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10/10/12

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SWIFTCAPTG2012
BESTPRACTICESINAIRFIELDCONCRETE
PAVEMENTMAINTENANCE
PARTIALANDFULLDEPTHPATCHREPAIRS
HakanEkim
TeknikaInc.,Toronto
September18,2012
Ban,Alberta
Requirements
QuickRepairswithnoorminimumclosures
oroperaAonaldelays
HighQualityandlonglasAngpatchrepairs.
Theydonotwishtoreturntotherepairina
verynearfuture
Noprematurefailure.FOD!
MajorChallenges
PropereducaAonofthemaintenance
personneltoensureworkisdoneasper
manufacturesspecs.
Nothavingenoughdataorsuccessfulcase
histories.
Lackofmutualunderstandinginbetween
variousparAesinvolved>>CommunicaAon??
10/10/12
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Commondenominator
ItiswidelyacceptedthateecAverepairswill
becomeincreasinglyimportantasmany
airportsmaynotreceivethefundsneededto
carryoutmajorrehabilitaAonsorreconstruct
distressedpavements
Engineeringandmaintenancemanagerscan
uAlizeavarietyofpavementrepairopAonsto
extendtheusefullifeoftheirpavements.
Thereisalreadyenoughknowledgeand
experiencetoperformproperpavement
repairs.
Availablematerialsandtechniquesarewell
establishedandprovenbutyetsomehownot
adapted.
TransportCanadaSurvey
ReportNo:AARMEC/C0204Revision,Nov.2002
Surveywasmadetoproduce:
PavementPreserva9onCataloguefor
CanadianAirelds
Thisextensiveworkwasbasedonliterature
surveyandreviewofpavementpreservaWon
pracWcesofCanadianAirportsbasedonthe
resultsandrepairpracWcessurvey
10/10/12
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Noeldperformancestudiesissuedbyorfor
CanadianAirportswerelocated
Only26outof70operatorsresponded
RecommendaAonsofTransportCanada
ThecontentoftheCatalogueshouldbeenhancedby
theinclusionofaddiWonaltechnicalandengineering
reportsthatcouldnotbelocated,andbythe
inclusionofnewreportsastheybecomeavailable.
ThecontentoftheCatalogueshouldalsobe
enhancedasnewpavementpreservaWon
technologiesaredevelopedandaddiWonaltechnical
informaWonisuncovered.
ToobtainaddiWonaltechnicalreportsand
informaWonfromCanadianairportoperatorsand
fromtheCanadianengineeringconsulWngindustry
willrequireconsiderableeort.
Wedoneedtoovercomethesemanagerial
issuesanddiculAes.
Wearefacingagreatchallengewhichisnot
onlythemaintenanceoftheassetsbutalsothe
necessitytouseexisAngfaciliAesbeyondtheir
designlivessimplyduetoeconomicand
environmentalcondiAons.
10/10/12
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TransportCanadaERD121
(nolongerupdated)
Typeofdefectsarewelldened.
DefectsareratedasLow,Medium,andHighseverity
Extentofrepairsclassiedinbetween0and4
(4beingextremeworsecase)
CondiWonRaWngisobtained
(PCN,LCN,Fric8onValuesnotincludednotafullassesment)
TransportCanadaDefect
ClassicaAons(ERD121)
PanelCracking
CornerCracking
EdgeCracking
Scalingandspaling
JointfaulWngandsealantfailure
SurfaceCrazing
Dcracking
Pumping
Compressionbuckling
PanelCracking(L)
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CornerCracking(M)
EdgeCracking(L,H)
Edge Cracking - High Severity
Scaling/Spaling
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JointFaulWng(M)/SealantFailure(M)
Joint Faulting - Medium Sev
Joint Sealant Failure - Medium Severity
SurfaceCrazing(M)
DCracking
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Pumping(M)/Buckling(H)
Concrete Slab Pumping Compression Buckling at an Inserted Surface Draina
FAAAC150/53806BChapter3Rigid
PavementDistresses(2007)
AC 150/5380-6B Chapter 3 Pavement Distresses
Rigid Pavement
1. Cracking
Longitudinal, Transverse, and Diagonal Cracks
Corner Breaks.
Durability "D" Cracking.
Shrinkage Cracking.
