Concrete Resurfacing - Repair of Concrete Floor or Pavement Surfaces

2/3/2018 Concrete Resurfacing - Repair of Concrete Floor or Pavement Surfaces
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How to Guide
Concrete
Resurfacing –
Before undergoing any kind of method as a part of
Repair of Concrete
resurfacing of concrete, it is necessary to conduct an
Floor or Pavement
evaluation of the existing surface. This evaluation is to
Surfaces
find whether the existing layer satisfies certain design
considerations.
Working at Heights
in Construction –
Regulation and
Precautions
Table of Contents [show]
Requirements of an Existing
Concrete Pavement Surface
As mentioned above, there are certain considerations
which have utmost importance before undergoing
resurfacing. They are:
1. In order to carry out the needed service, the existing Types of Sealants
layer must have adequate thickness. Used for Joints in
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Buildings -
Properties, Uses,
Repair of Concrete Floors and Pavements
Working
Concrete Pavement
2. The concrete surface might have longitudinal as well as
transverse joints. These joints must be able to transfer to
load smoothly to the underlying layer (Soil). This load
transfer must be done without affecting the smoothness of
the surface (Once the resurfacing is carried out).
The penetration of fine solids or moisture has to be

restricted by the joints or cracks present through the What are the Types
resurfaced layer or through the underlying pavement and of Mechanical
the resurfacing. Splices for Rebars?
3. In order to face severe exposure conditions, adequate

cover has to be provided for the reinforcement. The
reinforcement must possess a size and spacing in order
to make the crack present to be tight.
4. The maximum size of aggregates used in the service is

based on the thickness of resurfaced layer and the steel
spacing.
Reinforcement
5. Good and Durable aggregates have to be employed. In Calculator – Areas
areas where there are chances of freezing and thawing of Different
problems, it is recommended to have air entrainment. The Diameters and
use of salts in order to de-ice can also be employed. Numbers of Rebars
6. The material used for the construction of shoulders

must be either concrete or other stabilized materials, in
Recent Articles
order to avoid chances of infiltration of shoulder materials
in between the underlying pavement and the resurfacing Concrete
layer. Calculator –
Calculate
Concrete for
Slab, Beam,
Evaluation of the Existing Column and
Concrete Floor or Pavements Footings
for Resurfacing Stability of

Slopes for
As mentioned before, the condition of existing pavement
Excavations
must be evaluated before carrying out the resurfacing in Different
procedures. Soil Types
Stress in
Structural
Materials,
Their Types
and Sign
Conventions
What are
Different
Layers in a
Bituminous
Pavement?
Concrete
Cover
Specifications
The three basic elements of the evaluation of the existing for
pavements are the: Reinforcement
in Different
Codes
Evaluation of the functional condition or the
Serviceability Condition How to
Evaluation of the distress through surveys Choose Type
of Pile
Evaluation through Structural Testing Foundation
for
The three of the mentioned criteria are not mutually Construction?
exclusive to each other. They can either occur individually

in an existing pavement or in a combination. This different
condition of occurrence influences the decision behind the
resurfacing.
The major factor behind the selection of best overlay

option is by understanding the true condition of the
existing pavement or surface. The true evaluation must

give a picture on how it will behave when a new overlay is
laid over the existing one. This condition is based on
structural evaluation rather than functional evaluation.
Major points behind the evaluation of the existing

pavements are explained below:
Functional Adequacy of the Old

Surface
Serviceability condition is mainly related to the surface of
concrete subjected to traffic. This is the condition of the
pavement based on the ride quality. Evaluation method
makes use of panel ratings. Some of the agencies
evaluate based on the ride quality. One such example is
the response type ride quality measurements.
An overlay surface may be provided due to the functional

inadequacy of the old surface. This surface can be
provided to improve the skid resistance of the surface.
When the pavement surface does not follow one or more
levels of service, then a functional overlay can be
provided.
For functional overlay, the minimum thickness of the

overlay surface will be that needed to have construction
convenience or to bring the surface to an acceptable level
of service.
Distress Surveys
The nature and the extent of damage to the existing layer
can be determined through the distress surveys. This
data provides us an idea on the performance of the
resurfacing layer. Different methods are employed as a
part of the survey. But a standard method has not been
put forward yet.
The most popular method employed are the Pavement

Condition Index (PCI) and Concrete Pavement
Evaluation System (COPES). The PCI method is
employed for flexible pavement. The COPES is used for
concrete pavements.
A manual named Highway Pavement Distress

Identification Manual was used and followed in the past.
Structural Adequacy
The famous Non-destructive testing is employed to
understand the structural adequacy of the existing surface
layer. This is through the evaluation response from the
pavement to the applied loads. There is a relation
between the nature of the response and the structural
adequacy of the pavement.
AASHTO have developed another approach which is

named as “remaining life”. This as the name tells, will
evaluate the life that is consumed from the pavement.
The measure of consumption can be either based on time
or based on the number of loadings. This method gains
limitations of error in the measurement of remaining life. It
can show a higher or a lower value without any kind of
reason.
Another approach was again put forward by AASHTO

