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1. EPOXY INJECTION
A. Description. Inject concrete cracks with epoxy.
B. Materials.
1) Epoxy Injection Resin: Use an epoxy resin for injecting cracks that consists of
100 percent solids by weight, which will bond to dry, damp, or wet concrete, and which meets
the requirements of ASTM C881, Type IV, Grade 1 or Grade 2 with the following modifications.
The following requirements are minimum values for acceptable product properties:
a) Compressive properties of cured resin at 28 days (ASTM D695).
compressive strength 10 ksi (68.9 MPa) (minimum)
modulus of elasticity 200 ksi (1379 MPa) (minimum)
b) Tensile properties of cured resin at 14 days (ASTM D638)
tensile strength 7 ksi (48.3 MPa) (minimum)
tensile elongation at break 2.8% (minimum)
modulus of elasticity 340 ksi (2344 MPa) (minimum)
c) Flexural properties of cured resin at 14 days (ASTM D790)
modulus of rupture 10 ksi (68.9 MPa) (minimum)
tangent modulus of elasticity 340 ksi (2344 MPa) (minimum)
d) Bond strength against hardened concrete (ASTM C882)
strength at forty-eight hours 2.4 ksi (16.5 MPa) (minimum)
2) Epoxy Crack-Sealing Resin: Use an epoxy resin for sealing the crack surfaces
that consists of 100 percent solids by weight, which will bond to dry, damp, or wet concrete, and
which meets the requirements of ASTM C881, Type IV with the following modifications. The
following requirements are minimum values for acceptable product properties:
a) Compressive properties of cured resin at 28 days (ASTM D695)
compressive strength 10 ksi (68.9 MPa) (minimum)
modulus of elasticity 300 ksi (2068 MPa) (minimum)
b) Tensile properties of cured resin at 14 days (ASTM D638)
tensile strength 6.9 ksi (47.6 MPa) (minimum)
tensile elongation at break 2.0% (minimum)
modulus of elasticity 200 ksi (1379 MPa) (minimum)
c) Flexural properties of cured resin at 14 days (ASTM D790)
modulus of rupture 20 ksi (137.9 MPa) (minimum)
tangent modulus of elasticity 400 ksi (2758 MPa) (minimum)
d) Bond strength against hardened concrete (ASTM C882)
strength at forty-eight hours 2.8 ksi (19.3 MPa) (minimum)
Deliver the materials to the site in original, unopened containers, with a legible label on
each container. Each container’s label must display at least:

• component designation • complete mixing instructions

• product name • component weights and total
• mixing ratio (percent by weight • shelf life
• batch number and date of • manufacturer’s name,
• hazard warnings and HMIS • first aid instructions
Store the materials under conditions that meet the manufacturer’s recommendations.
C. Equipment. The Engineer may approve hand-held injection cartridge guns for
small jobs. Larger amounts of crack-injection require the use of an injection machine. Use only
an injection machine designed specifically for metering, mixing, and dispensing injection
epoxies. The machine must consist of an air driven, positive displacement pump, with sealed,
ASME approved stainless steel component reservoirs, an air pressure gauge and air pressure
regulators capable of a range of 0 to 100 psi (0 to 689 kPa), and an interlock to ensure positive
control of the component ratio at the nozzle . The machine must incorporate an air compressor
capable of continuous operation at 100 psi (689 kPa). The reservoir heaters must have
thermostatic controls and capacity sufficient to maintain component and resin temperatures of
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90º F (32º C) in an ambient temperature of 0º F (-18º C). Demonstrate to the Engineer before
starting the work, at a designated location, that the injection machine will pump, meter, mix, and
dispense the resin at a continuous pressure of 14 psi (96.5 kPa) at the injection nozzle.
D. Submittals. Submit the following information to the Engineer at least fifteen days
before starting the work. Submit this information for epoxies meeting ASTM 881, Class A,
Class B, and Class C. The same manufacturer must produce all resins proposed or used on
the project.
• Certifications from an independent testing laboratory that the component resins
meet or exceed all of the materials requirements in this specification.