2. Joint seal damage
3. Disintegration
Scaling, Map Cracking, and Crazing
Joint Spalling. p g
Corner Spalling.
Shattered Slab/Intersecting Cracks
Blowups
Popouts. p
Patching.
4. Distortion
Pumping.
Settlement or Faulting. g
5. Loss of Skid resistance
Polished Aggregates
Contaminants
TheKeystosuccessofpatchrepairsof
PCCpavements
MUSTHAVEGOODANDSOUNDPAVEMENT
MANAGEMENTSYSTEMINPLACE
1Understandthecauseoftheproblem,
2HaverealisWcexpectaWons,
3CorrectselecWonofmaterialsandmethods
accordingtooperaWonalcondiWons,
4SurfacepreparaWon,
5ApplicaWonandsupervision
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SelecAonoftherepairmaterial
dependson:
Ambienttemperature
Timerequiredforearlytracking,returntoservice
Sizeanddepthofrepair
Productperformance
CompliancewithspeciedproperWes
Previousgoodexperience
CosteecWvenessanddelivery
Technicalsupportfromthemanufacturer
Theperfectrepairproductshouldhavephysical,chemicaland
mechanical,properWes,similartotheparentconcrete.
DimensionalcompaAbilityofrepairmaterialisvery
important.
Theidealrepairshouldhaveamodulusjustlowerthanthe
parentconcrete
Therepairshouldhavethermalexpansionsimilartotheparent
concrete
Therepairshouldhaveshrinkagelowerthantheparent
concrete
Therepairshouldhavestrengthjustgreaterthantheparent
concrete
SelecAonofappropriaterepairmaterials
ImportanceOfModulusofElasWcity
StaWcmodulusofelasWcityisa
measureofsWness.(PoissonsraWoin
caseofconcrete)
HIGHERE:LESSDEFORMATION
UNDERAGIVENLOAD
Iftheloadisperpendiculartothe
bondlinehighermodulusmaynotbe
toosignicant.Ifhoweverparallelto
thebondlineloadistransferredto
thehighermoduliwhichmaythen
overstressedandfracture
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DryingShrinkageICRIGuidelineNo:03733
!n
!0
If !n = !0 No stress occurs.

If !n > !0 Shear Bond is stressed.
CoecientOfthermalexpansion
(ICRIGuideline:03733)
10/10/12
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Performance Undesirable Response Desirable Properties
Requirements (results if wrong material is selected)
Ambient
temperature
changes
Temperature
changes within
repair material
at early ages
Atmospheric gases
Cracking in repair
material due to thermal
contraction stresses
Spalling due to thermal
expansion stresses in
substrate
Deformation due to
thermal expansion from
high exotherm
Cracking due to thermal
contraction stresses in
repair material
Corrosion of
Thermal coeIfcient
similar to that of
substrate
Thermal coeIfcent
similar to that of
substrate
Low exotherm
during cure
Low permeability;
Resistance to Ireezing
Coeicient of thermal expansion for concrete is 11x10
-6
/C.
ACI 503R Polymeric Coeicient of Thermal
Materials Expansion is 4-11 times
greater than Concrete
Thereforepolymericmaterialswillexpand/contractmorethanthesubstrate.
Whenmovementisrestrainedstressisinducedatthebondline
VeryImportantespeciallyforlargepatchrepairs(>2m2)
PROBABLYTHEMOSTIMPORTANTCRITERIAWHEN
SELECTINGPATCHREPAIRMATERIALS
TexasA&MUniversitySystem,Project05110S
BestPracAcesforConcretePavements(Ref:10)
DanZollinger,DavidW.Fowler,AnalMukhopadhy
Lookedat10dierentmaterialscommercially
availablematerials.
Modulusisthelargerinuenceonstraindueto
temperaturechange.Thethermalstresses
inducedattheinterfacebetweentheconcrete
andrepairmaterialshouldbecomparedtothe
bondstrengthwhichresiststhestress.
