Structural Crack Repair by Epoxy Injection: 2020, Mohamed Awf

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
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

Only
in the case of very
thin constructions
17 6/8/20
18 6/8/20
CRACK IN CONCRETE STRUCTURES
Step by step
19 6/8/20
Step by step
20 6/8/20
Step by step
Starting
packer
21 6/8/20
Step by step
22 6/8/20
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
26 6/8/20
Step by step
Clean and stable
surface
27 6/8/20
Step by step
A nail ensures an
opening of the crack
28 6/8/20
Step by step
29 6/8/20
Step by step
Don´t forget the

curing time of the
patching !!!
(~ 24 h)
30 6/8/20
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

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STRUCTURAL CRACK REPAIR BY EPOXY INJECTION

2020, MOHAMED AWF

 Cracks are an element of all

 Cracks are not a failure of the

Concrete – internal processes

Durability of the construction

Water tightness of the construction

Strengthening of the construction

Stage of moisture of a crack

 The width of a crack is a

 Fine cracks normally require

 Injection materials with higher viscosity

 In the case of movement, a flexible

Micro fine Epoxy Polyurethane Acrylic

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

Pot life ~ 10 sec.

Cleaning water solvent solvent water

Dissolver 1-co. pump

Equipment for crack repair work

 Drill packer holes at a 45° angle to the

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

 Drill hole depth: ~d

d: building component thickness

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

16 6/8/20 Injection Training

Filling the whole crack at worst case scenario

Pmax. = (concrete strength x 10) / 3

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

Don´t forget the

THANK YOU FOR YOUR ATTENTION

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