• Either certification from the resins’ manufacturer of successful completion of a
certification course in using the manufacturer’s resins or references from at least five successful
previous projects similar in nature to the current work. The person holding this certification must
be at the project site throughout the injection work.
• Certification from the manufacturer that the component resins will not exceed
their useful shelf life within the project’s schedule.
• A form designed for recording daily data as work progresses.
• A construction plan for the Engineer’s approval that contains at least:
• A description and details of substrate preparation methods.
• A description of the particular resins for the project.
• Mixing and application methods for each resin used on the project.
• Curing methods.
• A quality control program.
• A safety program.
E. Procedures
1) Record Keeping. Keep daily records of the work in a format easy to understand.
Record ambient and substrate temperatures three times each work day: at the start of the day,
at mid-day, and at the end of the work day. Record precipitation and changes in precipitation
during the work day, along with the time of the changes. Record cleaning method by area
location, resin types by name, unit amounts of materials used, and materials coverage (by linear
meter of crack, etc.). Have the project supervisor sign and date each day’s records, and
provide a copy of each day’s records to the Engineer.
2) Preparation. Prepare crack surfaces by appropriate methods to ensure the
absence of all laitance, loose materials, grease, oils, efflorescence, or other contaminants.
Remove unsound concrete and patching materials. When using impact equipment for such
removal , use only equipment with a maximum impact force of 15 lb (66.7 N). Place injection
ports (surface-mount or drilled-in) or “tees” along the crack surface, at a maximum spacing no
larger than the thickness of the concrete mass. When using drilled-in injection ports, drill the
hole about ¾-inch (20 mm) deep for each port, using a hollow drill bit with a vacuum chuck.
Check that the drilled hole does not miss following the crack. The vacuum attached to the
chuck must have a motor with a minimum of 249 W. Vacuum the entire crack before sealing the
surface. Seal the crack surface by forcing the crack sealer into the crack, spreading the crack-
sealer into the crack, spreading the crack-sealer at least ½-inch (12 mm) to either side of the
crack, and by encapsulating each port or tee to prevent blow-outs during injection. If the back
face of the concrete is accessible, place ports and tees on the back face at the same spacing as
on the front, seal the crack, then inject the concrete from both faces. Stagger the spacing of the
ports on the back face with the ones on the front face. Use a crack-sealer resin with a color that
approximates the color of the concrete surface.
3) Injection. Heat the components so that their temperature at the nozzle is 90º F
(32º C) when the substrate temperature is below 70º F (21º C). Mix the components with a
mixing paddle at a speed low enough to avoid introducing air into the mixture when using a
pressure pot, and mix batches small enough to use before the epoxy gels. On vertical surfaces,
always start with the lowest port. Inject the resin at a steady pressure of 14 psi (96.5 kPa) until
resin free of air and water comes out of the next port above the active one. In the case of tight
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(less than 1/16 – inch (2 mm) wide) cracks in a thick mass of concrete, plug the next port above
the active one and pump until clear resin comes out of the one after the plugged one, then plug
the active port and move up one port to repeat the process, to ensure filling the depth of the
crack. Inject horizontal cracks similarly, starting at one end of the crack. Once started on filling
a crack, continue injection until the entire crack length contains epoxy. Do not stop injection in
the middle of a crack. In the case of a plugged port, chisel out the port, replace it, re-seal the
surface around it, and re-inject it. If the port is still plugged, move on to the next one.
4) Quality Control. Make sure the injection resins fill at least 98 percent of the
crack, both in depth and length. The Engineer may require coring of a crack to verify resin
penetration.
5) Clean Up. Remove the ports and the crack sealer after the epoxy cures. Clean
the crack surface to the satisfaction of the Engineer.
F. Measurement. The Engineer will measure crack length in linear feet (meters) for
payment. The Engineer may reduce the amount of payment for a crack’s injection in the case of
coring the crack and determining the injection reached less than 98 percent of the crack. In that
case, the reduction would consist of matching the payment to the apparent percentage of the
crack filled.
G. Payment . The Department will pay for Epoxy Injection at the unit price per linear
foot (meter) of crack. This payment will cover all costs of materials, equipment, labor, and other
items necessary to perform the work.