Injection may require an iterative process after initial cure to ensure complete crack or joint seal. 

11	 Insert maximum pressure. 

12		 Include if appropriate – i.e. injecting behind a steel draft tube liner. 
 

 

 

 

 

 


 


 

		

	 

		

	 

	 

	 

	 

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7. Notify COR any time quantity of injected resin is larger than expected. 

3.04		 REPAIR 

A.	 Remove defective or contaminated grout. Reclean and replace grout. 

3.05		 CLEANING 

A.	 Remove excess grout, and soiling from adjacent surfaces. 

B.	 13Remove packers. 

C.	 After grouting, repair drill holes using dry pack method in accordance with USBR M-47. 

1.	 Repair to depth of 3 inches, to depth of open hole after grout port is removed, or 

to depth of top of cured grout in hole, whichever is greater. 

END OF SECTION 

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SECTION 03 81 19 

CONCRETE CRACK HEALER AND PENETRATING SEALER 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR – BUREAU OF RECLAMATION 

REVISIONS 

Reference Standards Checked/Updated: 07/25/15 

Content Revisions: 

07/25/15 New Section 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

Refer to Part 1 the Guide to Concrete Repair to determine if the repair method detailed in this 

specification is appropriate for the damaged concrete. Contact Concrete, Geotechnical, and 

Structurall Lab (CGSL) 86-68530 for appropriate use. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

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SECTION 03 81 19
	

CONCRETE CRACK HEALER AND PENETRATING SEALER
	

PART 1 GENERAL 

1.01		 MEASUREMENT AND PAYMENT 

A.		 Concrete Crack Healer and Penetrating Sealer: 

1.		 Measurement: Area treated. 

2.		 Payment: Square foot price offered in Price Schedule. 

1.02		 REFERENCE STANDARDS 

A.		 ASTM International (ASTM) 

1.		 ASTM C881/C881M-14 Epoxy-Resin-Base Bonding Systems for 

Concrete 

2.		 ASTM C882/C882M-13a Bond Strength of Epoxy-Resin Systems 

Used With Concrete By Slant Shear 

3.		 ASTM D93-15 Flash Point by Pensky-Martens Closed Cup 

Tester 

4. ASTM D638-14 Tensile Properties of Plastics 

5. ASTM D1084-08 Viscosity of Adhesives 

6.		 ASTM D1475-13 Density of Liquid Coatings, Inks, and 

Related Products 

7. ASTM D2369-10(2015)		 Volatile Content of Coatings 

8.		 ASTM D3278-96(2011) Flash Point of Liquids by Small Scale 

Closed-Cup Apparatus 

9. ASTM D4258-05(2012)		 Surface Cleaning Concrete for Coating 

10.		 ASTM D4263-83(2012) Indicating Moisture in Concrete by the 

Plastic Sheet Method 

1.03		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

B.		 RSN 03 81 19-1, Approval Data: 

1.		 Certification from manufacturer that product is suitable for the intended 

application. 

2.		 The manufacturer’s current product data sheets. 

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3.		 1[Data sheet(s) for broadcast sand]. 

4.		 Independent testing laboratory certification that the materials meet required 

specifications. 

5.		 Manufacturer dates for polymer materials, lot numbers, and expiration date of 

each lot number. 

6.		 Table with likely cure time in minutes for allowable ambient temperature ranges, 

in increments of 10 degrees F. 

C.		 RSN 03 81 19-2, Qualifications: 

1.		 Applicator. 

a.		 Relevant experience level of the site supervisor. No substitution allowed 

without resubmittal and approval. 

b.		 Applicator’s key personnel (superintendent, assistant, and field installers). 

2.		 Manufacture’s technical representative. 

D.		 RSN 03 81 19-3, Work Plans: 

1.		 Work plan for each concrete surface to be treated. 

2.		 Estimated times for surface preparation and healer/sealer application. 

3.		 Manufacturer’s recommendations for: 

a.		 Surface preparation. 

b.		 Mixing. 

c.		 Healer/sealer application method and equipment. 

4.		 2

Sand broadcasting method. 

E.		 RSN 03 81 19-4, Quality Control Plan: 

1.		 Methods to: 

a.		 Ensure equipment calibration. 

b.		 Ensure properly mixed components. Tests to verify resin mixture. 

c.		 Measure daily temperate and humidity. 

d.		 Material storage. 

e.		 Measure concrete moisture content. 

F.		 3

RSN 03 81 19 -5, Daily Records: 

1 Include if sand will be broadcast onto surface. 

2 Include if sand will be broadcast on surface. 

3 Submit at the end of each working day. 

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1.		 At a minimum, document following: 

a.		 Mix ratios used in each mix. 

b.		 Treated area (ft2

). 

c.		 Temperature and humidity. 

d.		 Concrete repair details if performed 

e.		 Concrete moisture content just prior to application 

1.04		 QUALIFICATIONS 

A.		 Manufacturer’s Technical Representatives: 

1.		 Approved by manufacturer for services to be provided. 

2.		 Familiar with installation and testing of product on a similar or larger size project. 

B.		 Applicator: 

1.		 Minimum of 10 similar field applications using a healer/sealer system for 

rehabilitation of concrete over the last 5 years. 

2.		 Installation and design projects, contact names and phone numbers. 

C.		 Superintendent, assistant, and laborers/field installers: Minimum 3 years’ experience 

with similar repair projects. 

1.05		 DELIVERY, STORAGE AND HANDLING 

A.		 Store sufficient material on-site to perform entire application prior to field preparation. 

B.		 Deliver and store materials in manufacturer’s original unopened packaging with labels 

and seals intact, in accordance with manufacturers’ and or suppliers’ requirements. 

C.		 Keep storage space clean and dry. 

D.		 Maintain the temperature of the storage space per the manufacturer's recommendations. 

Record temperatures using a high-low thermometer. Make available to COR upon 

request. 

1.06		 ENVIRONMENTAL CONDITIONS 

A.		 Apply in accordance with following restrictions or in accordance with the manufacturer’s 

instructions whichever is more stringent. 

1.		 Apply on dry surfaces. 

2.		 Do not apply if it has rained with in the past 24 hours or rain is expected within 

the next 8 hours. 

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3.		 Concrete moisture content: Not to exceed 4.5 percent when measured by an 

electronic meter. 

4.		 Do not start application if temperature is expected to go below 50 degrees F 

before healer/sealer cured. 

PART 2 PRODUCTS 

2.01		 ACCESSORIES 

A.		 Electronic moisture meter: Prior to use, compare to moisture content measured by 

ASTM D 4263 

2.02		 MATERIALS 

A.		 Concrete healer/sealer: formulated to seal small cracks in concrete surfaces. 

B.		 HMWM: [_]4

, or equal meeting the material properties of Table 03 81 19A – Material 

Properties. 

C.		 Epoxy polymer: [_]5

, or equal meeting the material properties of Table 03 81 19– 

Material Properties. 

Table 03 81 19A - Material Properties 

Material Property Tested Test Procedure Acceptable Test Result 

HMWM Viscosity ASTM D 1084 10 – 25 cps 

Specific Gravity ASTM D1475 0.90 minimum @ 77 

degrees F 

Tensile 

Elongation 

ASTM D 638 30 Percent Minimum 

Odor Manufacture Data Sheet Low 

Vapor Pressure ASTM D 638 0.02 psi @ 77 degrees F 

maximum 

Flash Point ASTM D 93 175 degrees F minimum 

Solids Content Manufacture Data Sheet 100 percent 

4 Insert specific HMWM. Contact CGSL for product information. Values in table for example only. 

5 Insert specific Epoxy polymer. Contact CGSL for product information. Values in table for example only. 

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Table 03 81 19A - Material Properties 

Material Property Tested Test Procedure Acceptable Test Result 

Bulk Cure Manufacture Data Sheet Less than 3 hours @ 73 

degrees F 

Surface Cure Manufacture Data Sheet Less than 8 hours @ 73 

degrees F 

Less than 24 hours at 

application temperature 

Gel Time Manufacture Data Sheet 25-75 minutes at 

application temperature 

Percent Volatile ASTM D 2369 30 percent maximum 

Epoxy Polymer Viscosity ASTM D 2393 90 cps or less 

Tensile 

Elongation 

ASTM D 638 30 percent minimum 

Tensile Strength ASTM C 638 1500 psi minimum 

Flash Point ASTM D 3278 175 degrees F minimum 

Solids Content ASTM C 882 100 percent 

Pot Life Manufacturer Data 

Sheet 

20 to 60 min. 

