Selection reference
Choose concrete repair products by the repair
Start with what failed and where it sits: a spalled slab, a soffit, a leaking crack, a pile in the tidal zone. The orientation, depth, exposure and the time the structure can be out of service narrow the assortment quickly. Confirm the final choice against the current datasheet and the project specification.
| Repair situation | What to confirm | Examples in this category |
|---|---|---|
| Slabs, floors and horizontal spalls | Trowel or pour a horizontal repair mortar or patching compound. Confirm the depth range per lift, whether feather-edging is permitted, set time at site temperature, and how soon the area returns to foot, forklift or vehicle traffic. | SikaQuick 1000, SikaQuick 2500, Eucocrete Supreme, Dayton Thin Resurfacer; see Patching |
| Vertical and overhead repairs | Walls, beams, columns and soffits need a non-sag mortar with published build thickness per lift. Confirm polymer modification, corrosion inhibitor where reinforcing steel is exposed, whether a scrub coat or bonding agent is required, and hand versus spray placement. | EucoRepair V100, Five Star Structural Concrete VO, Stratarock High Build Repair; see Repair Mortars |
| Form-and-pour and structural section replacement | Deep or reinforced repairs use a pourable or pumpable mortar, often self-consolidating, with aggregate extension for larger volumes. Confirm the minimum and maximum placement depth, aggregate extension limits, strength gain at the age the structure must carry load, and any engineer approval. | Five Star Structural Concrete, Structural Concrete S300, Sikacrete 360 SCC, EucoRepair SCC |
| Cracks, leaks and joint spalls | Dormant structural cracks take low-viscosity epoxy injection; active leaks take hydrophilic polyurethane or hydraulic cement; floor cracks and joint spalls that need same-day traffic take rapid-set urethane or polyurea. Confirm crack width, moisture, movement and injection method first. | Simpson CI-SLV32, SikaFix HH, Euclid Speed Plug, Euco QWIKstitch, Quick Mender XO; see Concrete Crack Repair |
| Bonding agents and primers | Epoxy bonding agents suit structural new-to-old concrete and steel; acrylic and latex agents suit thin patches and overlays. Confirm open time against the mortar placement window, saturated-surface-dry requirements, and whether the mortar manufacturer prefers a scrub coat instead. | Eucoweld 2.0, Akkro-7T; Sikadur and Pro-Poxy epoxies under Bonding Adhesive |
| Marine, underwater and pile repair | Use products formulated for underwater or splash-zone placement. Confirm anti-washout behavior, working time in the tidal window, hand-pack versus pumped placement, salt-water cure and the jacket or form system the engineer has specified. | Structural Concrete Underwater PG, Underwater Hand Pack, Five Star Splash Zone, PileForm F pile jackets |
| Pavement, roadway and asphalt repair | Concrete pavement patches need rapid strength for reopening lanes; asphalt potholes and edges take a cold-applied asphalt patch that compacts in place. Confirm traffic-open time, temperature range for placement, and whether the specification calls for a DOT-approved material. | Five Star Highway Patch, Quikrete FastSet Concrete Mix; Perma-Patch under Asphalt Repair |
| Structural strengthening with carbon fiber | CFRP strips and fabrics add flexural, shear or confinement capacity and are designed by an engineer for each member. Confirm the laminate or fabric type, the paired epoxy, substrate preparation and the fire or finish protection the design requires. | Sika CarboDur strips; SikaWrap fabrics and Sikadur 30 under Carbon Fiber |
Compressive strength, set time and yield are meaningful only with their test method, temperature, water content and cure age. Use the current product datasheet before approving a substitution.
Field planning
Plan the concrete repair
Durable repairs depend on removing the cause of the failure, preparing a sound substrate and placing the material within its published limits. Use the manufacturer instructions with the project specification and ACI 546R or ACI 562 where they are referenced.
Diagnose before you order
Sound the area to find delaminated concrete beyond the visible spall, check for corroding reinforcement, and decide whether the damage is cosmetic, a durability problem or a structural deficiency. Structural repairs and any strengthening need an engineer's direction.
Active water, chemical exposure, freeze-thaw cycling and vehicle traffic each rule products in or out. A leaking crack is not an epoxy injection job, and a soffit repair is not a horizontal patch turned sideways.