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SelecAonofpatchrepairmethod
Ifthedamageisconnedtothetop1/3
rd
oftheslab,
thenparWaldepthpatchrepairscanbeOK
Ifthedamagegoesdeeperthanthetop3
rd
oftheconcreteslab,or
reachesdowelbars,thenfulldepthpatchrepairsmustbecarried
out

AvailableRepairMaterials
CemenAousMaterials
PortlandCementConcrete
withanaccelerator
CalciumAluminateCement
MagnesiumPhosphate
Cement
LatexModiedCement
orPMC
HotMix
ResinBased
Epoxybasedmortars
Polyurethanebasedmortars
MMA(MethylMethacrylate)
mortars
Polyesterbasedrepairmortars
PolyureasandVinylConcrete
ParAaldepthrepairofconcretepavements(1)
Removealldeterioratedand/or
delaminatedconcreteasshownby
surveyandindicatedbypaintlines
inaccordancewithpreferred
methodofremoval
Ensuresizeofrepairisatleast
50mmbeyonddamagedareas
Theperimeteroftherepairshould
haveaverWcalfaceandshouldnot
befeatheredged.
Thiscanbedonebysawcukng
(preferablemethod)ormilling.
JointpreparaWonincludingan
appropriatebondbreakeris
requiredatjoint/crackedges
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ParAaldepthrepairofconcretepavements(2)
Cleanconcretesurfacebywater
jekngorhighpressureairblast
Mixtherepairmaterialusingaforced
acWonmixer
Applytherepairmaterialin
accordancewithmanufacturers
instrucWons
CompacWonofrepairmaterial
Finishingtherepair,providingskidfree
surfacebysteelWnebrush
Curetherepairswithacuring
membranewithmin90%curing
eciency
ParWaldepthrepairsatjointsmust
includesealingjointswhennished
F
ig
u
r
e
C
-
5
.
J
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in
t
S
p
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ll R
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ir
a
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is
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in
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id
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t
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a
il
FAA150/53806B
Fulldepthrepairofconcretepavements(1)
Removealldeterioratedand/ordelaminated
concreteasshownbysurveyandindicatedbypaint
linesinaccordancewithpreferredmethodof
removal
Ensuresizeofrepairisatleast100mmbeyond
damagedareas
TheperimeteroftherepairshouldhaveaverWcal
faceandshouldnotbefeatheredged.
Thisshouldbedonebysawcukng
JointpreparaWonincludinganappropriatebond
breakerisrequiredatjoint/crackedges
Checkthesubbaseforsoundnessandifnecessary,
compactwithavibraWngplate
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Fulldepthrepairofconcretepavements(2)
Providedowelsorotherloadtransfermechanisms
atedges
MixtherepairmaterialusingaforcedacWonmixer
orusereadymixedconcrete
Ifusingaprebaggedmaterial,usegoodquality
aggregatesforbulkingoutinaccordancewith
manufacturersinstrucWons.
Applytherepairmaterialinaccordancewith
manufacturersinstrucWons
CompacWonofrepairmaterial
Finishingtherepair,providingskidfreesurfaceby
steelWnebrush
Curetherepairswithacuringmembranewithmin
90%curingeciency
FAA150/53806B
F
ig
u
r
e
C
-
9
.
F
u
ll D
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p
t
h
R
ig
id
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la
b
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ir
D
e
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il -
S
e
c
t
io
n

FAA150/53806B
10/10/12
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F
ig
u
r
e
C
-
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2
.
T
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m
p
o
r
a
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y
R
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p
a
ir
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o
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R
ig
id
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U
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in
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F
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FAA150/53806B
SurfacepreparaAontechniques
Inmostcases,theuseofaconcretesawisrecommendedforcukngverWcal
bordersaroundtheperipheryofthedelineatedrepairarea.Insuchacasethe
sidesofthesawcutmustberoughenedbygritblasWngamerexcavaWngthe
centreoftherepair
AlternaWvely,cutintothe
sidesatanangleof75
O
to
formamorWcejointto
holdthepatch
SurfacepreparaAontechniques
ForparWaldepthrepairs,theuseofjackhammersareNOT
recommended.Theimpactcausesmicrocrackinginthe
concreteandshaneringofaggregate.Thisresultsinpoorbond
andmayleadtodelaminaWonoftherepair.
Jackhammeringmaybeusedforfulldepthrepairsprovided
thattherepairareaisisolatedbysawcukng.
UltrahighpressurewaterblasWngisthepreferredmethodfor
parWaldepthrepairs.ThereisnovibraWontodamagethe
freshlyexposedconcretesurfaceandkeyisbener.