Gel Time ASTM C 881 20 to 30 minutes 

D. Sand: 

1. Clean silica sand. 

2. Less than 0.5 percent moisture 

3. Gradation: Refer to Table 03 81 19B - Sand Gradation 

Table 03 81 19B - Sand Gradation 

Sieve Size Percent Passing 

No. 8 100 percent 

No. 16 80-100 percent 

No. 50 0-72 percent 

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4.		 Or as approved by the healer/sealer manufacturer. 

PART 3 EXECUTION 

3.01		 MANUFACTURER’S TECHNICAL REPRESENTATIVE 

A.		 On-site during surface preparation and application to initial structure. Present as needed 

for remaining structures. 

B.		 Instruct proper mixing, application technique, safety precautions, traffic opening time, 

and environmental requirements. 

C.		 Approve products immediately before usage. 

3.02		 EQUIPMENT 

A.		 Use only approved equipment. 

B.		 Calibrated and maintained to assure constituent proportions. 

3.03		 SURFACE PREPARATION 

A.		 Clean, prepare, treat and dry substrate according to manufacturer's written instructions, as 

listed below and per ASTM D 4258, whichever is more stringent. 

B.		 Repair damaged or deteriorated concrete surfaces according to Section 6

[{03 81 14 -

Concrete Repair}{03 81 15 - Polymer Concrete Surface Repair}]. 

C.		 Use contained shotblasting, wet sandblasting, or water blasting to remove weathered, 

weakened or damaged concrete surfaces. 

1.		 If water blasting, use pressure sufficiently high to prepare surface. Pressures up 

to 15,000 psi may be necessary. 

2.		 Remove materials that weaken the bond between remaining concrete and 

healer/sealer material. 

D.		 Immediately prior to application of healer/sealer, clean surfaces and cracks with oil free 

compressed air. 

1.		 100 psi minimum. 

2.		 Direct air with nozzle into cracks. 

E.		 Block off adjoining surfaces not receiving healer/sealer to prevent spillage affecting other 

construction. 

6	 Select appropriate section for concrete repair. Contact CGSL for appropriate section. 

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F.		 Seal the underside of concrete surfaces, as needed, with a patching material to prevent 

leakage of the healer/sealer that might damage equipment or areas under the surface. 

G.		 COR will approve final surface profile and preparation. 

3.04		 INSTALLATION 

A.		 According to the approved work plan and manufacturer’s instructions: 

1.		 Mix components at correct speed. 

2.		 Batch size. 

3.		 Apply healer/sealer system. 

4.		 Coverage rate. 

5.		 Spray equipment: Airless. 

6.		 Time limits. 

B.		 Completely cover or flood area. 

1.		 Sweep, squeegee, pour or spray area, allowing material to flow into cracks. 

2.		 Repeat as necessary to fill cracks. 

C.		 Do not use healer/sealer showing an increase in viscosity. 

D.		 If healer/sealer does not penetrate surface of concrete, remove sealer, prepare surface and 

reapply. 

E.		 7

[Broadcast sand to refusal within time limits specified by manufacturer after application 

of healer/sealer. 

1.		 Usually within 15 to 20 minutes after final healer/sealer application 

2.		 Remove excess sand within 24 hours after curing 

3.		 8[Repeat application of healer/sealer and sand to achieve desired thickness of 

treatment or as approved by COR.] 

4.		 If broadcast sand did not adhere properly to the deck, reapply healer/sealer and rebroadcast sand as approved by COR. .] 

3.05		 CLEANING 

A.		 Remove excess healer/sealer, 9

[sand], and soiling from adjacent surfaces as approved by 

COR. 

7 Include if broadcast sand will be used.
	

8 For repairs with broadcast sand, a minimum of 2 applications is usually performed.
	

9 Include if broadcast sand will be used.
	

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SECTION 09 91 11 

PAINTING FOR CONCRETE 

GUIDE SPECIFICATION 

DEPARTMENT OF THE INTERIOR - BUREAU OF RECLAMATION 

WARNING 

Users of this guide specification should have expertise in the protective coatings field. This 

field is undergoing significant changes due to emerging technologies and environmental 

regulations that affect protective coatings formulation and performance. Reclamation has 

experienced unsuitable coating applications when users without adequate coating knowledge 

selected inappropriate materials. The Materials and Corrosion Laboratory, D-8540, in the 

Technical Service Center prepared this guide specification and is available to prepare or assist 

in preparing project specifications for coatings. 

REVISIONS 

Reference Standards Checked/Updated: 8/22/15 

Content Revisions: 

Editorial/Format Revisions: 

Template: CSI_15a.dotx 

NOTES 

1. Use for the following substrate types: New and aged concrete. 

2. Use on cementitious materials with surface tensile strength of 200 psi, minimum. 

3. Project to test surface tensile strength after surface preparation methods listed herein and 

prior to commencement of work to estimate coating adhesion strength to the substrate. 

Please provide corrections or comments to address shown on home page of USBR Guide 

Specifications intranet site: intra.usbr.gov/guidespecs 

Painting for Concrete 

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SECTION 09 91 11
	

PAINTING FOR CONCRETE
	

PART 1 GENERAL 

1.01		 COST 

A.		 1[Include cost in other items of price offered in the Price Schedule for items of work 

requiring coating.] 

B.		 2[Include cost in lump-sum price offered in the Price Schedule for 3{ ____ }.] 

1.02		 REFERENCE STANDARDS 

A.		 ASTM International (ASTM) 

1.		 ASTM C 920-14a Elastomeric Joint Sealants 

2.		 ASTM D 4138-07a(2013) Measurement of Dru Film Thickness of Protective 

Coatings by Destructive, Cross Section Means 

3.		 ASTM D 4259-88(2012) Abrading Concrete 

4.		 ASTM D 4263-83(2012) Indicting Moisture in Concrete by the Plastic Sheet 

Method 

5.		 ASTM D 4285-83(2012) Indicating Oil and Moisture in Compressed Air 

6.		 ASTM D 4414-95(2013) Measurement of Wet Film Thickness by Notch 

Gages 

7.		 ASTM D 6132-13 Nondestructive Measurement of Dry Film 

Thickness of Applied Organic Coatings Over 

Concrete Using an Ultrasonic Gage 

8.		 ASTM F 1869-11 Measuring Moisture Vapor Emission Rate of 

Concrete Subfloor Using Anhydrous Calcium 

Chloride 

B.		 Federal Standards (Fed Std) 

1. Fed Std 595B-89 Colors Used in Government Procurement 

C.		 The Society for Protective Coatings (SSPC)/NACE International (NACE) 

1.		 SSPC-AB1-15 Mineral and Slag Abrasives 

1 Specify cost of coating work to be included. 

2 Specify cost of coating work in one bid item. 

3 Specify item or applicable items. 

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2. SSPC-AB2-15 Cleanliness of Recycled Ferrous Metallic Abrasives 

3.		 SSPC-AB3-04 Newly Manufactured or Re-Manufactured Steel 

Abrasives 

4.		 SSPC-PA2-15 Measurement of Dry Paint Thickness with Magnetic 

Gages 

5.		 SSPC-QP1-12 Evaluating Painting Contractors (Field Application 

to Complex Industrial Structures) 

6.		 SSPC-QP3-10 Evaluating the Qualification of Shop Painting 

Contractors 

7. SSPC-SP13/NACE 6-04		 Surface Preparation of Concrete 

D.		 United States Bureau of Reclamation (USBR) 

1.		 USBR M-47 Standard Specifications for Repair of Concrete, 

August 2015 (Part 2, Appendix 1 of “Guide to 

Concrete Repair” available at http://www.usbr.gov/ 

(insert URL _______) 

1.03		 SUBMITTALS 

A.		 Submit the following in accordance with Section 01 33 00 - Submittals. 

1.		 Include following information with each set of data or certification: 

a.		 Applicable tabulation number from Coating Tabulations. 

b.		 Identification of items to be coated, including sub-letter and sub-number 

listed in Coating Tabulations. 

