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CONCRETE CRACKS REPAIR USING EPOXY RESIN

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 Concrete Cracks Repair Using Epoxy Resin
Renga Rao Krishnamoorthy 1 , Sharifah Nadhrah Syed Tajul Arif1
1
Faculty of Civil Engineering, Universiti Technologi Mara Shah Alam, Malaysia
Abstract — Epoxy repair methods for concrete are becoming
widely popular in Malaysia. The current assessment for repair is
not accurate and lack of accumulative research data. Moreover,
most of the repair methods for concrete is done based on deemed-
to-satisfy method based on readily available proprietary repair
systems. The research work presented provides additional
information on the assessment and repair of cracks for concrete
from various water cement ratios. Upon 28 days of curing, the
cubes undergoes the compression test, however, the compression
test will be timed and monitored only until obvious cracks appears
from the author’s naked eyes. At this juncture the Ultimate
Testing Machine’s (UTM) power will be killed immediately and
the sample removed thereafter. The samples will be repaired by
applying epoxy at cracks and will be left for drying at ambient
temperature in the laboratory. The repaired sample will be once
again tested under compression using UTM, however, at this point
the sample will be tested until failure and the strength recorded.
The outcome suggests that the repair method using epoxy was
able to sustain at least 80% to 85% of total strength achieved
when cracks appeared during testing. It was concluded that the
higher the water cement ratio, the higher the recorded strength
was after repair.
Keywords : Concrete, cracks, and epoxy
1. INTRODUCTION
Malaysia is one of fast developing nations in the world.
Malaysia is also well known for its aesthetic building
construction such as Kuala Lumpur Convention Centre
(KLCC), Sepang international Circuit, Malacca historical
building and others. The importance of the material use
inside the building should be emphasized in order to have
strong and durable building. Concrete building’s are
designed to maintain its serviceability at least 50 years or
more. In this context, concrete maintenance over the years
will be an important task for engineers. Concrete come
from the Latin word ‘concretus’ which means compacts
and condense. When water and sand is added into the
cement, they become mortar. Nowadays, concrete are made
from Portland cement, aggregate, sand, and water. The
materials are casting in the mold and being the concrete
form which is modern concrete is used. Concrete is widely
used for the making of structures, bridges, dams, pipes,
railways, highways and more. In early stage of cement, it is
the same as mortar-crushed and burn limestone. This
concrete technology was known by Ancient Roman and
used in the making of the Colosseum. Colosseum used
large amount of concrete.
Moreover, concrete have an ability to be cast which mean
that the concrete can be cast at any shape such as
rectangular, square, and even cylindrical. These concretes
are also economical because of the price of cement only 5
to 7 cents/kg and aggregates only cost few Ringgits per ton.
1
This can be strengthening by the fact of skilled and
unskilled workers that can increase in employment.
Furthermore, precast concrete has developed into famous in
our nation. Even precast concrete pipe is largely used for
sewage, drainage and water supply system. Concrete is a
very durable material.
There are also some disadvantages of the concrete which
are low tensile strength, low ductility, volume instability
and low strength-to-weight ration. Although concrete does
have disadvantages, concrete can last long over 10 to 30
years. These advantages and disadvantages can be
classified into the Table 1.1 below and easy to see.
Table 1.1 Advantages and disadvantages of concrete
Advantages Disadvantages
Able to be cast Low tensile strength
Economical Low ductility
Durable Volume instability
Fire resistant Low strength-to-weight
ratio
Aesthetic properties
Cracks are some of the problem that always occurs at the
building. Cracks can be seen easily because it is physical
properties of the building, but sometime cracks can also
occur inside the concrete and cannot be seen. This is more
dangerous because we do not know whether the building is
safe or not. It is very common of concrete to sustain cracks.
There is no perfect mixture of concrete. There are several
reasons that cause concrete cracks. Firstly, the excess water
in the mixture. Concrete does not need too much water
inside the mixture. Nowadays, the concrete used in site has
too much water added in the mixture. The more water
added inside, the higher the shrinkage happen. When the
concrete dried and harden, the shrinkage will happen due to
the evaporation of the excess water and can cause the early
age of crack on the concrete. The excess of water can
reduce the concrete strength. Secondly, concrete cracks due
to improper strength concrete mixture. Concrete has much
different strength, make sure the concrete strength that we
required is poured.
Next is never pour concrete on the frozen ground or winter
season. At 18°C, the concrete will freeze while at 35°C the
concrete will melt and immediately cause the cracking.
Concrete also cracks due to sun. The heat makes the
concrete to expend and at the end of the day, the concrete
contracts and back to its normal state. These can cause the
cracks happen. Cracks can be divided into two types which
are non-structural cracks and structural cracks. A structural
crack means it crack due to the incorrect design and faulty
in construction or overloading.
This type of crack may endangered the safety of the
building itself. While a non-structural crack means crack
due to induced stresses inside the concrete but it is
generally do not affect the weakness of the building.
