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Structural Crack Repair with Epoxy

This document discusses structural crack repair through epoxy injection. It notes that cracks are a normal part of reinforced concrete but can impact durability, water tightness and strength if not addressed. The document outlines typical causes of cracks and different crack types. It explains that crack repair is important for durability, water tightness and strengthening structures. Key factors in selecting injection materials include crack width, movement and moisture level. Common injection materials like epoxies, polyurethanes and acrylic resins are detailed. The document provides guidance on equipment selection and step-by-step application methods for drill-hole and surface packer injection.

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Mohammed Awf
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86 views32 pages

Structural Crack Repair with Epoxy

This document discusses structural crack repair through epoxy injection. It notes that cracks are a normal part of reinforced concrete but can impact durability, water tightness and strength if not addressed. The document outlines typical causes of cracks and different crack types. It explains that crack repair is important for durability, water tightness and strengthening structures. Key factors in selecting injection materials include crack width, movement and moisture level. Common injection materials like epoxies, polyurethanes and acrylic resins are detailed. The document provides guidance on equipment selection and step-by-step application methods for drill-hole and surface packer injection.

Uploaded by

Mohammed Awf
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
  • Introduction to Structural Crack Repair
  • Cracks in Concrete Structures
  • Reasons for Cracks
  • Types of Cracks
  • Purpose of Crack Repair
  • Measuring Crack Width
  • Crack Conditions for Material Identification
  • Material Selection Based on Crack Width
  • ASTM Standards for Injection Materials
  • Injection Materials and their Properties
  • Common Equipment for Crack Injection
  • Application of Crack Repair Techniques
  • Conclusion

STRUCTURAL CRACK REPAIR BY EPOXY INJECTION

2020, MOHAMED AWF


CRACKS IN CONCRETE STRUCTURES

 Cracks are an element of all


reinforced concrete structures

 Cracks are not a failure of the


concrete. They are part of the
function of the reinforcement

2 6/8/20
WHAT ARE TYPICAL REASONS FOR CRACKS

Concrete – internal processes


Shrinkage, thermal expansion …

External forces
Setting, weight, loads …
Other reasons:
- Wrong concrete mixing design
- Extreme weather conditions
- Missing or insufficient concrete curing
- Bad compaction of the concrete
- Wrong planning of the joints
[…]

3 6/8/20
WHAT TYPES OF CRACKS CAN BE OCCURE

Surface cracks
 Negative effect for durability

Separating cracks
 Negative effect for water tightness
 Negative effect for durability
 Negative effect for strength

4 6/8/20
WHY WE DO CRACK REPAIR WORK?

Durability of the construction


Closing a crack to avoid the ingress of damaging
substances (e.g. corrosion due to chlorides)

Water tightness of the construction


Closing a crack to refit the sealing function of the concrete
structure.

Strengthening of the construction


Force transmitting injections to rebuilt the strength
of a structure (e.g. after a unique overload)

5 6/8/20
HOW CAN WE MEASURE CRACK WIDTH?

6 6/8/20
WHAT KINDS OF CRACK CONDITIONS HAVE TO BE
IDENTIFIED FOR MATERIAL IDENTIFICATION?

Width of a crack

Movements of a crack

Stage of moisture of a crack

7 6/8/20
WIDTH OF A CRACK

 The width of a crack is a


basic element for the correct
choice of an injection material

 Fine cracks normally require


an injection material with low viscosity

 Injection materials with higher viscosity


can be helpful in the case of wide cracks

8 6/8/20
9 6/8/20
MOVEMENT OF A CRACK

 In the case of movement, a flexible


injection material like a polyurethane resin
or hydrophilic acrylate is necessary

Attention !!!
All flexible materials have only a very limited extensibility.
The crack must be injected at its maximum width to limit
the expansion of the material.

10 6/8/20
WHAT KIND OF INJECTION MATERIALS
ARE AVAILABLE IN THE MARKET?

Micro fine Epoxy Polyurethane Acrylic


cement resin resin resin

Application
temperature ≥ 5°C ≥ 8°C ≥ 5°C ≥ 5°C

Viscosity ~ 200 – 400 ~ 250 – 800 ~ 100 – 1200 ~ 2 – 60


(20°C) mPas mPas mPas mPas

Pot life ~ 10 sec.