Coldmillingisagoodmethodforremovinglargeareasof
concretebutiftheconcreteisweak,theaggregatesmaybe
pulledoutofthebondinginterfaceandweakenadhesion.
10/10/12
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ThisisnotsurfacepreparaWon!!

NO!!!
ExpedientSpallRepairMethodsandEquipmentForAireldPavements
MichaelI.Hammons&AtharSaeed
DocumentNo:AFRLRXTYTP20094552
AirforceResearchLaboratory,AirforceMaterielCommand,TyndallAirforceBaseFL
Selectedequipmentandprocedureswereevaluatedto
expediterepairofspallswithrapidsekngmaterials.The
objecWvewastodeveloponeormoremethodsto
excavateandpreparea2footwideby2footlongby4
inchdeepspallforplacementofarapidsekngrepair
materialin15minutesorless.AsecondaryobjecWvewas
tocorrelatevariousexcavaWonmethodswitharelaWve
lifeexpectancyoftherepair.ForveexcavaWonmethods,
2footwideby2footlongby4inchdeepspallswere
excavatedintriplicate.Thespallsweresubsequently
repairedusingacommonlyusedrapidsekng
cemenWWousrepairmaterial.
FindingsofHammonsandSaeed
MostecientmethodwastheCold
Planer.58%moreecientthanjack
hammers.
Secondecientmethodwasgang
saw
OnlyColdPlanarwasableexcavate
2x2x4areain15minutes
GREATESTMEANPULLOFF
STRENGTHWASFORTHECOLD
PLANAR(INBOTHPREANDPOST
TRAFICKING.
OTHERMETHODSWEREOFTHE
COLDPLANAR
10/10/12
16
SurfacepreparaWontechniques
HighpressurewaterblasAng
Millingmachineanddrum
10/10/12
17
AbruptSlopechangesmustbeavoided
Reference:Dept.oftheAirForce.,EngineeringTechnicalLenerETL0708

Figure 7. Repair with Abrupt Slope Change
(Not Recommended)

Figure 8. Repair without Abrupt Slope Chang
(Recommended)
Ensuresizeofrepairisatleast50mm(2)
beyonddamagedareas.??????


-'(*%

Largerepairs,redlinesaddedwheresawcutsshouldhavebeen
made
Reference:Dept.oftheAirForce.,EngineeringTechnicalLenerETL0708
The Same Repair with Red Lines Added to Indicate
10/10/12
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NaWonalConcretePavementTechnologyCentre
GuideForParWalDepthRepairofConcretePavements
April2012
IowaStateUniversityPublicaWon
enehls o lhs melho ncue lhe oovng:
Il s cosl-eeclve.
Mosl crevs re lycy mr vlh lhs melho.
Drvbcks o lhs melho ncue lhe oovng:
Wler rom svng eves lhe re slurle, ossby
eyng lhe rer rocess.
Wlhoul cre, lhe begnnng o sng cn occur l lhe
ckhmmer ne oulse lhe sv cul.
Ths melho s lme consumng n s nol s cosl
eeclve or rge rl-elh roecls s co mng.
Co mng s nolher olon or removng elerorle
concrele. The mng oerlon cn rocee elher cross
nes or re lo lhe vemenl cenlerne (Igure n
Igure ).
Mng ong lhe onl or crck s eeclve or removng
sng n rouces reclngur-she rer re,
vheres mng erencur lo lhe onl or crck s e
eclve or smer, nvu ss n rouces sh-
she rer re.
Mveslern slles slrle usng m or concrele
remov n lhe ery s n hve h success evng
lhe roune ege or Tyes n rl-elh rers
(Igure , Igure , n Igure ). Wlh lhe mng sys
lem n lher ovn rl-elh rer lechnques, M
veslern slles hve h ncrese success vlh lher
me rl-elh rers comre lo sv-n-ch
remov vhen lhe oshe verlc ege s eh n ce.
enehls o mng re s oov:
The lch sze s unorm or ong-lerm success.
The rough, rregur surce romoles bonng.
Mng s ecenl n economc vhen rerng
rge res.
Debrs s esy lo remove vlh shove n broom or
sk oer cku broom.
Mng requres ess bor lhn ckhmmer remov.
Drvbcks o lhs melho re s oov:
Mng creles slnr sze, vhch my nol conorm
lo sle.
