RAP-3

www.concrete.org

Spall Repair
by Low-Pressure Spraying
Reported by ACI Committee E 706
Brian F. Keane*
Chairman

J. Christopher Ball H. Peter Golter Jay H. Paul

Floyd E. Dimmick, Sr. Bob Joyce George I. Taylor
Peter H. Emmons§ Kenneth M. Lozen Patrick M. Watson‡
Timothy R. W. Gillespie John S. Lund David W. Whitmore
Richard Montani†
*
Primary author of RAP Bulletin No. 1.
†
Primary author of RAP Bulletin No. 2.
‡Primary author of RAP Bulletin No. 3.
§
Primary author of RAP Bulletin Nos. 4 and 5.

The committee would like to thank Brandon Emmons for his illustrations in these bulletins.

It is the responsibility of the user of this document to Structural Disclaimer

establish health and safety practices appropriate to the specific
circumstances involved with its use. ACI does not make any This document is intended as a voluntary field guide for
representations with regard to health and safety issues and the use the Owner, design professional, and concrete repair con-
of this document. The user must determine the applicability of tractor. It is not intended to relieve the user of this guide
all regulatory limitations before applying the document and of responsibility for a proper condition assessment and
must comply with all applicable laws and regulations,
including but not limited to, United States Occupational structural evaluation of existing conditions, and for the
Safety and Health Administration (OSHA) health and specification of concrete repair methods, materials, or
safety standards. practices by an experienced engineer/designer.

ACI Repair Application Procedure 3.

Copyright © 2003, American Concrete Institute.
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the copyright proprietors. Printed in the United States of America. the information provided.
 ACI RAP Bulletin 3

Spall Repair
FIELD GUIDE TO
CONCRETE REPAIR by Low-Pressure
APPLICATION PROCEDURES
Spraying
by Patrick “Doc” Watson

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 1

Introduction
Similar to wet-mix shotcrete but sprayed at a much lower
velocity, low-pressure spall repair spray comes in the form
of prepackaged mortar. The spray is applied using small concrete
pumps or heavy-duty grout pumps to force the low-slump
mortar through a hose. Air is added at the nozzle to impel the
mortar. Bond with the prepared substrate is achieved through
a combination of proper surface preparation, low-velocity
impact, and the material properties of the prepackaged mortar.
Compared with either wet- or dry-mix shotcreting, this
method allows the spray nozzle to be much closer to the
repair surface. This means it can be used in tight spaces. Due
to the viscous, sticky nature of the mixture and the low pressures
involved, there is considerably less rebound than with high-
velocity shotcreting.
Before any concrete repair is carried out, the cause of the
damage must be assessed and the objective of the repair must
Fig. 1—Typical plus or minus 1/4 in. profile. (From ICRI Guide
be understood.
No. 03732 Profile No. 7). This is the standard recommended
Typical causes of concrete deterioration include steel
surface profile for low-pressure spray-applied mortars.
corrosion, sulfate attack, alkali-aggregate reactions
(AARs), excessive deflection, and freeze-thaw damage.
Poor practices during the original construction can lead
to premature deterioration. Improper joint spacing and load
imbalances also contribute to cracking and spalling.
What is the purpose of this repair?
Depending on the mortar mixture selected, low-pressure
spray is used for surface repairs, structural repairs, or cosmetic
renovation. The spray can be formulated for freeze-thaw
durability, sulfate resistance, low permeability, and other
desired or specified characteristics.
When do I use this method?
Low-pressure spray is typically used for vertical and over-
head repairs. Successful applications have included structural
repairs to bridges, bridge and building piers, structural slab
undersides, tank walls (interior and exterior), stadiums, tunnels,
and retaining walls. Structural repairs utilizing low-pressure
spray are best done under the guidance of a qualified engineer.
The placement thickness can be 1/2 to 4 in. (13 to 100 mm) in
a single lift. Thicknesses greater than 6 in. (150 mm) are
possible in multiple lifts. If the repair application requires more
than a 4 in. (100 mm) thickness, other methods may be more Fig. 2—Chipping surface.
economical (see ICRI Guideline No. 03731, “Guide for Selecting
Application Methods for the Repair of Concrete Surfaces”).
The ingredients that make up the mortar vary widely, and Concrete Resulting from Reinforcing Steel Corrosion.”
the ingredients selected will depend on the specific repair situation. Because many of the materials applied using low-pressure
Formulas may contain ingredients such as corrosion in- spray are prepackaged, the manufacturer’s recommendations
hibitors, air-entraining agents, and bonding additives. should also be consulted.
The initial material costs are generally higher with this A typical roughness or profile recommendation for this re-
method than for a typical shotcrete application, but in-place pair method is ICRI Concrete Surface Profile (CSP) No. 7 or
costs are often lower or comparable because this method higher, as per ICRI Guideline No. 03730. A CSP No. 7 is
produces less rebound and requires less cleanup. Certified equivalent to an amplitude of approximately 1/4 in. (7 mm)
nozzle operators are not required. (see Fig. 1).
Factors that will influence the specific surface preparation
How do I prepare the surface? include, but are not limited to:
Consult the recommendations of ICRI Guideline No. 03732, • Desired roughness profile of the prepared surface (CSP);
“Selecting and Specifying Concrete Surface Preparation for • Method of preparation. These may include, but are
Sealers, Coatings, and Polymer Overlays,” or ICRI Guideline not limited to, hydrodemolition, sandblasting, and
No. 3730, “Surface Preparation for Repair of Deteriorated use of pneumatic hammers (see Fig. 2);