B.		 RSN 09 91 11-1, Approval Data: 

1.		 For each coating material: 

a.		 Manufacturer’s product data, application, and SDS sheets 

b.		 Include: 

1) Supplier’s name, address, and phone number. 

2) Manufacturer’s designated product name. 

2.		 4

[Paint Chip Samples: 

a.		 Color chip samples approximately 4 by 6 inch. 

b.		 Label each sample. Include manufacturer’s designated product name; 

color; and gloss. 

C.		 RSN 09 91 11-2, Final Approval Data: 

4	 Include when matching existing color and gloss. 

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1.		 For each coating material: 

a.		 Purchase orders. Include: 

1) Supplier’s name, address, and phone number. 

2) Purchase order number and date. 

3) Manufacturer’s designated product name. 

4) Batch number(s) for each material, except thinners. 

5) Quantities ordered for each material, except thinners. 

D.		 RSN 09 91 11-3, Certifications: 

1.		 5[Current SSPC-QP1 certification for field application to complex structures.] 

2.		 6[Current SSPC-QP3 certification shop application.] 

3.		 7

[Manufacturer’s certification that materials certified by a Qualified Products List 

(QPL) meet specified requirements.] 

4.		 8

[National Sanitation Foundation (NSF) 61 certification that materials meet 

specified requirements for coating systems in-contact with potable water.] 

E.		 RSN 09 91 11-4, Documentation: 

1.		 Applicator’s qualifications by training or experience for each coating. For 

experience include: 

a.		 3 recent jobs using comparable materials under similar conditions. 

b.		 Owners contact information of 3 recent jobs. 

F.		 RSN 09 91 11-5, Contractor Quality Testing Data for “Shop or Field Applied” Coatings 

(not required for a manufacturer’s standard coating systems): 

1.		 Date of work. 

2.		 Description of areas and work performed. 

3.		 Surface preparation. 

4.		 Surface cleanliness/ profile. 

5	 Specify to pre-qualify painting contractor. Note: Number of qualified contractors in vicinity of jobsite may 

limit competition. Check list of qualified contractors on SSPC website www.sspc.org. Delete if number of 

potential contractors/subcontractors is insufficient to provide adequate competition. 

6		 Specify to pre-qualify painting contractor. Note: Number of qualified contractors in vicinity of jobsite may 

limit competition. Check list of qualified contractors on SSPC website www.sspc.org. Delete if number of 

potential contractors/subcontractors is insufficient to provide adequate competition. 

7		 Specify for Federal and Military coating specifications if applicable (see Coating Tabulations and Coating 

Categories). 

8		 Specify for coating systems in-contact with potable water. 

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5.		 Ambient conditions. 

6.		 Dry film thickness. 

G.		 “Equal” Products: 

1.		 List of projects (not less than three) where material has been successfully used in 

applications similar to this project. Include: 

a.		 Project name and location. 

b.		 Type of structure. 

c.		 Owner’s name, address, and telephone number. 

d.		 Application dates. 

2.		 Manufacturer’s certification substitute coating material meets specified 

requirements. Include: 

1) Manufacturer’s name, address, and phone number. 

2) Batch number(s) for each material, except thinners. 

3)		 Signature of manufacturer’s technical representative and date of 

signature. 

b.		 Certified test reports that demonstrates substitute material meets or 

exceeds specified coating category requirements for physical and 

performance characteristics from each of following: 

1)		 Coating manufacturer. 

2)		 Independent laboratory. 

1.04		 QUALIFICATIONS 

A.		 Coating applicators qualifications: 

1.		 Qualified to apply specified coating materials by one of following: 

a.		 Successfully completed training in application of coating materials similar 

to materials and conditions specified. 

b.		 Skilled and experienced in application of coating materials similar to 

materials and conditions specified. 

B.		 9

[Manufacturer’s field representative: 

1.		 Procure services of manufacturer’s technical representative for coating material(s) 

listed in Coating Tabulation No.10 {__} to comply with manufacturer’s 

specification instructions for following: 

9	 Specify coating manufacturer technical representative is required to be on the jobsite to supervise surface 

preparation and application of special materials, i.e. cavitation resistant. 

10		 Specify tabulation listing special coating material. 

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a.		 Training. 

b.		 Substrate surface preparation requirements. 

c.		 Application requirements.] 

C.		 Compliance Criteria for Coating Materials: 

1.		 Material is of same composition and formulation to meet physical and 

performance test results for one of following: 

a.		 Submitted batch or previously tested batch materials complies with these 

specifications. 

b.		 Submitted batch materials are unchanged from previously tested batch 

materials that comply with manufacturer’s quality control (QC) and 

quality assurance (QA) programs. 

c.		 Submitted batch materials complies with manufacturer’s quality control 

(QC) and quality assurance (QA) programs as listed on product data and 

application sheets. 

1.05		 DELIVERY, STORAGE, HANDLING 

A.		 Deliver materials to jobsite in original, undamaged, unopened containers labeled with 

manufacturer’s name, designated product name, batch number, date of manufacture, and 

any special instructions. 

B.		 Deliver materials in containers not larger than 5 gallons as packaged by manufacturer 

unless suitable equipment is provided at jobsite to handle and thoroughly mix materials in 

larger containers. 

C.		 Store materials in well ventilated area. 

D.		 Do not expose to direct sunlight during storage. 

E.		 Comply with manufacturer’s storage instructions. 

F.		 Do not use coating material which has exceeded manufacturer’s specified storage 

stability period (shelf life). 

1.06		 ENVIRONMENTAL REQUIREMENTS 

A.		 Comply with the most restrictive requirements of the coating manufacturer’s and 

specifications. 

B.		 Do not apply coatings: 

1. Substrate surface temperature less than 5 degrees Fahrenheit above dewpoint. 

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2.		 Air and substrate surface temperature less than 50 degrees Fahrenheit and not to 

exceed manufacturer’s recommended maximum temperature limit or 95 degrees 

Fahrenheit. 

3.		 Humidity outside of manufacturer’s recommended range. 

C.		 Do not perform surface preparation or apply coatings when environmental conditions are 

not expected to meet specified requirements during surface preparation, coating 

application, and curing period. 

D.		 Maintain environmental conditions to meet specified requirements during coating 

application and curing period. Provide heat and dehumidification required to maintain 

temperature and humidity conditions. 

PART 2 PRODUCTS 

2.01		 MATERIALS 

A.		 General: 

1.		 Compliance criteria for coating materials: 

a.		 Material is of same composition and formulation to meet physical and 

performance test results for one of following: 

1)		 Submitted batch or previously tested batch materials complies with 

these specifications. 

2)		 Submitted batch materials are unchanged from previously tested 

batch materials that comply with manufacturer’s quality control 

(QC) and quality assurance (QA) programs. 