Ixlr mng my be requre lo ven lhe orgn
me chnne, esecy vhen mng ong crcks
(e.g., onglun) lo crele mnmum slnce o
n. lo n oulse me ce (Igure ).
Iqumenl n mobzlon my be cosly or sm
roecls.
Figure 16. Milling along the joint or crack
enehls o lhs melho ncue lhe oovng:
Il s cosl-eeclve.
Mosl crevs re lycy mr vlh lhs melho.
Drvbcks o lhs melho ncue lhe oovng:
Wler rom svng eves lhe re slurle, ossby
eyng lhe rer rocess.
Wlhoul cre, lhe begnnng o sng cn occur l lhe
ckhmmer ne oulse lhe sv cul.
Ths melho s lme consumng n s nol s cosl
eeclve or rge rl-elh roecls s co mng.
Co mng s nolher olon or removng elerorle
concrele. The mng oerlon cn rocee elher cross
nes or re lo lhe vemenl cenlerne (Igure n
Igure ).
Mng ong lhe onl or crck s eeclve or removng
sng n rouces reclngur-she rer re,
vheres mng erencur lo lhe onl or crck s e
eclve or smer, nvu ss n rouces sh-
she rer re.
Mveslern slles slrle usng m or concrele
remov n lhe ery s n hve h success evng
lhe roune ege or Tyes n rl-elh rers
(Igure , Igure , n Igure ). Wlh lhe mng sys"
lem n lher ovn rl-elh rer lechnques, M
veslern slles hve h ncrese success vlh lher
me rl-elh rers comre lo sv-n-ch
remov vhen lhe oshe verlc ege s eh n ce.
enehls o mng re s oov:
The lch sze s unorm or ong-lerm success.
The rough, rregur surce romoles bonng.
Mng s ecenl n economc vhen rerng
rge res.
Debrs s esy lo remove vlh shove n broom or
sk oer cku broom.
Mng requres ess bor lhn ckhmmer remov.
Drvbcks o lhs melho re s oov:
Mng creles slnr sze, vhch my nol conorm
lo sle.
Ixlr mng my be requre lo ven lhe orgn
me chnne, esecy vhen mng ong crcks
(e.g., onglun) lo crele mnmum slnce o
n. lo n oulse me ce (Igure ).
Iqumenl n mobzlon my be cosly or sm
roecls.
Figure 18. Type 1 spot milling
Figure 19. Type 2A joint milling
NaWonalConcretePavementTechnologyCentre
GuideForParWalDepthRepairofConcretePavements
April2012
IowaStateUniversityPublicaWon
bons beuer lo lhe exose concrele on lere ege
lhn on verlc ege. The ler so emnles lhe
corner l lhe bouom ege o lhe rer rom vhch hgh-
cemenl mxes cn shrnk n revenl bonng. The
lere ege so seems lo crele ess sng n ch
ng lhn verlc me ege.
Ixerence hs emonslrle lhl lere V-he m
or roune m cn be use on rl-elh rer
roecls. Mng vlh lhe V-he or roune he hs
been use very successuy on lrnsverse onls vlhoul
ny lon svng, vlh ony mnor chng l lhe
ege o lhe rer. I ny chng oes occur, lhe m
hes nee lo be checke or shrness. On occsons
vhen m he s nol use lo orm lhe eges, lhe eges
re lere usng sm ckhmmer lo remove lhe verl
c eges eh by lhe svng oerlon.
The slles o Knss n Soulh
Dkol mohe Mnnesol's mng roch by
requrng lhl verlc, nsle o lere, ege be eh by
lhe m (Igure n Igure ). Mng verlc ce
cn eve more chng l lhe lo ege, so some slles
such s Knss requre sv cul or lrnsverse onls
rere vlh rl-elh mng.
Figure 22. V-head milling
The mosl common m hes use loy re lhe V or
roune he n lhe verlc ege.
Me hes mnu
clure lo crele V she (Igure n Igure )
or roun she (Igure n Igure ) cn be use on
lrnsverse n onglun onls n crcks. The re
erre she s lere ege nyvhere rom lo
egrees lo lhe bouom o lhe onl. The lch mler
bons beuer lo lhe exose concrele on lere ege
lhn on verlc ege. The ler so emnles lhe
corner l lhe bouom ege o lhe rer rom vhch hgh-
cemenl mxes cn shrnk n revenl bonng. The
lere ege so seems lo crele ess sng n ch
ng lhn verlc me ege.
