SPECIFICATION

FOR CONCRETE
CRACK REPAIR

JKR 20601-0250-18

BAHAGIAN PERKHIDMATAN FORENSIK STRUKTUR

CAWANGAN KEJURUTERAAN AWAM DAN STRUKTUR
IBU PEJABAT JKR MALAYSIA
KUALA LUMPUR www.jkr.gov.my
 TABLE OF CONTENT

PAGE

1.0 GENERAL .................................................................................................................. 1

1.1 Submittals ................................................................................................................. 1

1.2 Materials .................................................................................................................... 1

1.2.1 Surface Seal Polymer Compound .................................................................. 1
1.2.2 Polymer Resin ................................................................................................ 1

1.3 Quality Assurance .................................................................................................... 2

1.3.1 Labeling .......................................................................................................... 2
1.3.2 Procedure for Use .......................................................................................... 2
1.3.3 Product Delivery, Storage and Handling ........................................................ 2
1.3.3.1 Delivery of Materials ....................................................................... 2
1.3.3.2 Date of Expiry ................................................................................. 2
1.3.3.3 Storage of Materials ....................................................................... 2
1.3.3.4 Handling of Materials ..................................................................... 3

1.4 Confirmatory Crack Survey ..................................................................................... 3

1.5 Execution of Works .................................................................................................. 3

1.5.1 Temporary Supports and Props ..................................................................... 3
1.5.2 Care During Works ......................................................................................... 3
1.5.3 Inspection of Concrete Surfaces and Cracks Prior to Surface Sealing ......... 3
1.5.4 Record of Crack Repair Works ...................................................................... 3

1.6 Testing Quality Control ............................................................................................ 4

2.0 CRACK REPAIR WORKS PROCEDURE ................................................................. 4

2.1 Crack Width Less Than or Equal to 0.3mm ........................................................... 4

2.1.1 Preparation of Concrete Surfaces .................................................................. 4
2.1.2 Routing of Cracks ........................................................................................... 4
2.1.3 Cleaning the Cracks ....................................................................................... 4
2.1.4 Sealing of V-Groove ....................................................................................... 4
2.1.5 Finishes Reinstatement .................................................................................. 5

2.2 Crack Width More Than 0.3mm But Less Than or Equal to 3.0mm .................... 5
2.2.1 Preparation of Concrete Surfaces .................................................................. 5
2.2.2 Installation of Packer ...................................................................................... 5
2.2.3 Cleaning Cracks and Holes ............................................................................ 6
2.2.4 Sealing of Cracks ........................................................................................... 6
2.2.5 Injection Equipment ........................................................................................ 6
2.2.6 Cleaning of Equipment ................................................................................... 7
2.2.7 Polymer Resin Injection ................................................................................. 7
2.2.8 Finishes Reinstatement .................................................................................. 8

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 SPECIFICATION FOR CONCRETE CRACK REPAIR

1.0 GENERAL

This specification shall be used for concrete structure with the following crack categories:

i. Crack width less than or equal to 0.3mm; and

ii. Crack width more than 0.3mm but less than or equal to 3.0mm

1.1 Submittals

The contractor shall submit the following particulars for each of crack repair works:

i. Material brand name, specification and properties stating standards to which

the materials comply;
ii. Name of manufacturer;
iii. Manufacturer’s brochures of the product;
iv. Method statement for each crack repair works;
v. Copy of product approval certificate from a National or International
Standards Institution; and
vi. Copy of product injectability test result.

1.2 Materials

1.2.1 Surface Seal Polymer Compound

The polymer compound for surface seal shall be of thixotropic nature and comply with the
following minimum requirement when tested with the respective European Standard (EN) as
specified below:

Compressive Strength ≥ 50 N/mm2

(BS EN 12190)

Tensile Bond Strength ≥ 2.0 N/mm2

(BS EN 12618-2) Cohesive Failure of Substrate

The compound shall be of such viscosity grade that it does not sag when applied in putty form
into a groove in overhead application. The compound shall on curing, able to withstand the
maximum grouting pressure without leak.

1.2.2 Polymer Resin

The polymer resin for concrete cracks injection shall comply with the following minimum
requirement when tested with the respective European Standard (EN) as specified below:

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 Compressive Strength ≥ 50 N/mm2
(BS EN 12190)

Tensile Bond Strength ≥ 2.0 N/mm2

(BS EN 12618-2) Cohesive Failure of Substrate

Viscosity 110 - 300 mPa.s

(EN ISO 3219)

The polymer resin shall be of such temperature class suitable for use in tropical climates and
of such viscosity grade suitable for pump application. It should be of two components with
very low viscosity for injection and pouring. It shall also be polymerized without shrinkage and
once hardened is waterproof and resistant towards chemical agents present in the
atmosphere.

