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.