Ixerence hs emonslrle lhl lere V-he m
or roune m cn be use on rl-elh rer
roecls. Mng vlh lhe V-he or roune he hs
been use very successuy on lrnsverse onls vlhoul
ny lon svng, vlh ony mnor chng l lhe
ege o lhe rer. I ny chng oes occur, lhe m
hes nee lo be checke or shrness. On occsons
vhen m he s nol use lo orm lhe eges, lhe eges
re lere usng sm ckhmmer lo remove lhe verl
c eges eh by lhe svng oerlon.
The slles o Knss n Soulh
Dkol mohe Mnnesol's mng roch by
requrng lhl verlc, nsle o lere, ege be eh by
lhe m (Igure n Igure ). Mng verlc ce
cn eve more chng l lhe lo ege, so some slles
such s Knss requre sv cul or lrnsverse onls
rere vlh rl-elh mng.
Figure 25. Vertical edge milling
The mosl common m hes use loy re lhe V or
roune he n lhe verlc ege.
Me hes mnu
clure lo crele V she (Igure n Igure )
or roun she (Igure n Igure ) cn be use on
lrnsverse n onglun onls n crcks. The re
erre she s lere ege nyvhere rom lo
egrees lo lhe bouom o lhe onl. The lch mler
m
m
m
m
W
m
B.# &-0,'%&,-' ".-!:)$3*@ ,.# 9'-!, /7 3#&.%0*&%: 3#%0"$
W
T
W
Figure 37. View of cardboard cut to t irregular random crack
W
W
m
m %+
,H%3";,+3/&,+3"4E(:=+% FC?"E(:=+% FF?",)3"E(:=+% F698"
m
W
Thiscouldonlybe
temporaryrepairand
needstobemonitored
closelytopreventFOD
10/10/12
19
10/10/12
20
10/10/12
21
Shrinkage Cracks
Somerecommendedrepairtechniques
Oversawingtheedgesof
repairscanleadtocorner
cracking
Usea4coretocutneat
roundedcorners,thencutinto
thesecoreswithasaw
10/10/12
22
Somerecommendedrepairtechniques
Coringisanexcellent
techniquefor
preparingpatch
repairs
Popoutcoredandlled
Coredcornersof
patchrepairs
Milled Surface
Patched repair
Proper Mix
Consistency
10/10/12
23
NEWICRIGUIDE
&EUROPEANREPAIRGUIDE
GuidelineforInorganicRepairMaterialData
SheetProtocol.
Guideline:320.3R2012
EN15042006:EuropeanRepairSpecicaWon
10/10/12
24
Resources
1. GuideforSelec8ngandSpecifyingMaterialsforRepairofConcreteSurfaces
ICRI,InternaWonalConcreteRepairInsWtute,
TechnicalGuidelines,GuidelineNo:03733
2. GuidelinesandProceduresforMaintenanceofAirportPavements.
FAAAdvisoryCircular,ACNo:150/53806B2007,
3. ExpedientSpallRepairMethodsandEquipmentforAireldRepairs
MichaelIHammons,AirForceResearchLaboratoryandAtharSeed,AppliedResearch
Associates.
AirbaseTechnologiesDivision,AirForceResearchLaboratory,AirForceMaterialCommand,
TyndallAirForceBaseFL.
4. EngineeringTechnicalLeVer0708:SpallRepairofPCCAireldPavementsinExpedi8onary
Environments,
DepartmentofTheAirForce,
AFCESA/CEO,TyndallAFB,FL
Resources
5. GuideforPar8alDepthRepairofConcretePavements
NaWonalConcretePavementTechnologyCentre,IOWAStateUniversity,InsWtutefor
TransportaWon.April2012
6. PavementPreserva8onCatalogueforCanadianAirelds.
ReportNo:AARME/C0204
TheTechnicalEvaluaWonEngineeringDivision
AerodromeSafetyBranch
TransportCanada,Onawa,Ontario,November2002
7. GuidelinesRespec8ngAirportPavementStructuralCondi8onSurveys
EngineeringReferenceDocumentERD121January2004
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