Repair Cracks, Spalls, and Minor Foundation Damage

A. Finished-Project Specification

Deliverable: one completed Foundation Defect Map and Repair Record documenting every mapped defect, its measurements, its classification, the repair product and batch information used, preparation and application details, curing method, and post-repair inspection results, together with before-and-after photographs of every repaired defect.

B. Defect Classification Schedule

Defect Type	Required Measurement	Minor-Repair Condition	Requires Qualified Review If
Crack	Width, length, orientation, pattern, moisture, displacement	Stable, within the approved width and length limits stated in the repair scope	Active displacement, growth since last measurement, or width/length beyond the approved scope
Spall	Depth, area, exposed-aggregate condition, edge soundness	Shallow, sound surrounding concrete, no exposed or corroded reinforcing steel	Depth reaches reinforcing steel, exposed steel shows corrosion, or surrounding concrete sounds hollow
Tie hole	Diameter, depth, condition of surrounding concrete	Clean, sound opening from an authorized form-tie location	Surrounding concrete is cracked, delaminated, or shows water staining beyond the opening
Edge damage	Length, depth, location relative to corners or joints	Localized, does not affect a load-bearing edge or joint detail	Damage affects a structural corner, bearing edge, or approved joint detail
Delamination	Sounding response over the full suspect area	Not authorized for minor repair under this chapter	Any hollow or dull sounding response; always requires qualified review

C. Document and Material Takeoff

• Controlling documents: repair history, concrete age and exposure record, and the approved minor-repair scope, obtained before any defect is touched.
• Repair materials: manufacturer-specified crack sealant, injection resin, or patching mortar, together with the compatible primer or bonding agent identified by the same manufacturer.
• Curing materials: curing compound or wet-cure covering matched to the repair product's manufacturer instructions.
• Escalation contact: a named structural or materials professional identified before evaluation begins, for use if a defect is classified as requiring qualified review in Steps 5–6.

D. Acceptance Standards

Check	Standard
Classification	Every defect measured, sounded, and classified before any preparation begins; every qualified-review defect stopped and escalated before further work
Substrate preparation	Loose, unsound, contaminated, or feather-edged concrete removed to the repair geometry required by the selected system
Substrate condition	Moisture, temperature, and cleanliness at the time of application match the manufacturer's stated limits for the selected product
Repair application	Primer, bonding agent, and repair material applied within manufacturer proportions, thickness, and working-time limits
Finish and profile	Repair consolidated without trapped voids or feather edges, and matched to the required surface profile for its intended use
Curing and protection	Repair cured and protected for the full period stated in the manufacturer instructions
Post-repair inspection	Repair bond, profile, and finish inspected and free of shrinkage cracking, debonding, or hollow areas

E. Preparation — Document Review and Defect Mapping

1. Obtain the repair history, concrete age, exposure, moisture conditions, structural information, and approved repair scope. Confirm the approved scope in writing before evaluating any defect.
2. Inspect and map each crack, spall, void, tie hole, edge defect, and previous repair. Record every defect's location on the Foundation Defect Map before measuring it.
3. Measure and record crack width, length, orientation, location, pattern, moisture, displacement, and apparent activity. Use the crack comparator gauge and tape measure for every crack, and record dimensions and condition for every spall, void, tie hole, and edge defect.

F. Sounding and Classification

1. Sound the surrounding concrete using the approved method to identify loose or delaminated material. Tap the area around every mapped defect with the specified hammer and record any hollow or dull response.
2. Classify defects as within the minor-repair scope or requiring qualified review. Compare each measured and sounded defect to the Defect Classification Schedule in Section B.
3. Stop work on any defect that exceeds the approved limits or indicates structural movement, corrosion, or continuing water entry. Escalate every qualified-review defect to the named structural or materials professional before proceeding on that defect.

G. Material Selection and Area Preparation

1. Select a repair material compatible with the substrate, exposure, movement, thickness, orientation, moisture, coating, and finish requirements. Confirm compatibility using the manufacturer instructions before purchasing or opening any product.
2. Establish dust, silica, debris, ventilation, and adjacent-surface controls. Mask and protect adjacent finished surfaces before any grinding, routing, or chiseling begins.
3. Remove loose, unsound, contaminated, or feather-edged concrete to the required repair geometry. Grind or chisel to a square or beveled edge as required by the selected system; do not leave a feather edge.
4. Route or prepare approved cracks to the dimensions required by the selected system. Use the crack router or chisel to the width and depth stated in the manufacturer instructions.

H. Substrate Preparation and Application

1. Clean the repair area using the specified mechanical, air, vacuum, or washing method. Remove all dust and loose material before checking substrate condition.
2. Prepare exposed steel only when authorized and according to the approved corrosion-repair detail. Do not clean, treat, or coat exposed reinforcing steel without specific written authorization.
3. Condition the substrate to the moisture state required by the repair product. Verify with the moisture meter before applying primer or bonding agent.
4. Apply primer, bonding agent, sealant, injection material, patching mortar, or repair concrete as specified. Mix and apply within the manufacturer's stated proportions and working time.
5. Consolidate and finish the repair without trapping voids or creating thin edges. Work the material fully into the prepared geometry and tool the surface to eliminate air pockets.
6. Match the required surface profile for waterproofing, flooring, coating, or exposed appearance. Finish the repair to the texture and plane required by the surface's intended use.

I. Curing and Closeout Inspection

1. Cure and protect the repair for the required period. Apply the specified curing compound or wet-cure covering and maintain it for the full manufacturer-stated duration.
2. Inspect for bond, shrinkage, cracking, debonding, hollow areas, profile, finish, and water tightness where applicable. Sound the cured repair and compare its profile to the surrounding surface.
3. Correct failed areas using the manufacturer-approved procedure. Remove and re-prepare any repair that fails the bond, profile, or finish check.
4. Record defect maps, measurements, product data, batch information, preparation, application, curing, photographs, and inspection results. Complete every field on the Foundation Defect Map and Repair Record before closeout.