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Ohio Department of Natural Resources

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OHIO
DIVISION OF WATER

Division of Water Fact Sheet

Fact Sheet 94–32

Dam Safety: Concrete Repair Techniques

C
oncrete is an inexpensive, durable, strong and 1. The Dry-Pack Method: The dry-pack method can be
basic building material often used in dams for used on small holes in new concrete which have a depth
core walls, spillways, stilling basins, control tow- equal to or greater that the surface diameter. Preparation
ers, and slope protection. However, poor workmanship, of a dry-pack mix typically consists of about 1 part
construction procedures, and construction materials may portland cement and 2 1/2 parts sand to be mixed with
cause imperfections that later require repair. Any long- water. You then add enough water to produce a mortar
term deterioration or damage to concrete structures caused that will stick together. Once the desired consistency is
by flowing water, ice, or other natural forces must be reached, the mortar is ready to be packed into the hole
corrected. Neglecting to perform periodic maintenance and using thin layers.
repairs to concrete structures as they occur could result in
failure of the structure from either a structural or hydraulic 2. Concrete Replacement: Concrete replacement is re-
standpoint. This in turn may threaten the continued safe quired when one-half to one square foot areas or larger
operation and use of the dam. extend entirely through the concrete sections or where
the depth of damaged concrete exceeds 6 inches. When
Considerations this occurs, normal concrete placement methods should
Floor or wall movement, extensive cracking, improper be used. Repair will be more effective if tied in with
alignments, settlement, joint displacement, and extensive existing reinforcing steel (rebar). This type of repair will
undermining are signs of major structural problems. In require the assistance of a professional engineer experi-
situations where concrete replacement solutions are re- enced in concrete construction.
quired to repair deteriorated concrete, it is recommended
3. Replacement of Unformed Concrete: The replacement
that a registered professional engineer be retained to per-
of damaged or deteriorated areas in horizontal slabs
form an inspection to assess the concrete's overall condi-
involves no special procedures other than those used in
tion, and determine the extent of any structural damage and
good construction practices for placement of new slabs.
necessary remedial measures.
Repair work can be bonded to old concrete by use of a
Typically, it is found that drainage systems are needed to bond coat made of equal amounts of sand and cement.
relieve excessive water pressures under floors and behind It should have the consistency of whipped cream and
walls. In addition, reinforcing steel must also be properly should be applied immediately ahead of concrete place-
designed to handle tension zones and shear and bending ment so that it will not set or dry out. Latex emulsions
forces in structural concrete produced by any external with portland cement and epoxy resins are also used as
loading (including the weight of the structure). Therefore, bonding coats.
the finished product in any concrete repair procedure
4. Preplaced Aggregate Concrete: This special commer-
should consist of a structure that is durable and able to
cial technique has been used for massive repairs, par-
withstand the effects of service conditions such as weath-
ticularly for underwater repairs of piers and abutments.
ering, chemical action, and wear. Because of their complex
The process consists of the following procedures: 1)
nature, major structural repairs that require professional
Removing the deteriorated concrete, 2) forming the
advice are not addressed here.
sections to be repaired, 3) prepacking the repair area
Repair Methods with coarse aggregate, and 4) pressure grouting the
Before any type of concrete repair is attempted, it is voids between the aggregate particles with a cement or
essential that all factors governing the deterioration or sand-cement mortar.
failure of the concrete structure are identified. This is 5. Synthetic Patches: One of the most recent developments
required so that the appropriate remedial measures can be in concrete repair has been the use of synthetic materials
undertaken in the repair design to help correct the problem for bonding and patching. Epoxy-resin compounds are
and prevent it from occurring in the future. The following used extensively because of their high bonding proper-
techniques require expert and experienced assistance for ties and great strength. In applying epoxy-resin patching
the best results. The particular method of repair will depend
on the size of the job and the type of repair required. Continued on back!
 mortars, a bonding coat of the epoxy resin is thoroughly In general, the concrete repair procedures discussed above
brushed onto the base of the old concrete. The mortar is should be considered on a relative basis and in terms of the
then immediately applied and troweled to the elevation quality of concrete that one wishes to achieve for their
of the surrounding material. particular construction purpose. In addition to being ad-
equately designed, a structure must also be properly con-
Before attempting to repair a deteriorated concrete sur- structed with concrete that is strong enough to carry the
face, all unsound concrete should be removed by sawing or design loads, durable enough to withstand the forces asso-
chipping and the patch area thoroughly cleaned. A sawed ciated with weathering, and yet economical, not only in
edge is superior to a chipped edge, and sawing is generally first cost, but in terms of its ultimate service. It should be
less costly than mechanical chipping. Before concrete is emphasized that major structural repairs to concrete should
ordered for placing, adequate inspection should be per- not be attempted by the owner or persons not experienced
formed to ensure that (1) foundations are properly prepared in concrete repairs. A qualified professional engineer expe-
and ready to receive the concrete, (2) construction joints are rienced in concrete construction should be obtained for the
clean and free from defective concrete, (3) forms are grout- design of large scale repair projects.
tight, amply strong, and set to their true alignment and
grade, (4) all reinforcement steel and embedded parts are Crack Repair
clean, in their correct position, and securely held in place, The two main objectives when repairing cracks in concrete
and (5) adequate concrete delivery equipment and facilities
are structural bonding and stopping water flow. For a struc-
are on the job, ready to go, and capable of completing the
tural bond, epoxy injection can be used. This process can be
placement without addition unplanned construction.
very expensive since a skilled contractor is needed for proper
Concrete Use Guidelines installation. The epoxy is injected into the concrete under
In addition to its strength characteristics, concrete must pressure, welding the cracks to form a monolithic structure.
also have the properties of workability and durability. This method of repair should not be considered if the crack is
Workability can be defined as the ease with which a given still active (moving). For a watertight seal, a urethane sealant
set of materials can be mixed into concrete and subse- can be used. This repair technique does not form a structural
quently handled, transported, and placed with a minimal bond; however, it can be used on cracks that are still active.
loss of homogeneity. The degree of workability required Cracks should be opened using a concrete saw or hand tool
for proper placement and consolidation of concrete is prior to placing the sealant. A minimum opening of 1/4 inch is
governed by the dimensions and shape of the structure and recommended since small openings are hard to fill. Urethane
by the spacing and size of the reinforcement. The concrete,
sealants can be reapplied since they are flexible materials and
when properly placed, will be free of segregation, and its
mortar is intimately in contact with the coarse aggregate, will adhere to older applications. As previously noted, all of
the reinforcement, and/or any other embedded parts or the factors causing cracking must be identified and addressed
surfaces within the concrete. Separation of coarse aggre- before repairing the concrete to prevent the reoccurrence of
gate from the mortar should be minimized by avoiding or cracks.
controlling the lateral movement of concrete during han-
Any other questions, comments concerns, or fact sheet
dling and placing operations. The concrete should be de- requests, should be directed to the Division of Water at the
posited as nearly as practicable in its final position. Placing following address:
methods that cause the concrete to flow in the forms should
be avoided. The concrete should be placed in horizontal Ohio Department of Natural Resources
layers, and each layer should be thoroughly vibrated to Division of Water
obtain proper compaction.
Dam Safety Engineering Program
All concrete repairs must be adequately moist-cured to be 2045 Morse Road
effective. The bond strength of new concrete to old con- Columbus, Ohio 43229-6693
crete develops much more slowly, and the tendency to Voice: (614) 265-6731 Fax: (614) 447-9503
shrink and loosen is reduced by a long moist-curing period. Website: http://www.dnr.state.oh.us/water

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