2 Repair Application Procedures Bulletin 3

Fig. 3—Presaturate prepared surface with water.

• Possible contamination of the surface by chemicals,

oils, soaps, or carbonation. Test for carbonation with
a pH indicator. The pH should be 11.5 or higher; (a)
• Methods of treatment for contaminated surfaces.
• Required substrate saturation (see Fig. 3);
• Reinforcing requirements from the mortar manufac-
turer, the engineer, or the owner; and
• Treatment of existing cracks and joints: Repair the
cracks? How? Fill the joints? If so, how and with what?
How do I select the right material?
Low-pressure spray-applied repair materials are proprietary,
prepackaged cementitious products. Specifiers, applicators,
and owners should consult ICRI Guideline No. 03733, “A
Guide for Selecting and Specifying Materials for Repair of
Concrete Surfaces.” Consult the American Concrete Institute
publications on concrete repair by ACI Committee 546,
Repair of Concrete. Refer to manufacturers’ data sheets for
material properties.
Physical property requirements such as bond strength,
freeze-thaw durability, permeability, and flexural strength will
vary from project to project.
When low-pressure spray-applied materials are used, some
repair applications may require that the material be coated
with a protective barrier system. When this is the case, (b)
confirm the required curing and drying time before installing
the coating. Fig. 4(a) and (b)—Application of mortar with pressure
equipment and nozzle.
What equipment do I need?
Be sure that all necessary equipment and tools are on site • Air compressor with pressure gages and controls.
and in proper working order. Have backup equipment or (Some pumps come equipped with built-in air
alternate methods planned and available. Typical equipment compressors and controls.);
needed for low-pressure spray application of repair mortars • A suitable mixer for mixing the mortar is needed. A
includes, but is not limited to: backup mixer is recommended in case of breakdown.
• Concrete or grout pumps suitable for low-pressure (Some repair type pumps come equipped with mor-
spray. Field experience has shown that ball valve tar mixers.); and
pumps are not suitable. Short stroke, swing-type • A water measuring device, preferably a meter. (Many
piston pumps or heavy-duty rotor-stator pumps repair-type pumps equipped with mixers include
perform well; built-in water meters.).
• If using a rotor-stator or “moyno” type pump, have a • A means of communication between the pump and
backup rotor on hand at the job site; mixer operators and the nozzleman.

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 3

Fig. 5—Skilled worker applying final finish to surface. Fig. 6—Application of curing compound.

• All finishing, handling, and testing tools required by must comply with all applicable laws and regulations including,
specification or good concreting practices. but not limited to, United States Occupational Safety and Health
What are the safety considerations? Administration (OSHA) health and safety standards.
Prepackaged mortars are hazardous materials and should Preconstruction meeting
be treated as such. Job-site safety practices should include, Prior to proceeding with the repair, a preconstruction meeting
but are not limited to, the following where applicable: is recommended. The meeting should include representatives
• Material Safety Data Sheets (MSDS) should be on from all participating parties (owner, engineer, contractor,
hand; materials manufacturer, etc.), and specifically address the
• Safety equipment: all machinery and equipment being parameters, means, methods, and materials necessary to
used must have the correct safety equipment, guards, achieve the repair objectives.
and warnings in place;
• Protective clothing: protective gloves for workers in Repair procedure
contact with wet, cementitious material; 1. The prejob (preconstruction) meeting agenda might
• Protective eyewear: safety glasses or face shields will include:
be needed for all workers; • On-site availability of power;
• Eyewash facilities should be provided; • On-site availability of water;
• Respirators: dust masks will be needed for workers • Site accessibility;
operating the material mixer; • Debris removal and disposal;
• Ventilation of closed spaces: confirm that adequate • Dust, odor, and emissions control;
ventilation is available before operating equipment • Confirmation that all materials documentation is on
that emits dangerous exhaust; hand—for example, MSDS sheets;
• Secured storage should be available for all hazardous • Methods of curing and time required for curing;
materials; • Possible emergencies and breakdowns—what to do
• Fuel for equipment operation needs a safe storage if they occur;
area, well marked and visible; and • Finish requirements;
• A safety meeting with all involved should be held • Testing required; and
and led by the prime contractor’s safety manager • All other concerns that could affect the progress of
prior to beginning repair operations. the repair.
It is the responsibility of the user of this document to establish 2. Apply the repair.
health and safety practices appropriate to the specific • Inspect and approve the surface preparation. (See
circumstances involved with its use. ACI does not make any ICRI and ACI references);
representations with regard to health and safety issues and the • Presaturate the prepared substrate. Twenty-four hours
use of this document. The user must determine the applicability is standard. Prepared saturated surface should be saturated
of all regulatory limitations before applying the document and surface-dry when the repair mortar is sprayed;