Surface preparation and bond
Most datasheets call for removal to sound concrete, a saw-cut perimeter to avoid feather edges, a roughened profile per ICRI 310.2R, and a clean, saturated-surface-dry substrate. Exposed reinforcing steel is cleaned and, where specified, coated before the mortar goes in.
Follow the mortar manufacturer on bond: many one-component mortars use a scrub coat of the same material, while others require an epoxy or acrylic bonding agent applied within its open time. Do not combine methods unless the datasheet allows it.
Depth, lifts and extension
Each product publishes a minimum and maximum depth per lift. Vertical and overhead mortars are rated by build thickness without sagging; horizontal and form-and-pour materials by neat depth and by depth with approved aggregate extension.
Extension changes yield, water demand and strength. Use only the aggregate type, gradation and proportion the datasheet names, and plan multiple lifts where the repair exceeds the neat limit.
Temperature, cure and return to service
Rapid-setting mortars gain strength quickly at 70 °F and slow down in cold weather; hot weather shortens working time. Follow ACI 305R and 306R practices when placing outside the published range, and match the return-to-service time to the traffic the repair will carry.
Cure as the datasheet directs: wet cure, curing compound or none for some rapid products. Confirm that any planned coating, sealer or joint filler is compatible with the cured repair material and its cure method.
Before you order
Concrete repair specifications & quantity planning
Use the project specification and the selected manufacturer data to confirm performance, quantity, accessories and documents before the shutdown or pour date.
Match the specified performance
Read compressive, bond and flexural strength with test method and age. Check for ASTM C928 where a rapid repair material is specified, ICRI 320.3R data-sheet reporting, corrosion inhibitor, polymer modification, freeze-thaw ratings and NSF/ANSI 61 where the repair contacts potable water.
Calculate bags, kits and cartridges
Measure the repair volume from area and average depth, add an allowance for waste and overbreak, then divide by the published yield of the exact bag at the intended consistency or extension. Add bonding agent by coverage rate and injection resin by crack length, width and depth. Round up to whole units.
Assemble the submittal
Identify the manufacturer, product, package size and SKU for each material in the system, including bonding agent, extension aggregate and curing product. Gather the current datasheet, installation guide, SDS and any DOT or agency approval the specification requests.
Project orders
Request concrete repair project pricing
Send the specified repair materials and quantities for your restoration, shutdown or pavement work. If the product is still under review, include the specification and a description of the damage and we will confirm a fit before quoting.
Include with your request
- Manufacturer, product and package size, or the specification section
- Repair area, average depth and orientation
- Exposure: traffic, water, chemicals, freeze-thaw or marine
- Delivery ZIP and required-on-site date
Concrete repair questions
What is the difference between a repair mortar and a patching compound?
The terms overlap. Repair mortars are generally structural materials placed at greater depth, often polymer-modified or extended with aggregate, for form-and-pour or vertical work. Patching compounds are usually thinner, faster-setting materials for surface spalls, resurfacing and small horizontal defects. Choose by depth, orientation and strength requirement rather than by name.
Which concrete repair mortar works on vertical and overhead surfaces?
Use a mortar published as non-sag for vertical and overhead placement, such as EucoRepair V100, Five Star Structural Concrete VO or SikaTop 123 Plus, and stay within its build thickness per lift. Horizontal patching compounds will slump on walls and soffits.
Should I inject cracks with epoxy or polyurethane?
Epoxy injection restores strength in dormant structural cracks that are dry or damp. Polyurethane resins and hydraulic cements stop active leaks and tolerate movement but do not structurally bond the crack. Floor cracks that must carry traffic the same day are usually filled with a rapid-set urethane or polyurea repair material.
Do I need a bonding agent under a concrete patch?
Follow the mortar datasheet. Many one-component mortars bond through a scrub coat of the same material on a saturated-surface-dry substrate, while others require an epoxy or acrylic bonding agent placed within its open time. Using an unlisted bonding agent can void the manufacturer's performance data.
How soon can a concrete repair take traffic?
Rapid-setting materials such as SikaQuick 1000 or Five Star Structural Concrete are published for early return to service at moderate temperatures, often within hours; standard mortars need days. Cold weather extends every published time. Check the datasheet for the strength required by your traffic and the temperature on site.
Can I use these products to repair asphalt?
Use a cold-applied asphalt patch for asphalt potholes and edges. Cementitious repair mortars are for concrete pavement and slabs; they do not bond permanently to asphalt. The Asphalt Repair category lists the asphalt products in this assortment.
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