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SURFACE
Honeycomb and larger surface voids require procedures resembling those for typical concrete
repairs. But there’s nothing typical about the recommended approaches to repairing these voids.
They vary greatly.
While repairing voids or honeycomb in concrete surface, the most common question that arises
is what should be the thickness of the repair. Some agencies do not require a minimum thickness,
while others set limits, such as 1 inch or 2 inches (25 mm to 50 mm). Some suggests using an epoxy
as bonding agents while other suggests using of cement grout.
In any case, good concrete repair practice calls for removing any loose material within the void.
According to scientists, honeycomb often contains loose coarse aggregate if the void is caused by a
leak in the form. If the void is caused by poor concrete consolidation; the coarse aggregates often
are intact.
3. A suitable mix contains 1 part Portland cement and 4 parts sand and has a water-cement ratio
of about 0.35. If the repair is deeper than 1 inch (or 25 mm), apply the mortar in layers no
thicker than 3⁄4 inch to avoid sagging and loss of bond.
4. After placing each layer, wait about 30 minutes before placing the next layer. You don’t have to
scratch or otherwise prepare a preceding layer before placing the next, but do not let the in-
place mortar dry.
5. To complete the repair, overfill the void slightly. After the material has hardened slightly but can
still be trimmed off with the edge of a steel trowel, shave off the excess material, working from
the center toward the edges. When finishing the repair, exercise extreme care to avoid
impairing the bond.
REFERENCES
Guide to Concrete Repair by W. Glenn Smoak