3)		 Submitted batch materials complies with manufacturer’s quality 

control (QC) and quality assurance (QA) programs as listed on 

product data and application sheets. 

2.		 Materials required by these specifications and not listed in Coating Categories are 

subject to certification and testing in accordance with this Section. 

3.		 Provide compatible products of same manufacturer for coating system 

components. 

B.		 Abrasives: 

1.		 Mineral and slag abrasives: SSPC-AB1, type I (natural minerals) and type II 

(slags), class A, except flint minerals are not permitted. 

2.		 Ferrous metallic abrasives: 

a.		 SSPC-AB2 for recycled cleanliness. 

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1)		 Screen and air wash abrasive recycled at the job site to remove dirt 

and fines. 

2)		 Add new abrasive so combined new and recycled abrasive mixture 

meets specified abrasive requirements for moisture, friability, 

silica, anchor pattern, and oil content. 

3)		 Do not recycle abrasive with toxic or hazardous material. 

4)		 Do not recycle nickel slag. 

b. SSPC-AB3 class I (steel) or II (iron) for angular shaped grit. 

3.		 Make every commercially available effort to render the hazardous waste stream 

non-hazardous. 11[Additive stabilizers for leachable toxic metal wastes are 

allowed, except elemental iron is not permitted.] 

4.		 Do not exceed toxicity threshold limit for hazardous materials. 

C.		 Coatings: 

1.		 Specified in Coating Categories. 

2.		 Apply only one coating category per option in Coating Tabulations. 

3.		 Volatile Organic Compounds (VOC): 

a.		 Do not to exceed maximum permitted by Federal, State, and local air 

pollution control regulations. 

b.		 Do not exceed maximum content as supplied in container or by addition of 

thinner material. 

4.		 Factory color or tint. Do not color or tint at jobsite. 

5.		 Use thinners recommended by manufacturer for each coating material. 

6.		 Use of accelerator products is not permitted unless approved by Contracting 

Officer. 

D.		 Fillers and Caulks: 

1.		 Flexible gaps or crevices: 

a.		 Coating manufacturer’s standard flexible filler or caulk material. 

b.		 Caulk material: Meet or exceed ASTM C 920-08 type S or M, grade NS, 

class 25, suitable for water immersion service. 

2.		 Nonflexible gaps or crevices: Coating manufacturer’s standard filler or caulk 

material. 

E.		 12[Soluble Salt Removal: 

Specify for removal of paints containing toxic (heavy) metals in conjunction with Section 02 83 30, 

Removal and Disposal of Coatings Containing Heavy Metals. 

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1.		 Chlor-Rid as manufactured by Chlor-Rid International Inc., PO Box 908 Chandler 

AZ 85244, 480-821-0039, www.chlor-rid.com, or equal with following essential 

characteristics: 

a.		 Water soluble. 

b.		 Biodegradable. 

c.		 Zero volatile organic compounds. 

2.		 Deionized Water 

PART 3 EXECUTION 

3.01		 PROTECTION 

A.		 Protect adjacent items or from contamination and damage during cleaning and coating 

operations. 

1.		 Includes surfaces and equipment in physical contact with areas being cleaned or 

coated. 

2.		 Protect from abrasive blast particles and airborne coating particles. 

3.		 Prevent damage from bumping or striking with foreign objects. 

B.		 Protect newly coated surfaces until coating is thoroughly dry or as determined by coating 

manufacturer’s instructions. 

3.02		 SURFACE REPAIR 

A.		 Repair contractor damaged or contaminated surfaces as determined by COR. 

1.		 Repair damaged surfaces to original condition and appearance. 

2.		 Before coating damaged coated surfaces, re-clean exposed surface and apply 

coating materials. 

3.03		 SURFACE PREPARATION 

A.		 Curing: Cure at least 30 days before painting, except concrete slab on grade, which shall 

be allowed to cure 90 days before painting. Before coating application, repair 

cementitious defects greater than 3/4-inch in depth by one of following: 

1.		 13[In accordance Section _______ Repair of Concrete. 

2.		 In accordance with USBR M47. 

3.		 In accordance with manufacturer’s product instructions.] 

12 Specify for surfaces contaminated with soluble salts 

13 Specify repair procedure. 

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B.		 Remove dirt, dust, grease, oil, laitance, efflorescence, form oil, and curing compounds. 

1.		 Dirt, Grease, and Oil: 

a.		 Wash new and existing uncoated surfaces with a solution composed of 1/2 

cup trisodium phosphate, 1/4 cup household detergent, and 4 quarts of 

warm water. 

b.		 Then rinse thoroughly with fresh water. 

c.		 Wash existing coated surfaces with a suitable detergent and rinse 

thoroughly. 

d.		 For large areas, water blasting may be used. 

2.		 14[Fungus, mold, and mildew by one of following: 

a.		 Wash brush affected area with solution of 5 ounces of trisodium 

phosphate, 3 ounces of household detergent, 1.25 percent sodium 

hypochlorite, and 3 quarts of warm potable water. After 24 hours, 

thoroughly flush with potable water. Repeat process if growth returns. 

b.		 Use commercial products formulated and suitable for removal. Follow 

manufacturer’s instructions. 

3.		 Efflorescence: 

a.		 Scrape or wire brush followed by washing with a 5 to 10 percent by 

weight aqueous solution of hydrochloric (muriatic) acid. 

b.		 Do not allow acid to remain on the surface for more than five minutes 

before rinsing with fresh water. 

c.		 Do not acid clean more than 4 square feet of surface, per workman, at one 

time. 

C.		 Specific surface preparation methods: 

1.		 15[See Coating Tabulations: 

2.		 Method T: SSPC-SP13/NACE 6, except as specified: 

a.		 Section 4.3.3: Fractures and micro-cracks caused by impact tools are to be 

repaired in accordance with ASTM D 4259. 

b.		 Do not use: 

1) Section 4.3.3: Scabbling impact tool. 

2) Section 4.4: Chemical surface preparation. 

3) Section 4.5: Flame (Thermal) cleaning and blasting. 

c.		 Paint and Loose Particles: Remove by wire brushing. 

14 Specify for surfaces with fungus, mold, and mildew growth.
	

15 Specify specific surface preparation method(s) listed in Coating Tabulations(s).
	

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3.		 Manufacturer’s instructions. 

D.		 Surface profile: 

1.		 Prepare in accordance with manufacturer’s instructions for cementitious materials 

and service environment. 

2.		 Where manufacturer’s instructions do not specify a surface profile, use on of the 

following: 

a.		 Prepare surfaces to appearance of medium (100) abrasive paper, minimum 

or: 

b.		 Atmospheric Service Environments: 1 mil or greater angular profile and 

less than specified millage of first applied coat. 

E.		 Cosmetic Repair of Minor Defects: Repair or fill mortar joints and minor defects, 

including but not limited to spalls, in accordance with manufacturer's recommendations 

and prior to coating application. 

F.		 After surface preparation, repair following surface irregularities: 

1.		 Air pockets (bugholes): Greater than 1/8-inch in diameter by adhesive epoxy or 

manufacturer’s repair compound filler. 

2.		 Protrusions, fins, or bulges: Grind down by SSPC-SP13/NACE 6 surface 

preparation methods to 1/16-inch or less of surrounding surface. 

3.		 Cracks: Use material compatible with manufacturer’s coating material listed in 

Coating Tabulations. 

G.		 Prepare surface free of moisture, frost, and ice before coating application. 

H.		 Concrete moisture content: 

1.		 Do not apply coatings to damp surfaces as determined by ASTM D 4263 and/or to 

horizontal surfaces that exceed 3 pounds of moisture per 1000 square feet in 24 

hours as determined by ASTM F 1869. 

