Concrete repair & Maintenance – how to…
Updated: 2 days ago
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:
Determine the cause(s) of damage
Evaluate the extent of damage
Evaluate the need to repair
Select the repair method and material
Prepare the existing concrete for repair
Apply the repair method
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. Other organizations, such as the American Concrete Institute (ACI), the Portland Cement Association, the International Concrete Repair Institute, and private authors 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.
In our experience, the first two steps, determining the cause and evaluating the extent of damage, are where most quick concrete fixes go wrong. A surface patch over cracking caused by rebar corrosion will fail again within a season, because the underlying steel keeps expanding as it rusts. Before recommending a repair method, we look at exposed rebar and surrounding cracking patterns to confirm whether the damage is cosmetic spalling, active corrosion, or a structural issue that needs an engineer's sign-off.
The most common causes we see in commercial parking structures and building foundations are freeze-thaw cycling, chloride exposure from de-icing salts or coastal air, and chemical exposure from vehicle fluids or industrial processes. Each of these calls for a different repair material and surface prep, which is why skipping straight to "what product do we use" before diagnosing the cause tends to produce a repair that looks fine for a year and then fails in the same spot.
If you're a property or facilities manager noticing cracking, spalling, or rust staining on an exterior concrete surface, it's worth getting a professional evaluation before it spreads. Minor surface issues caught early are a relatively inexpensive patch; the same damage left untreated for a few more freeze-thaw cycles can turn into a full section replacement.
