How common is it for the femoral artery to be punctured during a heart cath and then need surgery to repair?

Uncommon. Femoral artery aneurysm or pseudoaneuyrsm formation at the site of left heart catheterization is very uncommon, less than 1% of cases in the hands of an experienced interventional cardiologist.
1% Bleeding at the puncture site occurs at approximately 1% of femoral catheterizations. There is a recent trend which originated in europe to perform cardiac catheterization from the radial artery approach. This almost completely eliminates the risk of bleeding from the puncture site.

Related Questions

How common is a femoral artery injury during a heart cath that needs surgery to repair?

Fairly rare. About 15-20 % of all femoral artery catheterizations have some type of complication, either bleeding or clotting. Much fewer than this actually require surgery. Read more...