2.		 In all cases follow manufacturer’s recommendations: 

3.		 Test substrate surface for moisture content before applying coating. 

4.		 Perform one test per 1,000 square feet, minimum. 

5.		 Perform tests in accordance with moisture content inspection procedures specified 

and coating manufacturer allowable moisture content. 

I.		 16[Soluble salt for field coated surfaces: 

1.		 Test for soluble salts or chloride specific ion after surface preparation. 

Specify if soluble salts are suspect (Note: use on relatively smooth surfaces because test sleeves will not 

adhere to rough surfaces). 

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2.		 Perform two tests per 17{1,000} square feet, minimum. 

3.		 Measure or chloride soluble salt ion on concrete substrate surfaces by one of 

procedures in SSPC-Guide 15. 

4.		 Procedure to have lower threshold limit of 1 micrograms per square centimeter. 

5.		 Acceptance Criteria: 

a.		 Atmospheric service exposure: Do not exceed 7 micrograms per square 

centimeter. 

b.		 Burial and immersion service exposure: Do not exceed 3 micrograms per 

square centimeter. 

J.		 Re-clean or perform additional surface preparation of completed surfaces contaminated 

before coating application. 

3.04		 APPLICATION EQUIPMENT 

A.		 Air compressor and spray application equipment: 

1.		 Equip with pressure gauges and pressure regulators. 

2.		 Equip with air supply lines free from oil and moisture. Keep lines free of oil and 

moisture during work. 

3.		 Inspect air supply lines on air compressors for oil and moisture in accordance 

with ASTM D 4285. 

3.05		 COATING APPLICATION 

A.		 In accordance with manufacturer’s instructions. 

B.		 Surfaces exposed to public view shall display a uniform texture and color matched 

appearance. 

C.		 Apply to surfaces free of moisture as determined by sight or touch. 

D.		 Apply an even film of uniform thickness which tightly bonds to substrate or previous 

coat. 

1.		 Fill crevices and cover irregularities. Work coating materials into joints, crevices, 

and open spaces. Edges, corners, and crevices receive a film thickness equal to 

adjacent painted surfaces. 

2.		 Apply each coat so dry film shall be of uniform thickness and free from runs, 

drops, ridges, waves, laps, brush marks, or other voids and variations in color, 

texture, and finish. Hiding shall be complete. 

17	 Square footage may increase or decrease according to job requirements. 

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3.		 Touch up damaged coatings before applying subsequent coats. Interior areas shall 

be broom clean and dust free before and during the application of coating 

material. 

E.		 Primer Coats: 

1.		 Cover peaks of surface profile by specified dry film thickness. 

2.		 Apply stripe coats to edges, corners, and similar surfaces. 

F.		 Intermediate and Topcoats: 

1.		 Apply number of coats and coating thickness specified in Coating Tabulations. 

2.		 Apply within re-coat window recommended by manufacturer. 

3.		 Tint intermediate coats with manufacturer’s standard color to differentiate 

between coats. 

3.06		 CONTRACTOR FIELD QUALITY TESTING 

A.		 18[Wet Film Thickness (WFT) Testing: 

1.		 Inspect wet film thickness immediately after application in accordance with 

ASTM D 4414. 

2.		 Compensate for reduced thickness to achieve specified thickness in Coating 

Tabulations. 

B.		 19[Dry Film Thickness (DFT) Testing and Acceptance: 

1.		 Inspect hardened coating system before exceeding re-coating interval: 

a.		 ASTM D 4138. 

b.		 ASTM D 6132. 

2.		 Number of tests and numerical averaging 

a. ASTM D 4138: Average of 3 tests per 1,000 square feet. 

b.		 ASTM D 6132: In accordance with SSPC-PA2. 

3.		 Acceptance Criteria: 

a.		 80 percent of minimum specified thickness. 

b.		 150 percent of maximum specified thickness. 

4.		 Repair areas tested by destructive method. 

18	 Specify in-lieu-of dry film thickness testing. 

19		 (a) Specify in-lieu-of non-destructive wet film thickness testing. (b) Specify if Project has DFT 

measurement capability for Tooke gauge (ASTM D 4138-destructive testing) and/or ultrasonic gauge 

(ASTM D 6132) or rely on Contractor to provided measurements. 

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C.		 20[Discontinuity (Holiday) Testing: 

1.		 Burial and Immersion Exposure: Inspect nonconductive coating in accordance 

with ASTM D 4787. 

a.		 Use maximum test voltage for any DFT as recommended by coating 

manufacturer to prevent coating damage. 

b.		 Do not use detergent wetting solution. 

c.		 Inspection of coating systems with aluminum, graphite, or other 

conductive pigments is not required. 

3.07		 COATING REPAIR 

A.		 Repair within minimum and maximum re-coat window time in accordance with coating 

manufacturer's recommendations and applicable Coating Tabulation. 

B.		 Repair pinholes, holidays, laps, voids, and other defects. 

Inspect repaired areas for compliance with specifications 

3.08		 21COATING TABULATIONS 

Tabulation No. 70 

Items to be coated: 

a. Concrete surfaces at canal safety ladders. 

Coating materials Number and thickness of 

coats 

Surface preparation method 

For concrete surfaces: 

Base coats: 

Meets: CID A-A-3120*, Type C, 

chlorinated rubber base, or 

commercial equal for 

continuous immersion service. 

Color and gloss: see color 

schedule 

2 or more heavy coats. 

Follow manufacturer’s 

instructions for dry or wet 

film thickness per coat. 

T 

* CID A-A-3120 is prepared by Federal Supply Service, 1941 Jefferson Davis Highway, 

Crystal Mall Building 4, Arlington VA 22202 

20	 Specify only if one of following requirements can be meet: 1) Instrument ground connection to exposed 

steel reinforcement or embedded steel at several connection points. 2) If ground connection is not 

available, a conductive underlayment will be required (applied to prepared surface prior to application of 

nonconductive coating). 

21		 Delete Tabulations not applicable to project. 

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Tabulation No. 70 

099CT_70.DOC 

Tabulation No. 71 

Items to be coated: 

a. Damp-proofing or moisture vapor barrier of below grade concrete surfaces. 

b. 

c. 

Coating materials Number and thickness of 

coats 

Surface preparation method 

For concrete surfaces: 

Base coats: 

No. 35, Exterior Bituminous 

Coating 

Color: 

Manufacturer’s standard color 

2 or more heavy base 

coats. 

Follow manufacturer’s 

instructions for dry or wet 

film thickness per coat. 

T 

Approved Materials: 

1. Materials from MPI – Master Painters Institute, APL – Approved Products List 

www.paintinfo.com or www.mpi.net. 

2. The Society for Protective Coatings (SSPC)/NACE International (NACE) 

www.sspc.org 

099CT_71.DOC 

Tabulation No. 72 

Items to be coated: 

a. Interior surfaces of septic tanks and lift station for sewage treatment systems. 

b. Distribution boxes for sewage treatment systems. 

c. 

Coating materials Number and thickness of 

coats 

Surface preparation 

method 

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Tabulation No. 72 

For concrete surfaces: 

Base coats: 

Category options: IE-2AA 

IE-2AB 

Color: 

Manufacturer’s standard black 

2 or more coats, apply at 8 to 

10 mils DFT, per coat. 

Follow manufacturer’s 

instructions for wet film 

thickness per coat to achieve 

a total system of 16-mil DFT, 

minimum. 

T 

099CT_72.DOC 

Tabulation No. 74 

Items to be coated: 

a. Exposed surfaces of concrete. 

b. 

Coating materials 

Epoxy 

Number and thickness of 

coats 

Surface preparation method 

For cementitious surfaces 

subject to atmospheric or 

immersion exposure but not 

direct sunlight where color 

topcoat is not required: 

Base coats: 

Category options: 

IE-1A1 

IE-1C 

IE-1D 

2 or more base coats. 