4 Repair Application Procedures Bulletin 3

 • Install the specified reinforcement; How do I check the repair?
• Install/apply bonding agents, corrosion inhibitor Requirements may include:
sacrificial anodes, if called for; • Before and after photos;
• Mix the repair mortar and load it into pump hopper. • Confirmation of acceptable surface preparation. This
• Begin spray operations with pump, compressor, and can include the prepared surface profile and the pH
suitable spray nozzle; and of the prepared surface. A pH of 11.5 or greater is
• Apply the mortar at the thickness recommended by recommended;
the material manufacturer. Most low-pressure spray • Confirm repair depth;
materials require application in lifts when the thickness of • Material property tests performed by a qualified
the total application layer exceeds 3 in. (76 mm). testing agency. This is usually done to confirm the
3. Finish the repair. material manufacturers’ published material properties;
Confirm the final finished appearance of the repair with the • In-situ direct tensile strength tests of the prepared
owner. This may vary from rough as-sprayed to smooth troweled. surface;
If smooth troweling is specified, production may be reduced • In-situ bond direct tensile tests of the hardened, cured
and additional labor may be required. One nozzle operator repair; and
may require multiple finishers to keep pace. This will be • Confirmation that all materials used were as speci-
influenced by such factors as: fied, cross checking material purchase orders with
• The installed thickness of the material being applied; quantities estimated and with actual quantities billed.
• The drying conditions caused by ambient and substrate
temperatures;
Sources for additional information
• The setting characteristics of the repair mortar; and
ACI Committee 308, 1998, “Standard Specification for Curing Concrete
• Whether the repair is vertical or overhead. (ACI 308.1-98),” American Concrete Institute, Farmington Hills, Mich.,
Because of the non-bleeding, sticky nature of these materials, 1998, 9 pp.
use of an evaporation control film when finishing is recommended. ACI Committee 308, 2001, “Guide to Curing Concrete (ACI 308R-01),”
American Concrete Institute, Farmington Hills, Mich., 2001, 31 pp.
Proper curing is important and should be conducted in ACI Committee 503, 1993, “Use of Epoxy Compounds with Concrete
accordance with ACI 308.1-98, “Standard Specification (ACI 503R-93),” Appendix A, Farmington Hills, Mich., 28 pp.
for Curing Concrete.” Additional curing information is avail- ACI Committee 506, 1995, “Guide to Shotcrete (506R-90 (Reapproved
1995)),” American Concrete Institute, Farmington Hills, Mich., 41 pp.
able from ACI 308R-01, “Guide to Curing Concrete.” ACI Committee 546, 1996, “Concrete Repair Guide (ACI 546R-96),”
For most cementitious low-pressure spray-applied mortars, American Concrete Institute, Farmington Hills, Mich., 1996, 41 pp.
application of a curing compound that complies with the mois- “Guide for Selecting Application Methods for the Repair of Concrete
Surfaces,” ICRI Guideline No. 03731, 1996.
ture retention requirements ASTM C 309 is satisfactory. As “Guide for Selecting and Specifying Materials for Repair of Concrete
an alternate, moist cure for 7 days. Surfaces,” ICRI Guideline No. 03733, 1997.
Always refer to the mortar manufacturer’s instructions for “Selecting and Specifying Concrete Surface Preparation for Sealers,
Coatings, and Membranes,” ICRI Guideline No. 03732, 1997.
specific curing methods and materials recommenced for the “Surface Preparation for Repair of Deteriorated Concrete Resulting from
product selected. Reinforcing Steel Corrosion,” ICRI Guideline No. 03730, 1995.

Spall Repair by Low-Pressure Spraying (ACI RAP-3) 5