(Third Approach). This will make use of the distress
surveys and the material properties of the existing
pavement to determine the structural capacity of the layer.
The Structural Design of the

Pavement or Floors for Resurfacing
When comparing the structural deficiency and the
functional deficiency, the former will override the latter.
This is because the thickness that is demanded by the
structural deficiency to be solved will be anyway greater

than the thickness that is demanded by the functional
deficiency.
The resurfacing thickness design involves many

approaches. But it involves the determination of the
following requirements:
Structural Capacity: Determination of the capacity

that will account the prevailing and the estimated
future traffic for the design life planned for the
resurfacing layer.
Effective structural capacity or the In-situ structural
capacity
Difference between the structural capacity and the
effective structural capacity
Other Requirements in Concrete Resurfacing
Some of the other factors that will be a concern during the

resurfacing are mentioned below:
Interface Between Concrete Layers

These forms the area between the underlying layer and
the overlay surface. This a very important concern in the
design consideration. The nature of bond is judged by the
interface. This bonding will affect the performance of the
whole resurfacing layer.
When talking about interface materials, they serve mainly

two purposes. The interface material either will improve
the bond between the underlying layer and the
resurfacing layer. Or they can be used to separate the
underlying layer and the resurfacing layer.
The first purpose will make the two layers to behave

monolithically under load action and transfer. The second
purpose will make the individual elements to act as

separate elements. The second purpose means there is a
little or no kind of connection between the two layers.
Based on this we have bonded resurfacing and

Unbonded resurfacing.
Bonded Resurfacing
The bonded resurfacing mainly makes use of plain
cement concrete slurry or grout to serve the purpose of
the bond between the old and the new layer. The
preparation of the grout is carried out in a mobile mixer.
The materials used are Portland cement and water.

Mainly the water cement ratio used is not greater than
0.62. In certain areas, these are not used. But instead of
grout, the resurfacing material is itself used as bonding
interface material. They are applied on a clean surface.
The method proved to be efficient in increasing the bond
and durability in its performance.
Unbonded Resurfacing
Unbonded resurfacing is mainly used in conditions
where the underlying layer is very weak and have high
distress. In such a condition, if a bond is made between
the new overlay and the old a problem of reflective
cracking is said to occur.
This is because the stress in the weak bottom layer gets

transferred to the new top layer. Hence under such
situations, an unbonded interface material is used. This
will hence make the two layers to act and perform
individually.
To have such a positive layer, numerous materials are

available. Some of them are asphalt-aggregate mixtures
of various type and the polyethylene, Other materials are

wax based curing compounds and liquid asphalts. Initially,
a liquid asphalt layer that is covered with a polyethylene
sheet was preferred.
It is also specified to use thick layers of surfacing than

thin layers. Thin layers can also create chances of
reflective cracking in the overlay. The below shows the
recommendations for asphalt unbonded surface layer
provision in different conditions:
In the case of the underlying pavement have joint or

crack that is greater than 6mm, and also deterioration
of slabs and spalling is highly evident; an asphalt
layer of a thickness not less than 25mm have to be
provided.
In case the faulting and slab deterioration is not
evident highly, a thin layer of asphalt is provided of a
thickness not greater than 13mm. A slurry seal
material can also be employed that have a nominal
thickness of 3mm. This thin layer must be able to
cover all the defects that are reflected on the surface
of the existing (damaged) pavement.
In the case where the fault and cracks are not
evident, a slurry seal of a minimum thickness of 3mm
is provided. Or an asphalt layer that is followed by a
sand cover can also be recommended.
The figure below shows that the inadequate thickness of

the layer will not prevent keying of the overlay.
Fig.1: Before and after providing interface material

between the damaged and the new layer
Drainage for Concrete Surface

It is a need for the provision of cross slopes in the
pavements to facilitate proper water drainage. But now it
has been necessary to bring texture to the pavement
surface to gain proper and efficient skid resistance also. It
is also recommended to provide a subsurface drainage
facility when a resurfacing is carried out.
During the evaluation of the pavement, the designer is

asked to evaluate the existence of joint faults, pumping,
corner breaks or any other kind of distress in the
pavement. This is usually reflected in the PCC pavement.
In the case of AC pavements, distress is like fatigue

cracking and potholing. Any symbol of moisture affected
distress implies that the drainage system is inadequate.
So, before the overlay construction, proper drainage must
be maintained.
In the case of an interface layer that is not bonded, open-

graded drainage layers will behave well as the interface
material.
Reinforcement for Concrete

Resurfacing
Certain pavements will make use of reinforcement as
distributed deformed steel. This will ensure the control of
the various type of cracking. The cracking thus observe is
a result of joint spacing.
This is mainly due to the shrinkage that is related to the

hydration reaction of the Portland cement (drying
shrinkage). This varies with the temperature and the
slab’s moisture content.
The reinforcement that is provided to the resurfacing is

very much similar to that employed in the installation of a
new pavement. The AASHTO 1993 provides the whole
details on the same.
For overlays that are joined through joints, the slab length
is the factor that will govern the reinforcement design.
When the slab has a length lesser than 4.6m,
reinforcement is not recommended. But in the case of
slabs with long length, the reinforcement is provided with
the cross-sectional area varying from 0.05 to 0.20 % of
the slab cross section.
In the case of overlays that are concrete reinforced,

longitudinal reinforcement must be provided to keep
transverse cracks that are formed tightly closer. This will
avoid the penetration of undesirable chemicals and carry
out good load transfer. Here, the percentage of steel used
is greater than that used for jointed overlays.
A minimum of 0.6% of a cross section of the slab will be

required. Recent practice makes use of 0.9% of the
cross-sectional area of the slab.
Joints in Concrete Floors and