Apply at 8 to 10 mils DFT, 

per coat. 

Total system: 

16-mil DFT, minimum 

T 

Follow manufacturer’s 

surface preparation and 

application instructions to 

apply subsequent coats. 

Coating materials 

Epoxy/polyurethane 

Number and thickness of 

coats 

Surface preparation method 

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Tabulation No. 74 

For cementitious surfaces 

subject atmospheric 

exposure and direct sunlight 

where color topcoat is 

required: 

Base coats: 

Category options: 

IE-1A1 

IE-1C 

IE-1D 

2 or more base coats. 

Apply at 8 to 10 mils DFT, 

per coat. 

Total system: 

16-mil DFT, minimum 

T 

Follow manufacturer’s 

surface preparation and 

application instructions to 

apply subsequent coats. 

Finish coats: 

Category options: 

AE-1AT over IE-1A1 

AE-1CT over IE-1C 

AE-1DT over IE-1D 

Color and gloss: see color 

schedule 

1or more compatible 

manufacturer’s finish coats. 

Apply at 3 to 4 mils DFT, per 

coat. 

Total system: 

19-mil DFT, minimum 

Follow manufacturer’s 

surface preparation and 

application instructions to 

apply subsequent coats. 

099CT_74.DOC 

Tabulation No. 78 

Items to be coated: 

a. Dustproofing interior floor and vertical concrete surfaces. 

b. 

c. 

Coating materials 

Epoxy 

Number and thickness of 

coats 

Surface preparation 

method 

For concrete surfaces: 

Base coats: 

Amber clear epoxy 

Follow manufacturer’s 

instructions for number of 

coats and thickness per coat. 

T 

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Tabulation No. 78 

Approved Material: CC400EP Clear Epoxy Sealer as manufactured by Hilti North American, 

5400 South 122nd East Avenue, Tulsa OK 74146, 918-252-6000, www.hilti.com; or equal with 

following essential characteristics: 

Composite: 

Two component, amber clear, water-based, polyimide epoxy 

Performance characteristics: 

Flexibility, ASTM D 522: Passes, 1/8–inch mandrel bend 

Impact resistance, ASTM D 2794: 50 inch-pounds, minimum 

099CT_78.DOC 

Tabulation No. 79 

Items to be coated: 

Warehouse concrete floor. 

Coating materials 

Epoxy 

Number and thickness of 

coats 

Surface preparation method 

For concrete floor surfaces: 

Category: AES-1F 

Color: see color schedule 

1 or more prime coats, apply 

at 6 to 8 mils DFT, per coat. 

T 

2 or more intermediate 

coats, apply at 1/16-inch, 

per coat. 

Follow manufacturer’s 

surface preparation and 

application instructions to 

apply subsequent coats. 1 or more topcoats, apply at 

8 to 12 mils DFT, per coat. 

Total system: 

1/8-inch, plus or 

minus 1/64-inch 

099CT_79.DOC 

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3.09 22 COATING CATEGORIES 

Category IE-2AA 

Amercoat 78HB; as manufactured by:
 

PPG Protective & Marine Coatings, One PPG Place, Pittsburgh, Pennsylvania 15272,
 

412-434-3131, www.ppgamercoatus.ppgmc.com
 

or equal, having following essential characteristics: 

COMPOSITION: 

Self-priming, two component, amine-cured, coal-tar epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS: 

Solids by volume: 75 percent, minimum 

VOC, as supplied: 1.9 pounds per gallon (228 grams per 

liter), maximum
 

Mix ratio - resin:hardener: 19:1
 

Mixed usable pot life at 50 degrees F: 8 hours, minimum
 

Ambient application temperature: 50 degrees F, minimum
 

Surface application temperature above 5 degrees F, minimum
 

dew point:
 

Maximum DFT per coat: 16 mils
 

Recoat time at 50 degrees F: 72 hours, maximum
 

Full cure time before immersion at 50 14 days, minimum
 

degrees F and 50 percent humidity:
 

Application methods: Brush, roller, or spray
 

Color/finish: Black or dark red/flat
 

PERFORMANCE REQUIREMENTS: 

Fresh/deionized water immersion test, 

ASTM D 870: 

Salt water immersion test, ASTM D 870; 

ASTM D 1141 formula A with no heavy 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

Delete categories not applicable to project. 

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metals: with no blisters evident on either 

scribed or unscribed sides. 

Abrasion resistance, ASTM D 4060, CS-17 120 milligram loss or less 

wheel, 1,000 cycles, 1-kg load: 

Flexibility, ASTM D 522, 180 degree bend passes 

over 1-inch mandrel: 

Pencil hardness, ASTM D 3363: 2B, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

Pulloff tape, ASTM D 3359: 4A or better 

Cathodic disbondment, ASTM G 8: passes 90 day test 

099XC_IE2AA.DOC 

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Category IE-2AB 

Use one of following: 

Bitumastic 300M; as manufactured by: Carboline, 350 Hanley Industrial Court, St. Louis 

MO, 314-644-1000, www.carboline.com 

Targuard; as manufactured by: Sherwin-Williams, 101 Prospect Avenue NW, Cleveland 

OH 44115, 216-566-2000, www.sherwin-williams.com 

Hi-Build Tnemec-Tar, Series 46H-413; as manufactured by: Tnemec Company, 6800 

Corporate Drive, Kansas City MO 64141, 800-863-6321, www.tnemec.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Self-priming, two component, polyamide, coal-tar epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS: 

Solids by volume: 72 percent, minimum 

VOC, as supplied: 1.88 pounds per gallon (225 grams per 

liter), maximum 

Mix ratio - resin:hardener: Varies by manufacturer 

Mixed usable pot life at 75 degrees F: 2 hours, minimum 

Ambient application temperature: 50 degrees F, minimum 

Substrate temperature above dew point: 5 degrees F, minimum 

Maximum DFT per coat: 16 to20 mils, varies by manufacturer 

Recoat time: Varies by manufacturer 

Full cure time before immersion at 70 14 days, minimum 

degrees F and 50 percent humidity: 

Application methods: Brush, roller, or spray 

Color/finish: Black or dark red/flat, gloss, or 

semigloss; varies by manufacturer 

PERFORMANCE REQUIREMENTS: 

Fresh/deionized water immersion test, 

ASTM D 870: 

Salt water immersion test, ASTM D 870; 

ASTM D 1141 formula A with no heavy 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

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metals: with no blisters evident on either 

scribed or unscribed sides. 

Abrasion resistance, ASTM D 4060, CS-17 120 milligram loss or less 

wheel, 1,000 cycles, 1-kg load: 

Flexibility, ASTM D 522, 180 degree bend passes 

over 1-inch mandrel: 

Pencil hardness, ASTM D 3363: 2B, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

Pulloff tape, ASTM D 3359: 4A or better 

Cathodic disbondment, ASTM G 8: passes 90 day test 

099XC_IE2AB.DOC 

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Category IE-1A1 

Amerlock 400 or Amerlock 2; as manufactured by:
 

PPG Protective & Marine Coatings, One PPG Place, Pittsburgh, Pennsylvania 15272,
 

412-434-3131, www.ppgamercoatus.ppgmc.com
 

or equal, having following essential characteristics: 

COMPOSITION: 

Self-priming, two component, polyamide epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS: 

Solids by volume: 80 percent, minimum 

VOC, as supplied: Amerlock 400: 1.4 pounds per gallon 

(168 grams per liter), maximum 

Amerlock 2: 1.5 pounds per gallon (180 

grams per liter), maximum 

Mix ratio - resin:hardener: 1:1
 

Mixed usable pot life at 50 degrees F: 2 hours, minimum
 

Ambient application temperature: 50 degrees F, minimum
 

Surface application temperature above 5 degrees F, minimum
 

dew point: 

Maximum DFT per coat: 10 mils 

Recoat time at 50 degrees F: Amerlock 400: 3 months, maximum 

Amerlock 2: 1 month, maximum 

Full cure time before immersion at 50 14 days, minimum
 

degrees F and 50 percent humidity:
 

Application methods: Brush, roller, or spray
 

Color/finish: Variety of colors/semigloss
 

PERFORMANCE REQUIREMENTS: 

Fresh/deionized water immersion test, 

ASTM D 870: 

Salt water immersion test, ASTM D 870; 

ASTM D 1141 formula A with no heavy 

metals: 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

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scribed or unscribed sides. 

