When a reinforced concrete structure is repaired to prevent cracking due to corrosion product expansion, the size and strength of the patch material used to extend the service life of the structure are important design characteristics that must be made but which are not fully understood. An experimental test regime was created to study the effects of patch shape, depth of the patch with respect to existing reinforcement layers, and patch width were investigated. Specimens were exhibited to continuously increasing internal pressure from the location of a reinforcing bar to simulate an accelerated effect of the volumetric expansion pressure caused by corrosion product formation. The typical specimen cracking patterns revealed initial cracking formed directly above the location of the expanding pressure bar, with subsequent tangential cracking at the patch edges, and eventual spalling of the patched section. All repaired specimens exhibited a moderate to significant reduction in the maximum internal pressure capacity and an increase in the total fracture energy until spalling occurred in the specimen. Triangular shaped repair sections cast within the depth of the simulated corrosion rebar required almost 3 times higher fracture energy, but could only withstand 38% of the maximum pressure before spalling occurred than other deeper rectangular-shaped repair sections. As the patch depth increases beyond different layers of reinforcement, the maximum inner pressure significantly increases and total fracture energy significantly decreases.