Pavements
The movements that are created in the pavements due to
the variation in temperature and the change in concrete
volume must be facilitated by providing adequate joints at
desirable locations.
In the case of a plain cement concrete resurfacing, the

joint location and provision are related to the type of
interface that is used. When a bonded resurfacing is
employed, it must match with the joints that are used in
the underlying pavement layer. Any failure in this will
cause reflective cracking on the new layer.
Hence, the performance of the pavement is reduced. But

when the unbonded interface is used, an entirely different
behavior is shown.
It is recommended that the transverse joints in the surface

should have a mismatch if any by an amount of 0.6 to
0.9m (when compared with the original pavement). The
joint has to match with the one in the underlying
pavement. This consideration will help in the reduction of
stress concentration and their related distresses.
Advantages of Concrete
Resurfacing
1. The concrete resurfacing act as a part of
maintenance and longevity for the surface. This helps
in prevention of cracks for a longer period and make
the formation of potholes (In the case of driveways)
loose its existence.
2. The concrete possesses a light color which tend to
control the temperature maintaining a comfortable
cooling effect during summer seasons.
3. Concrete resurfacing is now provided by staining with

variety of color which adds aesthetic beauty to the
surface.
4. Variety of color options are available in the concrete
resurfacing option. This can give a great look for the
home exterior.
5. The removal of snow from the concrete surface is
found easier when compared with any other surface.
Disadvantages of Concrete
Resurfacing
1. Improper overlay and evaluation of the existing

condition will bring the decision of concrete
resurfacing to fail. This may lead to show the cracks
on the surface. The only remedy for this is the
complete removal of the pavement and construct a
new surface.
2. The choice is not found economical for larger areas.
Read More:
Types of Failures in Flexible Pavements and their

Causes and Repair Techniques
Types of Distress in Bituminous Pavements and their

Causes
What is Screed in Concrete Construction? Properties

and Composition of Screeds
What is Cold Joint in Concrete? Methods of Treating

Cold Joints
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2/3/2018 Concrete Resurfacing - Repair of Concrete Floor or Pavement Surfaces

What are you looking for?    

App Building How To Guide Concrete Construction

Install App Buildings  Concrete  Construction 

How To Guide  Geotechnical  Structural 

Home  How To Guide  Repair/Protection Guide 

Concrete Resurfacing – What are you looking for? 

Table of Contents [show]

The penetration of fine solids or moisture has to be

3. In order to face severe exposure conditions, adequate

4. The maximum size of aggregates used in the service is

6. The material used for the construction of shoulders

for Resurfacing Stability of

exclusive to each other. They can either occur individually

The major factor behind the selection of best overlay

existing pavement or surface. The true evaluation must

Major points behind the evaluation of the existing

Functional Adequacy of the Old

An overlay surface may be provided due to the functional

For functional overlay, the minimum thickness of the

The most popular method employed are the Pavement

A manual named Highway Pavement Distress

AASHTO have developed another approach which is

Another approach was again put forward by AASHTO

The Structural Design of the

structural deficiency to be solved will be anyway greater

The resurfacing thickness design involves many

Structural Capacity: Determination of the capacity

Other Requirements in Concrete Resurfacing

Some of the other factors that will be a concern during the

Interface Between Concrete Layers

When talking about interface materials, they serve mainly

The first purpose will make the two layers to behave

purpose will make the individual elements to act as

Based on this we have bonded resurfacing and

The materials used are Portland cement and water.

This is because the stress in the weak bottom layer gets

To have such a positive layer, numerous materials are

of various type and the polyethylene, Other materials are

It is also specified to use thick layers of surfacing than

In the case of the underlying pavement have joint or

The figure below shows that the inadequate thickness of

Fig.1: Before and after providing interface material

Drainage for Concrete Surface

During the evaluation of the pavement, the designer is

In the case of AC pavements, distress is like fatigue

In the case of an interface layer that is not bonded, open-

Reinforcement for Concrete

This is mainly due to the shrinkage that is related to the

The reinforcement that is provided to the resurfacing is

In the case of overlays that are concrete reinforced,

A minimum of 0.6% of a cross section of the slab will be

Joints in Concrete Floors and

In the case of a plain cement concrete resurfacing, the

Hence, the performance of the pavement is reduced. But

It is recommended that the transverse joints in the surface

3. Concrete resurfacing is now provided by staining with

1. Improper overlay and evaluation of the existing

Types of Failures in Flexible Pavements and their

Types of Distress in Bituminous Pavements and their

What is Screed in Concrete Construction? Properties

What is Cold Joint in Concrete? Methods of Treating

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