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

use an LV epoxy (500 cps  Horizontal. Remove Ports & Cap Seal 2 . Port Installation with unwanted dust  Remove contaminants with “oil-free” 2. Inject the Epoxy “V-Groove” the crack until sound concrete is reached. Install the Cap Seal compressed air or vacuums  If concrete adjacent to crack is deteriorated. 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. grinders fill crack 1.  Moving cracks are not typically injected & Tensile Strengths Equipment Safety For high or low pressure systems: • MSDS for all materials used  Injection Ports • Protective Clothing. 3. Choosing the Right Epoxy When to Use Injection Method?  Crack width <. Eyewear & Gloves  Wire Brush or Grinder • Eye wash station / Ventilation  Air Guns • Special Precautions for flammable/combustible material  Hand-Actuated Delivery System • Necessary cleaning equipment  Spring Actuated Capsules • Notify occupants of pending repairs  Balloon-Actuated Capsules Preparation Repair Procedure  Clean surface ½” wide on each side of crack  Wire brush recommended . 4. Flexural.02” .

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 3 . 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. 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.