ACI PRC-546.3-23 PDF

Full title and description

ACI PRC-546.3-23 — Materials Selection for Concrete Repair—Guide. Reported by ACI Committee 546, this guide provides practical guidance for selecting materials used to repair, overlay, protect, and strengthen concrete. It summarizes material types, key properties, performance considerations, and common application issues to help owners, specifiers, designers, and contractors make informed material choices for specific repair applications and service conditions. First printing: February 2024. ISBN: 978-1-64195-244-6.

Abstract

This guide presents an overview of repair and overlay material categories (cementitious, polymer-modified, epoxy, urethane, methacrylate, silane/siloxane sealers, membranes, and protective coatings) and describes the material properties and performance criteria that most strongly influence durability and constructability. It covers material selection for deep and shallow repairs, thin overlays, crack repair and injection, surface sealers and traffic-bearing systems, waterproofing, and aggressive-environment applications. Guidance is provided on matching materials to substrate conditions, structural demands, exposure, and expected service life.

General information

• Status: Active (current guide).
• Publication date: First printing: February 1, 2024 (reported as PRC-546.3-23).
• Publisher: American Concrete Institute (ACI), Farmington Hills, MI, USA.
• ICS / categories: Concrete technology; repair and rehabilitation of concrete structures; construction materials and methods; (categories: concrete repair, overlays, protective systems).
• Edition / version: ACI PRC-546.3-23 (report/version number “-23”; first printing published February 2024). Supersedes earlier guidance in ACI 546.3R-14.
• Number of pages: 96 pages (formatted guide/report length).

Scope

The document provides guidance for selecting materials for the repair and overlay of concrete elements. It addresses types of repairs (deep, shallow, overlays, thin toppings), material categories and typical uses, important material properties (volume stability, mechanical properties, adhesion, permeability, chemical resistance), constructability and aesthetic considerations, and selection practices for different exposure classes and aggressive environments. The guide is intended to be used alongside project specifications, performance requirements, and applicable test methods.

Key topics and requirements

• Classification of repair types and corresponding material families (cementitious, polymer-modified cement, epoxy, polyurethane, methacrylate, protective coatings, sealers, membranes).
• Material property priorities: dimensional/volume stability, bond/adhesion, mechanical strength and modulus compatibility, permeability and transport properties, chemical resistance, and freeze–thaw durability.
• Constructability factors: curing and set times, workability, placement and finishing methods, repair thickness limits, and compatibility with existing substrates.
• Crack repair and injection: selection criteria for low-viscosity epoxies, elastomeric injections, and surface routing and sealing.
• Overlay and topping selection: surface preparation, bond promotion, thermal and modulus compatibility, and traffic/abrasion resistance.
• Protective systems and waterproofing: criteria for materials that reduce ingress, resist chloride/chemical attack, and extend service life.
• Environmental and exposure considerations: selection guidance for marine, deicing-salt, chemical, and submerged exposures.
• Quality assurance: reference to appropriate test methods and performance criteria for verifying material properties and acceptance.

Typical use and users

Used by structural and materials engineers, specifiers, owners, facility managers, repair contractors, testing laboratories, and product manufacturers. Typical projects include bridge deck and superstructure repairs, parking structures, industrial floors, building facades, marine structures, and any concrete element requiring durability rehabilitation or protective overlays. The guide supports specification development, product evaluation, and pre-selection during design and condition-assessment phases.

Related standards

Related guidance and standards include other ACI repair and practice documents (ACI 546 series and ACI PRC materials and practice reports), relevant ASTM test methods and material standards for adhesives, coatings, and cementitious repair materials, and owner or jurisdictional codes/specifications (for example, project-specific performance requirements and local building codes). This guide explicitly updates and replaces material-selection guidance previously found in ACI 546.3R-14.

Keywords

concrete repair; materials selection; overlays; cementitious repair; polymer-modified; epoxy injection; methacrylate; polyurethane; surface sealer; protective coatings; volume stability; bond; constructability; durability; waterproofing; ACI Committee 546.

FAQ

Q: What is this standard?

A: ACI PRC-546.3-23 is a guide published by the American Concrete Institute (Committee 546) that provides recommendations for selecting materials used in concrete repair, overlays, and protective systems.

Q: What does it cover?

A: It covers types of repair applications (deep repairs, shallow repairs, thin overlays, crack repair, surface sealers), material families and their typical uses, key material properties affecting performance, constructability considerations, and guidance for matching materials to exposure and service conditions.

Q: Who typically uses it?

A: Structural and materials engineers, repair contractors, specifiers, facility owners, testing labs, and product manufacturers use the guide for material preselection, specification development, and to inform decision-making on repair projects.

Q: Is it current or superseded?

A: It is the current guide in active use (report number PRC-546.3-23, first printing February 2024) and updates/succeeds prior guidance (for example ACI 546.3R-14).

Q: Is it part of a series?

A: Yes. It is part of ACI’s suite of repair and rehabilitation publications produced by Committee 546 and complements other ACI repair guides and practice documents in the ACI 546 series and related ACI codes and reports.

Q: What are the key keywords?

A: Concrete repair, materials selection, overlays, cementitious repair, polymer-modified, epoxy, methacrylate, polyurethane, protective coatings, volume stability, bond, constructability, durability.