Abrasion resistance, ASTM D 4060, CS-17 100 milligram loss or less 

wheel, 1,000 cycles, 1-kg load: 

Flexibility, ASTM D 522, 180 degree bend passes 

over 1⁄4-inch mandrel: 

Pencil hardness, ASTM D 3363: 2B, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

Pulloff tape, ASTM D 3359: 4A or better 

Cathodic disbondment, ASTM G 8: passes 90 day test 

099XC_IE1A1.DOC
 

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Category IE-1C 

Hi-Build Epoxoline II, Series N69 or V69; as manufactured by: 

Tnemec Company, 6800 Corporate Drive, Kansas City MO 64141 

800-863-6321, www.tnemec.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Self-priming, two component, polyamidoamine epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS: 

Solids by volume: 67 percent, minimum 

VOC, as supplied: N69: 2.29 lbs/gal (275 grams/liter) 

V69: 1.95 lbs/gal (234 grams/liter) 

Mix ratio - resin:hardener: 1:1 

Mixed usable pot life at 50 degrees F: 15 hours, minimum 

Ambient application temperature: 50 degrees F, minimum 

Surface application temperature above 5 degrees F, minimum 

dew point:
 

Maximum DFT per coat: 10 mils
 

Recoat time at 50 degrees F: 12 hours, minimum
 

Full cure time before immersion at 50 12 days, minimum
 

degrees F and 50 percent humidity:
 

Application methods: Brush, roller, or spray
 

Color/finish: Limited colors/semigloss
 

PERFORMANCE REQUIREMENTS: 

Fresh/deionized water immersion test, 

ASTM D 870: 

Salt water immersion test, ASTM D 870; 

ASTM D 1141 formula A with no heavy 

metals: 

Abrasion resistance, ASTM D 4060, CS-17 

wheel, 1,000 cycles, 1-kg load: 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

100 milligram loss or less 

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Flexibility, ASTM D 522, 180 degree bend passes 

over 1-inch mandrel: 

Pencil hardness, ASTM D 3363: 2B, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

Pulloff tape, ASTM D 3359: 4A or better 

Cathodic disbondment, ASTM G 8: passes 90 day test 

099XC_IE1C.DOC
 

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Category IE-1D 

Bar-Rust 235; as manufactured by: 

ICI Devoe Coatings, 4000 Dupont Circle, Louisville KY 40207 

502-897-9861, www.devoecoatings.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Self-priming, two component, modified polyamide-amine epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS: 

Solids by volume: 68 percent, minimum 

VOC, as supplied: 2.40 pounds per gallon (292 grams per 

liter), maximum
 

Mix ratio - resin:hardener: 4:1
 

Mixed usable pot life at 77 degrees F: 4.5 hours, minimum
 

Ambient application temperature: 50 degrees F, minimum
 

Surface application temperature above 5 degrees F, minimum
 

dew point:
 

Maximum DFT per coat: 10 mils
 

Recoat time at 60 degrees F: 6 hours, minimum
 

Full cure time before immersion at 60 14 days, minimum
 

degrees F and 50 percent humidity: 

Application methods: Brush, roller, or spray 

Color/finish: Variety of colors, off-white/semigloss 

PERFORMANCE REQUIREMENTS: 

Fresh/deionized water immersion test, 

ASTM D 870: 

Salt water immersion test, ASTM D 870; 

ASTM D 1141 formula A with no heavy 

metals: 

Abrasion resistance, ASTM D 4060, CS-17 

wheel, 1,000 cycles, 1-kg load: 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

passes, 3,000 hour test with aerated 

water held at ambient temperature 

with no blisters evident on either 

scribed or unscribed sides. 

100 milligram loss or less 

Painting for Concrete 

09 91 11 - 27 
 

 


	


	


 

Feature Name
	

Spec Title Solicitation No.
	

Flexibility, ASTM D 522, 180 degree bend passes 

over 1-inch mandrel: 

Pencil hardness, ASTM D 3363: 3H, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

Pulloff tape, ASTM D 3359: 4A or better 

Cathodic disbondment, ASTM G 8: passes 90 day test 

099XC_IE1D.DOC
 

Painting for Concrete 

09 91 11 - 28 
 

 

 

 


	


	


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


	


	


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 


 

Feature Name
	

Spec Title Solicitation No.
	

Category AE-1AT 

Amercoat 450HS; as manufactured by:
 

PPG Protective & Marine Coatings, One PPG Place, Pittsburgh, Pennsylvania 15272,
 

412-434-3131, www.ppgamercoatus.ppgmc.com
 

or equal, having following essential characteristics: 

COMPOSITION: 

Topcoat – Two-component, aliphatic polyurethane 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS, PRIMER: 

Solids by volume: 63 percent, minimum 

VOC, as supplied: 2.4 pounds per gallon (287.5 grams per 

liter), maximum
 

Mix ratio - resin:hardener: 4:1
 

Mixed usable pot life at 50 degrees F: 6 hours, minimum
 

Ambient application temperature: 50 degrees F, minimum
 

Surface application temperature above 5 degrees F, minimum
 

dew point:
 

Maximum DFT per coat: 3 mils
 

Recoat time at 50 degrees F and 50 12 days, minimum
 

percent humidity:
 

Application methods: Brush, roller, or spray
 

Color/finish: Variety of colors/gloss
 

PERFORMANCE REQUIREMENTS: 

QUV accelerated weathering test, ASTM 

D 4587, ASTM G 154: 

Flexibility, ASTM D 522, 180 degree bend
 

over 1-inch mandrel:
 

Pencil hardness, ASTM D 3363:
 

Pulloff adhesion, ASTM D 4541, annex A2,
 

type II tester:
 

Pulloff tape, ASTM D 3359:
 

Passes 3,000 hour test with no blisters 

evident on either scribed or unscribed 

sides, or color difference ASTM D 2244. 

passes 

2B, minimum 

500 psi or greater 

equal to 4A or better 

099XC_AE1AT.DOC
 

Painting for Concrete 

09 91 11 - 29 
 

 

 

 


	


	


 


 


 


 


 


 


 


	


	


 


 


 


 


 


 


 

Feature Name
	

Spec Title Solicitation No.
	

Category AE-1CT 

Endura-Shield II, Series 1074, gloss, or Series 1075, semigloss; as manufactured by: 

Tnemec Company, 6800 Corporate Drive, Kansas City MO 64141 

800-863-6321, www.tnemec.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Topcoat – Two-component, aliphatic acrylic, polyurethane 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS, PRIMER: 

Solids by volume: 68 percent, minimum 

VOC, as supplied: 1.84 lbs/gal (220 grams/liter) 

Mix ratio - resin:hardener: 8:1 

Mixed usable pot life at 77 degrees F: 2 hours, maximum 

Ambient application temperature: 50 degrees F, minimum 

Surface application temperature above 5 degrees F, minimum 

dew point: 

Maximum DFT per coat: 5 mils 

Recoat time at 75 degrees: 8 hours, minimum 

Application methods: Brush, roller, or spray 

Color/finish: Variety of colors/gloss or semigloss 

PERFORMANCE REQUIREMENTS: 

QUV accelerated weathering test, ASTM 

D 4587, ASTM G 154: 

Flexibility, ASTM D 522, 180 degree bend
 

over 1-inch mandrel:
 

Pencil hardness, ASTM D 3363:
 

Pulloff adhesion, ASTM D 4541, annex A2,
 

type II tester:
 

Pulloff tape, ASTM D 3359:
 

Passes 3,000 hour test with no blisters 

evident on either scribed or unscribed 

sides, or color difference ASTM D 2244. 

passes 

2B, minimum 

500 psi or greater 

equal to 4A or better 

099XC_AE1CT.DOC
 

Painting for Concrete 

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Feature Name
	

Spec Title Solicitation No.
	

