A pilot trial under the Fully Optimized Road Maintenance (FORMAT) project of using thin bonded concrete overlay (BCO) for spalling repair was carried out in the Houston district on SH 146 near Baytown, Texas. In this paper, the practical considerations for the use of thin BCO in terms of the procedures and the material characteristics key to its success are presented, and the effectiveness of this treatment for spall damage in continuously reinforced concrete pavements (CRCPs) is assessed through varied field tests performed before and after the application. Also addressed is its feasibility relative to traffic control and user cost, existing pavement condition, and future maintenance factors as it is considered in the decision-making process of Strategic Analysis of Pavement Evaluation and Repair (SAPER) software. The results show that the application of the treatment combination (i.e. full depth repair, milling, and thin BCO) cost-effectively extended pavement life, improved load carrying ability with reduced user delay, and improved safety control and that it is an innovative and effective method of repair for CRCPs compared with other strategy alternatives.