15 March 2001
exposed, a space at least 1/2 inch (13 millimeters) completely around the bar or wire must be
3.5. Concrete Soundness. Visually check the underlying concrete for soundness and remove
any concrete found to be unsound.
3.6. Cleaning. Clean out the spall recess using high-pressure water and compressed air.
3.7. Sweeping. Sweep the area to prevent debris from reentering the spall repair area.
3.8. Joint Filler. Install preformed joint filler to provide a rigid boundary next to the joint or crack
and to retain the shape of the joint. This filler must extend the full length of the joint or crack for
the full depth of the spall repair area.
3.9. Bonding Agent.
If required for the repair material, apply bonding agent
to the spall repair
surface (Figure 16.1.). Always ensure that the spall repair is clean before adding bonding agents
or any repair material. If the spall repair area is large and portland cement concrete (PCC) is the
repair material to be used, be sure to place the grout rapidly so areas do not begin to dry prior to
filling the area. Place the spall repair material (Figure 16.2.), finish the surface (Figure 16.3.), and
follow the curing procedure recommended by the manufacturer of the repair material or refer to
the guidelines outlined in Chapter 16, "Spall Repair Procedures."
3.10. Sawing. Where the spalled area abuts a joint, an insert or other bond-breaking medium
shall be used to prevent bond at the joint face. After the curing is complete, a reservoir for the
joint sealant shall be sawed with a small-diameter saw blade to the dimensions required for other
joints, or as required to be routed for cracks. Sandblast each face of the fresh sawcut, wash with
high-pressure water, airblast, and sweep the area. Place the proper width backer rod at the
required depth for the sealant. Place the sealant from the bottom up and in one smooth operation
from the beginning to the end of the joint or crack.