Aamer Syed, Senior Product Manager, Sika

Corporation, Lyndhurst, NJ.

Field Guide to Concrete Repair

Application Procedures
ACI Fall 2011 Convention
October 16 20, Cincinnati, OH

ACI ACI
WEB SESSIONS WEB SESSIONS

Purpose of Epoxy Injection

1. To restore structural integrity to
concrete constructions
Structural Crack 2. To resist the penetration of moisture in
Repair by Epoxy concrete elements

Injection
ACI RAP Bulletin 1
Aamer Syed
Vertical Cracks Horizontal Cracks

How Epoxy Works Properties

Epoxies (Thermosetting Resins) have
varying:
Epoxy Too Thick Cured Modulus of Elasticity
to Use Material
Resin A Viscosity
Water = 1 centipoise
Syrup = 3000 centipoise
Pot Life Gels Hardens Solid Coefficient of Thermal Expansion
Mix A with B
Exothermic Reaction
Produces Heat
Liquid Semi-Solid
Hardener Mixing time is critical
B Manage the working time

1
 Choosing the Right Epoxy
When to Use Injection Method?
Crack width <.02 - use
an LV epoxy (500 cps
Horizontal, Vertical & Overhead Cracks or less)
For wider cracks or one
where conventional repair methods sided injection medium
viscosity or gel can be
do not work used
Other specs to consider:
Structural Crack Repair Rigidity (MOE)
Working Life
Static Cracks Moisture Tolerance
Color
Compressive, Flexural,
Moving cracks are not typically injected & Tensile Strengths

Equipment
For high or low pressure systems:
Injection Ports
Wire Brush or Grinder
Air Guns
Hand-Actuated Delivery System
Spring Actuated Capsules
Balloon-Actuated Capsules
Safety
MSDS for all materials used
Protective Clothing, Eyewear & Gloves
Eye wash station / Ventilation
Special Precautions for
flammable/combustible material
Necessary cleaning equipment
Notify occupants of pending repairs

Preparation Repair Procedure

Clean surface wide on each side of crack

Wire brush recommended , grinders fill crack

1. Port Installation
with unwanted dust

Remove contaminants with oil-free 2. Install the Cap Seal

compressed air or vacuums

If concrete adjacent to crack is deteriorated, 3. Inject the Epoxy

V-Groove the crack until sound concrete is
reached.
4. Remove Ports & Cap Seal

2
 Port Installation Install the Cap Seal
Properly installed this contains
Two types of Ports the epoxy as it is injected under
Surface Mounted pressure into the crack
mainly used If not done right leaks will occur
Socket Mounted Consistent application is a must:
used when crack inconsistencies = failure point
is blocked
Capseal can be epoxies as well
Spacing is typically 8 as polyester, wax or silicone
assume 4 travel of caulk
material in one direction
Manifold system can be
used for simultaneous
injection

Inject the Epoxy Remove Ports and Cap Seal

Epoxy must be batched
and mixed properly Can remove by heat, chipping or grinding
Start at widest point Can be left if appearance is not of importance
Vertical cracks are done
from the bottom up
Continue injection until refusal
If hairline crack try increasing
pressure and time (This must
be managed to prevent
blowout)
When injection into port is
complete cap immediately

Verification
Penetration - Core samples
Fine Cracks Epoxy glows under Black Light
Structural Compressive & Tensile
ASTM 42

Non-Destructive
Impact Echo
Ultrasonic Pulse Velocity
Spectral Analysis of Surface Waves