>1h ~ 5 - 60 min. ~ 5 - 60 min.
(20°C) – 60 min

Cleaning water solvent solvent water

Dissolver 1-co. pump


Equipment 1-co. pump 1-co. pump
1-co. pump 2-co. pump

11 6/8/20
EQUIPMENT AND ACCESSORIES
COMMON PACKERS

12 6/8/20
APPLICATION

Equipment for crack repair work

Injection pumps
- One-component pump
- Two-component pump

Packer systems
- Drill-hole / mechanical packer
- Surface packer

13 6/8/20
APPLICATION OF A DRILL-HOLE PACKER

 Drill packer holes at a 45° angle to the


concrete

 Ø of drill hole = Ø of packer + 1-2mm

 Drill hole depth: ~d

~45
°

d: building component thickness


d/2: interval
- from packer to packer
- from packer to crack

14 6/8/20
APPLICATION OF A DRILL-HOLE PACKER

direction of
injection

View C-C

View A-A Source: ZTV-Ing., German regulation

15 6/8/20
Bild durch Klicken auf Symbol hinzufügen

16 6/8/20 Injection Training


APPLICATION OF A DRILL-HOLE PACKER

Only
in the case of very
thin constructions

17 6/8/20
APPLICATION OF A DRILL-HOLE PACKER

18 6/8/20
CRACK IN CONCRETE STRUCTURES

Step by step

19 6/8/20
CRACK IN CONCRETE STRUCTURES

Step by step

20 6/8/20
CRACK IN CONCRETE STRUCTURES

Step by step

Starting
packer

21 6/8/20
CRACK IN CONCRETE STRUCTURES

Step by step

22 6/8/20
CRACK IN CONCRETE STRUCTURES

Filling the whole crack at worst case scenario

23 6/8/20
INJECTION PRESSURE

Pmax. = (concrete strength x 10) / 3

Example:
Concrete Class C25/30 (EN 206-1)
= 30 N/mm2 (for cubes)

Pmax. = (30 x 10)/3 = 100 bar

24 6/8/20
APPLICATION OF A SURFACE PACKER

25 6/8/20
APPLICATION OF A SURFACE PACKER

26 6/8/20
APPLICATION OF A SURFACE PACKER

Step by step
Clean and stable
surface

27 6/8/20
APPLICATION OF A SURFACE PACKER

Step by step
A nail ensures an
opening of the crack

28 6/8/20
APPLICATION OF A SURFACE PACKER

Step by step

29 6/8/20
APPLICATION OF A SURFACE PACKER

Step by step

Don´t forget the


curing time of the
patching !!!
(~ 24 h)

30 6/8/20
APPLICATION OF A SURFACE PACKER

Step by step
High injection
pressure can damage
the patching !!!

31 6/8/20
CRACK INJECTION

THANK YOU FOR YOUR ATTENTION

32 6/8/20

2020, MOHAMED AWF STRUCTURAL CRACK REPAIR BY EPOXY INJECTION
Cracks are an element of all reinforced concrete structures Cracks are not a failure of the concrete. They are part of the
3 6/8/20 WHAT ARE TYPICAL REASONS FOR CRACKS Concrete – internal processes Shrinkage, thermal expansion … External forces S
4 6/8/20 WHAT TYPES OF CRACKS CAN BE OCCURE Surface cracks  Negative effect for durability Separating cracks  Negative ef
5 6/8/20 WHY WE DO CRACK REPAIR WORK? Durability of the construction Closing a crack to avoid the ingress of damaging subst
6/8/20 6 HOW CAN WE MEASURE CRACK WIDTH?
7 6/8/20 WHAT KINDS OF CRACK CONDITIONS HAVE TO BE IDENTIFIED FOR MATERIAL IDENTIFICATION? Width of a crack Movements of a
The width of a crack is a basic element for the correct choice of an injection material Fine cracks normally require an in
6/8/20 9
In the case of movement, a flexible injection material like a polyurethane resin or hydrophilic acrylate is necessary Attent

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