This manual (FHWA-RD-99-152) presents guidelines and recommendations to assist highway maintenance agencies and other related organizations in planning, constructing, and monitoring the performance of concrete pavement partial-depth spall repair projects. Included in the manual are discussions pertaining to when partial-depth spall repair operations are appropriate, the types of repair materials and construction methods that should be used, how each individual step in a spall repair operation should be performed, and how the performance and cost-effectiveness of spall repairs can be evaluated. This report will be of interest and benefit to various levels of agency maintenance personnel, from crew supervisors to the chief maintenance engineer.

This project investigated the properties and performance of the products used for spall repair of concrete pavement. A survey of Texas Department of Transportation (TxDOT) maintenance engineers produced a roster of 10 repair materials currently in use in the state. After identifying the key characteristics of a successful repair material, a laboratory testing program was developed to evaluate the properties of the repair materials. These materials were tested for strength, compatibility, and bond to quantify their characteristics relative to those products known to work well.

Following the two damaging California earthquakes in1989 (Loma Prieta) and 1994 (Northridge), many concrete wall and masonry wall buildings were repaired using federal disaster assistance funding. The repairs were based on inconsistent criteria, giving rise to controversy regarding criteria for the repair of cracked concrete and masonry wall buildings. To help resolve this controversy, the Federal Emergency Management Agency (FEMA) initiated a project on evaluation and repair of earthquake-damaged concrete and masonry wall buildings in 1996. The ATC-43 project addresses the investigation and evaluation of earthquake damage and discusses policy issues related to the repair and upgrade of earthquake-damaged buildings. The project deals with buildings whose primary lateral-force-resisting systems consist of concrete or masonry bearing walls with flexible or rigid diaphragms, or whose vertical-load-bearing systems consist of concrete or steel frames with concrete or masonry infill panels. The intended audience is design engineers, building owners, building regulatory officials, and government agencies. The project results are reported in three documents. TheFEMA306report, Evaluation of Earthquake Damaged Concrete and Masonry Wall Buildings, Basic Procedures Manual, provides guidance on evaluating damage and analyzing future performance. Included in the document are component damage classification guides, and test and inspection guides. FEMA 307, Evaluation of Earthquake Damaged Concrete and Masonry Wall Buildings, Technical Resources, contains supplemental information including results from a theoretical analysis of the effects of prior damage on single-degree-of-freedom mathematical models, additional background information on the component guides, and an example of the application of the basic procedures. FEMA 308, The Repair of Earthquake Damaged Concrete and Masonry Wall Buildings ,discusses the policy issues pertaining to the repair of earthquake-damaged buildings and illustrates how the procedures developed for the project can be used to provide a technically sound basis for policy decisions. It also provides guidance for the repair of damaged components.