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ConcreteOnline self-study

Reinforced Concrete Bridge Repair Methods

1 PDH · about 60 minutes · Course no. BR-C02 · Instructor: Michael Craig, PE

About the instructor

Michael Craig, PE is Senior Vice President and Southeast Director at Strinteg Corporation, leading bridge inspection and structural engineering across eight states and Puerto Rico. In 27+ years he has inspected over 4,000 structures and completed 3,000+ load ratings and 160+ load tests. He has managed repair and preservation design for complex bridges, including cable-stayed bridges. He holds PE licenses in twelve states, DC and Puerto Rico, SPRAT Level 1, and FAA Part 107 credentials.

Patching concrete is the most common repair on the bridge inventory, and one of the most often redone. A patch that debonds, cracks or sets off new corrosion around its edges a few years later costs more than the original work, plus a second lane closure. This course walks through the full repair sequence for reinforced concrete bridge members: evaluating and categorizing the damage, removing concrete and treating the reinforcement, preparing the substrate, choosing a repair material, placing and curing it, and accepting the work. It also covers the ring-anode (halo) effect, which makes chloride-contaminated members corrode faster next to new patches, and the tools used to limit it, such as embedded galvanic anodes. It also covers crack injection, deck repairs, hydrodemolition and inspection of the finished work. The main sources are TxDOT's Concrete Repair Manual (Chapters 2 and 3, read online), the Michigan DOT Construction Manual Section 712 on concrete bridge rehabilitation, ACI TechNote 364.6T-02 on concrete removal around corroded reinforcing steel, the FHWA Bridge Preservation Guide (Spring 2018) and the FHWA/NHI Underwater Bridge Repair, Rehabilitation, and Countermeasures reference manual (FHWA-NHI-10-029). Agency-specific values are reported as that agency's requirements, not as national rules. Worked numbers in the examples are illustrative and were computed for this course, not taken from a real bridge. The ACI 546R and ACI 345.1R guides in the catalog are paywalled and were not reviewed, so no requirement is quoted from them.

⬇ Download study guide (PDF)

Learning objectives

  • Evaluate damage before repair
  • Prepare surfaces and reinforcement
  • Select repair materials
  • Avoid the ring-anode effect

Outline

  1. Why patches fail
  2. Step 1: Evaluate before you repair
  3. Step 2: Categorize the damage
  4. Step 3: Remove the concrete
  5. Step 4: Treat the reinforcement
  6. Step 5: Prepare the substrate
  7. Step 6: Select the repair material
  8. Step 7: Mix, place and cure
  9. The ring-anode (halo) effect
  10. Galvanic versus impressed-current protection
  11. Crack repair by epoxy injection
  12. Deck repairs and hydrodemolition
  13. Inspection and acceptance
  14. Worked example: planning a pier cap patch (illustrative)
  15. Open the course (20 screens, 2 knowledge checks)
  16. Final quiz — 10 questions, 70% to pass

References

  1. ACI 546R-14, Guide to Concrete Repair
  2. ACI 345.1R-16, Guide for Maintenance of Concrete Bridge Members
  3. TxDOT, Concrete Repair Manual, Chapter 2 (Damage Assessment and Repair Types) and Chapter 3 (Repair Materials and Procedures), txdot.gov/manuals/brg/crm.html (online manual, read October 2026)
  4. Michigan DOT, Construction Manual, Section 712 — Bridge Rehabilitation, Concrete, mdotwiki.state.mi.us/construction (read October 2026)
  5. ACI TechNote 364.6T-02 (reapproved 2011), Concrete Removal in Repairs Involving Corroded Reinforcing Steel, American Concrete Institute
  6. FHWA, Bridge Preservation Guide: Maintaining a Resilient Infrastructure to Preserve Mobility, Spring 2018
  7. FHWA, Underwater Bridge Repair, Rehabilitation, and Countermeasures, NHI Course 130091A Reference Manual, FHWA-NHI-10-029