1.3 Quality Assurance

1.3.1 Labeling

All containers shall have the following markings:

i. Name of manufacturer;
ii. Manufacturer's product identification;
iii. Manufacturer's instructions for mixing; and
iv. Warning for handling and toxicity, where applicable.

1.3.2 Procedure for Use

The Contractor shall submit to the S.O. for his approval, the mixing and application
procedures to be adopted in the works.

1.3.3 Product Delivery, Storage and Handling

1.3.3.1 Delivery of Materials

All repair materials shall be delivered in manufacturer's sealed containers with labels legible
and intact.

1.3.3.2 Date of Expiry

Expired repair materials should not be used on site.

1.3.3.3 Storage of Materials

All repair materials shall be properly stored in weatherproof store at temperatures between
5°C - 38°C or otherwise recommended by the manufacturer.

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1.3.3.4 Handling of Materials

All repair materials shall be handled in a safe manner and in a way that shall avoid breaking
container seal.

1.4 Confirmatory Crack Survey

Prior to the commencement of the work, the contractor shall conduct a survey to identify all
cracks which would require injection repair. If, crack location drawing supplied in the contract,
the contractor shall conduct confirmatory crack survey to confirm the location of the cracks.
The locations for the repair should be clearly marked out and identified. The crack mapping
record shall comply with clause 1.5.4 of this specification.

1.5 Execution of Works

Approval of the S.O. is required prior to commencement of any crack repair works.

1.5.1 Temporary Supports and Props

Before repair may be done to any structural member, the Contractor shall provide adequate
supports and props to the structural members to ensure the safety and stability of the member
and the structure is not impaired. The support and prop system shall be of such configuration
and design according to the national standard and approved by the S.O.

1.5.2 Care During Works

The Contractor shall at all times during the hacking, grooving and drilling works exercise due
care against cutting into any reinforcement.

Where reinforcement is cut or damaged, the Contractor shall notify the S.O. who shall decide
the manner in which the reinforcement shall be repaired, all at the Contractor's own cost and
no claim for extra in this respect shall be allowed.

1.5.3 Inspection of Concrete Surfaces and Cracks Prior to Surface Sealing

All concrete surfaces and cracks shall be inspected by the Contractor before application of
surface seal polymer. The surfaces shall be free from loose material and contaminants. The
surface shall be sufficiently dry. The Contractor should seek the approval of the S.O. before
commencement of the surface sealing works.

1.5.4 Record of Crack Repair Works

The Contractor shall maintain continuous record of all crack repair works. The record, in
duplicate, shall be in such form approved by the S.O. The repair drawing shall consist of the
following but not limited to the information as follows:

i. Identification of crack member type; e.g. slab, beam, column;

ii. Provide general description of crack and sketch showing crack pattern;

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 iii. Maximum width and length of crack; and
iv. Picture of crack before, during and after the repair works.

The Contractor shall submit the record in duplicate to the S.O. immediately on completion of
each crack repair work for verification. Thereafter the verified record shall be jointly signed by
the Contractor and the S.O. The original copy of the record shall be kept by the S.O., and the
signed duplicate copy returned to the Contractor. The information from the record shall be the
basis of computing the actual final quantity for crack repair works under the Contract.

1.6 Testing Quality Control

Unless otherwise specified in the contract, the Contractor shall propose a testing quality
control plan for the S.O. approval. The proposed plan shall comply with Clause 9.3, BS EN
1504-10. All cost for execution of the approved plan shall deem to be included in the
contractors cost for the works.

2.0 CRACK REPAIR WORKS PROCEDURE

2.1 Crack Width Less Than or Equal to 0.3mm

2.1.1 Preparation of Concrete Surfaces

Where cracks to be repaired are located in concrete that have spalled or otherwise been
damaged or are unsound, such concrete shall first be removed to expose sound parent
concrete free of loose and unsound material. The removal and surface preparation work shall
be carried out using mechanical equipment approved by the S.O.

2.1.2 Routing of Cracks

All cracks to be repaired shall be routed along its length with sharp-edged V-grooves to a
depth and width of approximately 10mm respectively using light chipping mechanical
hammers or cutting machine approved by the S.O.

2.1.3 Cleaning the Cracks

On completion of the groove routing work, the exposed concrete surface and the inside of the
cracks shall be thoroughly cleaned using water. The water used shall be clean water free of
contaminants. The surfaces and cracks shall be allowed to air dry and thereafter they shall
be cleaned and dried using high pressure compressed air jet. The equipment supplying the
compressed air shall be equipped with efficient oil and water trap approved by the S.O. to
prevent contamination to the concrete surface.

2.1.4 Sealing of V-Groove

The composition of surface seal polymers compound, to be used in a mix shall be strictly in
accordance with the manufacturer instructions.

