15 March 2001
SUMMARY OF SPALL REPAIR
3.1. Selecting Repair Materials and Procedure. Refer to Figures 3.1. through 3.6. for details
on spall repairs in various slab locations and spall repair boundaries. Refer to Table 3.1. for
notes on Figures 3.1. through 3.6. Select the spall repair materials and the spall repair procedure
(saw and patch is recommended). The recommended patch materials are discussed in
Chapter 13; however, use of these materials (concrete, joint sealer, joint filler, etc.) must meet
specifications and/or be authorized by base engineers. As with any repair operation, the
cleanliness of the area to be patched is one of the most important factors in a long-lasting patch.
Extra care must always be taken to ensure the repair area is clean before repair. The timing of
the repair should be such that the prepared spall recess is not exposed to the elements for more
than 24 hours without additional cleaning.
3.2. Removing Old Sealant. Remove any sealant present in the joint or crack adjacent to the
spall as discussed in Chapters 5 and 9.
3.3. Boundaries. Cut
a boundary around the area
to a depth
of at least
2 inches (50 millimeters)
using a concrete or a hand saw (Figure 14.1.). The spall repair area should be sized as
described in Chapter 12.
3.4. Concrete Removal. Remove the concrete inside the boundary to a depth of at least 2
inches (50 millimeters), or 1/2 inch (13 millimeters) into visually sound concrete, which ever is
deeper. Use a light jackhammer (less than 30 pounds (14 kilograms)) equipped with a chipping
hammer (Figure 14.2.), scarifier, or high-pressure water blaster (Figure 9.4.). If a dowel is
exposed during the concrete removal, it must be replaced (References 1.3.1., 1.3.6., or 1.3.9. for
details on dowel replacement). If more than 90 degrees of the perimeter of reinforcement is