Category AE-1DT 

Devthane 379 UVA as manufactured by: 

ICI Devoe Coatings, 4000 Dupont Circle, Louisville KY 40207 

502-897-9861, www.devoecoatings.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Topcoat – Two-component, aliphatic acrylic, urethane 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS, Topcoat: 

Solids by volume: 63 percent, minimum 

VOC, as supplied: 2.6 pounds per gallon (311 grams per 

liter), maximum
 

Mix ratio - resin:hardener: 4:1
 

Mixed usable pot life at 77 degrees F: 4 hours, minimum
 

Ambient application temperature: 50 degrees F, minimum
 

Surface application temperature above 5 degrees F, minimum
 

dew point: 

Maximum DFT per coat: 3 mils 

Recoat time at 60 degrees F: 6 hours, minimum 

Application methods: Brush, roller, or spray 

Color/finish: Variety of colors, white/gloss 

PERFORMANCE REQUIREMENTS: 

QUV accelerated weathering test, ASTM 

D 4587, ASTM G 154: 

Flexibility, ASTM D 522, 180 degree bend
 

over 1-inch mandrel:
 

Pencil hardness, ASTM D 3363:
 

Pulloff adhesion, ASTM D 4541, annex A2,
 

type II tester:
 

Pulloff tape, ASTM D 3359:
 

Passes 3,000 hour test with no blisters 

evident on either scribed or unscribed 

sides, or color difference ASTM D 2244. 

passes 

2B, minimum 

500 psi or greater 

equal to 4A or better 

099XC_AE1DT.DOC
 

Painting for Concrete 

09 91 11 - 31 
 

 

 

 


	


	


 


 


 


 


 


 


 


 


	


	


 


 


 


 


 


 


 


 

Feature Name
	

Spec Title Solicitation No.
	

Category AES-1F 

Series 201 Epoxoline, primer; Series 221 Lami-Tread, double broadcast, intermediate coat; 

Series 280 Tneme-Glaze, topcoat; as manufactured by: 

Tnemec Company, 6800 Corporate Drive, Kansas City MO 64141 

800-863-6321, www.tnemec.com 

or equal, having following essential characteristics: 

COMPOSITION: 

Primer – Two-component, polyamine epoxy 

Intermediate coat – Two-component, aggregate-filled, polyamine, epoxy 

Topcoat – Two-component, polyamine epoxy 

Lead and chromate free. 

PHYSICAL CHARACTERISTICS, PRIMER: 

Solids by volume: 94 percent, minimum 

Weight per gallon: 8.63 pounds per gallon, minimum 

VOC, as supplied: 0.33 pounds per gallon (39 grams per 

liter), maximum 

Optimum application temperature: 70 to 90 degrees F 

Maximum DFT per coat: 8 mils, varies by manufacturer 

Recoat time at 75 degrees F: 16 hours, maximum 

Application methods: Brush, roller, squeegee, or spray 

Color: Clear 

PHYSICAL CHARACTERISTICS, INTERMEDIATE COAT: 

Solids by volume mixed with aggregate: 95.5 percent, minimum 

VOC, as supplied: 0.75 pounds per gallon (90 grams per 

liter), maximum
 

Optimum application temperature: 70 to 90 degrees F
 

Maximum DFT per coat: 1/16-inch
 

Recoat time at 75 degrees F: 24-hours, maximum
 

Application methods: Roller, trowel, or squeegee
 

Color: Medium gray, tile red, buff
 

PHYSICAL CHARACTERISTICS, TOPCOAT: 

Solids by volume: 96 percent, minimum 

VOC, as supplied: 0.34 pounds per gallon (41 grams per 

liter), maximum
 

Optimum application temperature: 70 to 90 degrees F
 

Painting for Concrete 

09 91 11 - 32 
 

 

 

 

 

 

 

 

 

 

 

 


	


	

	 

		

		

		

		

		

		

		

		

		

		

		

	 


	


	

		

		

		

		

		

		

		

		

		

		

		

		

	 

Feature Name
	

Spec Title Solicitation No.
	

Maximum DFT per coat: 12 mils 

Recoat time at 75 degrees F: 24-hours, maximum 

Application methods: Brush, roller, or spray 

Color/finish: Variety of colors/gloss 

PERFORMANCE REQUIREMENTS: 

Abrasion resistance, ASTM D 4060, CS-17 90 milligram loss or less 

wheel, 1,000 cycles, 1-kg load: 

Pencil hardness, ASTM D 3363: 2H, minimum 

Pulloff adhesion, ASTM D 4541, annex A2, 500 psi or greater 

type II tester: 

099XC_AES1F.DOC 

3.10		 23[COLOR SCHEDULE] 

A.		 Colors and glosses of finished coats: 

1.		 Meet requirements of schedule _____ (Color Schedule) specified below. 

2.		 Meet accurate match of color and gloss of specified coated surfaces. 

B.		 24[Color 25{and gloss} to meet one or more of following: 

1.		 Munsell Book of Color. 

2.		 Fed Std 595B. 

3.		 Manufacturer’s standard color.] 

C.		 26[Match existing color and gloss in Tabulation No. __.] 

D.		 27[Gloss abbreviations: 

1.		 G - Full Gloss. 

2.		 SG - Semigloss. 

23	 Alternative to using Color Schedule: For limited items to receive a specific color, finished colors may be 

specified in Coating Tabulation by Munsell Color, Federal Standard 595B, or manufacturer’s standard 

color and gloss. 

24 Specify color references listed in Color Schedule. 

25 Specify if gloss column is listed in Color Schedule table. 

26 Specify to match an existing color and gloss. 

27 Specify gloss types if listed in Color Schedule table. 

Painting for Concrete 

09 91 11 - 33 
 

 

 

 

 

 

 

 

 

 


	


	

		

		

		

		

		

		

		

	 

		


	


	


	


	


	


	

		

		

		

		

		

		

		

		

		


	


	


	


	

Feature Name
	

Spec Title Solicitation No.
	

3.		 ES - Eggshell. 

4.		 L - Lusterless. 

5.		 VF – Velvet flat. 

6.		 SF – Satin flat. 

7.		 F - Flat.] 

E.		 Color schedule table: 

1.		 Numbers listed in the "Tabulation No." column correspond to Items to be coated 

listed in Coating Tabulations. 

Schedule ____. - Color Schedule. 

Tabulation 

No. 

28[Item Surface] Color Color No. 29[Gloss] 

2 Concrete floor. Gray 30[16440] G 

3 Vertical concrete walls. Gray 31[7.5YR7/4] SG 

3.11		 32[COLOR SCHEDULE 

A.		 Color and gloss of finished coats to be selected by CO with approval of coatings.] 

END OF SECTION 

28 Specify item surface with exact wording listed in Coating Tabulation.
	

29 Specify gloss column if specified gloss type is available for coating products.
	

30 Example of Federal Standard 595B notation.
	

31 Example of Munsell Color notation.
	

32 Specify if color and gloss of finished coated items are to be selected after bid acceptance and include 

responsible code or office in RSN table. 

Painting for Concrete 

09 91 11 - 34