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The surface seal polymer compound shall be mixed in a clear container free from harmful
residue or foreign particles. The mix shall be thoroughly blended using mechanical mixer to a
uniform and homogeneous mixture. Small batches of mix not exceeding 1 litre may be hand-
mixed by use of spatulas. Palette knives or similar devices to obtain a uniform homogenous
mixture. When paddle type mechanical mixer is used, care shall be taken to prevent air
entrapment in the mixture. Each mix should be of such amount that it can be immediately
used before the material gels.

The compound shall be applied to the dry groove in the crack, by trowel or such other means
approved by the S.O..

The compound shall be properly worked into place and consolidated thoroughly so that all
contact surfaces are wetted by the compound and entrained air reduced to the level
recommended by the manufacturer. It shall allowed to cured to form well bonded and leak
free seal.

2.1.5 Finishes Reinstatement

The surface of the seal shall be finished flushed with adjacent concrete. Grinding machine
shall be used to flush the excessive sealant.

2.2 Crack Width More Than 0.3mm But Less Than or Equal to 3.0mm

2.2.1 Preparation of Concrete Surfaces

Refer to 2.1.1

2.2.2 Installation of Packer

The Contractor shall provide and install packer of appropriate diameter and length complete
with shut-off nipple or valve into the pre-drilled holes provided for injection of packer point.
Hole for installation of packer for injecting polymer resin shall be provided by the contractor
at specified distance along the crack. The spacing of holes shall be such that complete filling
of the crack by polymer resin can be achieved.

The packer holes shall be properly cleaned from loose material and contaminants prior to
installation. The surface packer shall be properly bonded using surface seal polymer, care
being taken to ensure the opening through the hole and packer point is clear from being
blocked by polymer.

For surface packers, the distance between packers shall not be more than 2/3 of the thickness
or depth of the element.

For mechanical drilled-in packer, the hole diameter should be sufficient for insertion of packers
and should be at an angle of 45˚-60˚ intersecting the crack lines, in a staggered pattern at
both sides of the groove lines. The distance between packers shall not be more than 1/2 to
the thickness or depth of the element. The maximum distance of packer to the center of the

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crack lines shall not be more than 50mm. For drilled in mechanical packers, the contractor
shall provide suitable mechanical packers with irreversible ball bearing.

2.2.3 Cleaning Cracks and Holes

On completion of drilling work, the exposed concrete surface and the inside of the cracks shall
be thoroughly cleaned using water. The water used shall be clean water free of contaminants.
The surfaces and cracks shall be allowed to air dry and thereafter they shall be cleaned and
dried using high pressure compressed air jet. The equipment supplying the compressed air
shall be equipped with efficient oil and water trap approved by the S.O. to prevent
contamination to the concrete surface.

2.2.4 Sealing of Cracks

The composition of surface seal polymers compound, to be used in a mix shall be strictly in
accordance with the manufacturer instructions.

The surface seal polymer compound shall be mixed in a clear container free from harmful
residue or foreign particles. The mix shall be thoroughly blended using mechanical mixer to a
uniform and homogeneous mixture. Small batches of mix not exceeding 1 litre may be hand-
mixed by use of spatulas. Palette knives or similar devices to obtain a uniform homogenous
mixture. When paddle type mechanical mixer is used, care shall be taken to prevent air
entrapment in the mixture. Each mix should be of such amount that it can be immediately
used before the material gels.

The compound shall be applied to the dry crack, by trowel or such other means approved by
the S.O..

The compound shall be properly worked into place and consolidated thoroughly so that all
contact surfaces are wetted by the compound and entrained air reduced to the level
recommended by the manufacturer. It shall be allowed to cure to form well bonded and leak
free seal.

The surface of the seal shall be finished flushed with adjacent concrete. The surface seal
polymer shall be allowed to cure base on manufacturer recommendation prior to injection of
polymer resin.

2.2.5 Injection Equipment

The Contractor shall provide sufficient number of injection equipment for the Works. Injection
pump shall be the hydraulic type, in good working condition and capable of injecting the
polymer resin material under pressure up to 276 kPa or sufficient to fill up the crack. The
pump shall be fitted with all the necessary items including pressure hose, injector and feeder
tank.

A direct reading pressure gauge shall be calibrated and fitted properly on the discharge hole
to allow injection pressure reading to be taken.

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A device capable of measuring accurately the quantity of grout injected shall be fitted to the
injection system. Where volumetric meter is used for measuring, it shall provide direct reading
in milliliters.

The meter shall be calibrated no later than three (3) preceding months by a recognized test
agency. The Contractor shall furnish the S.O. such calibration certificate as proof. Where
other means of volume measurement is to be used, it shall be to the approval of the S.O.

2.2.6 Cleaning of Equipment

All equipment used for injection shall be thoroughly cleaned after every use. The Contractor
shall ensure that the equipment are dry and free from oil, dirt, solvent or other deleterious
matter before each time they are to be reused.

2.2.7 Polymer Resin Injection

Polymer resin shall be injected into the crack through the packer point using the injection
pump fittings.

For horizontal member, injection of the polymer resin shall begin at the widest section. For
vertical member, the injection of polymer resin shall begin at the lowest entry port.

If surface packers are used, injection of polymer resin through one packer point shall continue
until polymer resin starts to come out from the adjacent port. At this point the injection packer
point shall be sealed off by closing the valve or nipple. Injection shall proceed to the adjacent
packer point where the polymer resin has just appeared. The sequence shall be followed until
all packer point are injected.

If mechanical drilled-in packers are used, the injection should be stop when the injection pump
has reached its maximum build up pressure. Injection shall proceed to the adjacent packer
point. The sequence shall be followed until all packer point is injected.

During injection, care shall be taken to ensure that the injection rate and pressure is such that
all cracks are completely filled without damage to the surface seal or structure. All precautions
must be taken to prevent entrapment of air in the polymer resin.

When leak occurs in the surface seal or new crack plane emerges, the injection shall be stop.
All leaks shall be resealed using surface seal polymer and allowed to cure before injection is
recommenced.

New crack plane which emerges shall be V-groove, cleaned, provided with packer point,
sealed and cured as described herein before prior to recommencement of polymer resin
injection. The grooving work on such crack shall not begin until adjacent injection polymer
resin has sufficiently cured.

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2.2.8 Finishes Reinstatement

Where the concrete surface is to receive no further treatment or coat of finishing, the stem of
the packer point pipe projecting beyond the surface of concrete shall be cut of flushed with
the concrete surface using suitable tool approved by the S.O. The cutting operation shall not
begin until the epoxy polymer resin has sufficiently cured according to the manufacturer. Care
shall be taken during the cutting off work to prevent damage to the surrounding epoxy polymer
sealant or concrete.

The surface of the seal shall be finished flushed with adjacent concrete. Grinding machine
shall be used to flush the excessive sealant.

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 ACKNOWLEDGEMENT

We would like to thank all committee members below for their invaluable support and assistance rendered
during the entire review process:

Committee Members
Ir. Hj. Mohd Noor Azudin bin Hj. Mansor Pengarah Kejuruteraan Pakar (Struktur)
Ir. Mohd Shaifuddin bin Abdul Razak Bahagian Perkhidmatan Forensik Struktur
Ir. Hanizah binti Argadan Bahagian Perkhidmatan Forensik Struktur
Ir. Emmy Sherina binti Ismail Hashim Bahagian Perkhidmatan Forensik Struktur
Ir. Bernard Toides Bahagian Perkhidmatan Forensik Struktur
Ir. Mohd Firdaus bin Mohd Bahagian Perkhidmatan Forensik Struktur
Ir. Amirul Haikal bin Azizan Bahagian Perkhidmatan Forensik Struktur
Ir. Mohd Hairul Nizam bin Shukor Bahagian Perkhidmatan Forensik Struktur
Mohd Fairoze Mazly bin Zulkifli Bahagian Perkhidmatan Forensik Struktur
Nur Naemah binti Esa Bahagian Perkhidmatan Forensik Struktur
Benny Anak Andrew Esing Bahagian Perkhidmatan Forensik Struktur
Ir. Norhayati binti Khairudin Bahagian Kejuruteraan Awam
Ir. Hafizah binti Zakaria Bahagian Rehabilitasi dan Konservasi
Ir. Amisah binti Ahwang Bahagian Rehabilitasi dan Konservasi
Ir. Lee Choon Siang Bahagian Rehabilitasi dan Konservasi
Ezuan bin Jamadon Bahagian Rehabilitasi dan Konservasi

Reviewers
Mr. Steven Ng Sika Kimia Sdn. Bhd
Mr. Rafiq Rashid Sika Kimia Sdn. Bhd
Mr. Tengku Mohd Khairi Tengku Khalid Mapei Malaysia Sdn. Bhd
Mrs. Chan Swee Fun Mapei Malaysia Sdn. Bhd

Cover and Illustration

Othman bin Mohd Joned Bahagian Perkhidmatan Forensik Struktur

Secretariat
Ir. Bernard Toides Bahagian Perkhidmatan Forensik Struktur
Othman bin Mohd Joned Bahagian Perkhidmatan Forensik Struktur
 BAHAGIAN PERKHIDMATAN FORENSIK STRUKTUR
CAWANGAN KEJURUTERAAN AWAM DAN STRUKTUR
TINGKAT 4-10, MENARA KERJA RAYA BLOK G
IBU PEJABAT JKR MALAYSIA
50480 KUALA LUMPUR