Moreover, non-structural cracks may because of the
environmental value such as weathering, corrosion of
reinforcement and shrinkage. Crack often happen in
concrete building. Sometime crack will occur even three to
four hours after the building is fully finished and crack
does not exactly happen within three to four years. Cracks
happen due to temperature, volume change, drying
shrinkage, thermal contraction and many more. The crack
needs to be repaired in order to maintain our reputation,
aesthetic value, and even to decrease the amount of fatal
accident such as collapse’s building.
This research used epoxy resin for concrete repair. Epoxy
resin used was in the form of sticky-liquid form (Sikadur
31SBA S08). Sikadur 31 SBA S08 is a solvent free that
also contain epoxy. This sikadur have a lot of advantages
which are harden without shrinkage, easy to apply, high
strength, and high humidity could not be affected by the
hardening. This research used 1 to 3 ratio of compartment
A and B. Epoxy resins are also known as polyepoxides,
there are in a class of reactive pre-polymers and polymers
which include epoxide groups. The epoxy resin is being
injected inside the crack occur.
Epoxy is in a family of thermosetting resin which has the
characteristic unique to them. Thermosetting is in a
polymer that is irreversible, once cured and harden, it
cannot melt back because of the cross linking. Cross
linking from the epoxy itself and epoxy molecule cross-
linked with each other that make them become strong
enough and harder, indirectly the strength increase. Epoxy
are already use in the sophisticated aerospace application.
This research use epoxy to seal the crack. The researcher
gets into the concrete lab to experiment it. The researcher
must make 15 samples of mould. Five mould for each
water cement ratio. Then, after curing the mould is tested
using compressive strength test machine to see the crack.
When the crack is seen, inject the crack using epoxy resin.
Leave it for one day, and test it again to see the strength.
The result is taken to make a conclusion. The significance
of the study can be discussed in several aspects. The
significance of this study generally is to seek for the
strength of epoxy resin where most of the people applied
the usage of concrete building nowadays. As for the Civil
Engineering students, the study is significant in order to
assist them in order to find the better and effective ways of
2
the usage of epoxy to repair the crack in concrete. Besides
that, this study also enables several students which do not
know and lack of knowledge about the existence of
concrete crack to discover the function of epoxy resin.
Furthermore, concrete crack repair is important in order to
maintain our building from fatal accident happen. For some
reason, cracks happen due to neighbouring country
earthquake. Even it is just a small crack, but it can effect to
the whole building. In order to avoid this from happening,
the researcher used epoxy resin, the most suitable resin to
be used in the concrete as sealant.
This study investigates to determine the maximum strength
achieved at crack initiation for different water-cement
ratios observed behavior using the Compressive Strength
Test Machine (CS). Moreover, this research is to repair the
initiated crack using epoxies injection and to determine
strength of the repaired concrete after applying epoxy.
Water cement ratio is the amount of the water that needs to
be added into the concrete mix that is design by the
engineer to get standard strength of concrete. Amount of
water that is used for concrete will affect the strength of the
concrete. More water is added in to the mix design, the
lower the compressive strength, weight and density of the
cubes.
2. EXPERIMENTAL PREPARATION
2.1. Measurement device
Compressive strength test machine can be use to test for
compression strength. The main objective of this machine
is to measure the compressive strength of the concrete
mixture. It is needed to make sure that the concrete is
strong enough to be used commercially and also able to
support heavy loads.
There have a few precautions step that need to be done
during the test. The maximum size of aggregate in the
concrete is less than 40 mm. other than that, the cube must
be placed at the center of the platens before the load is
applied. Furthermore, the wire mesh guard or the cover of
the machine need to be closed before run the machine to
avoid any crushed pieces of the cube being to the eye.
The Procedure of this research Step is as follow:
Step 1: Place cube at the Compressive Strength Test
Machine to be tested.
Step 2: Apply load until crack occurs and quickly push the
stop button before it fully breaks.
Step 3: Observe and record the strength of the concrete
until the crack occurs.
Step 4: Repeat steps 1 to 3 for the strength test on the
concrete to take an average of the strength.
 Applying epoxy (Sikadur 31) at the crack occurs in
order to repair it and leave it for one day
Step 5: The concrete that have been injected or applied by
the epoxy (Sikadur 31) is placed on the Compressive
Strength Test Machine to be tested again.
Step 6: Apply load until it failed.
Step 7: Observe and record the strength of the concrete
after applying the epoxy.
Step 8: Repeat step 5 to 7 for the strength test on the
concrete to take an average.
Figure 1: Compressive strength test machine
2.2 Materials
2.2.1. Cement
Cement is a material that acts as a binder to bind the
aggregates and sand together in the concrete mixture. It is
grey and very fine material that bind only after it mixed
with water. There have lot types of cement in the world.
One of the types that used in this study is Portland cement.
2.2.1 Coarse Aggregate
Aggregate that left for about 4.75 mm sieve can be
classified as coarse aggregates. The coarse aggregate can
be obtained from the artificial crushing of rocks. The size
can be classified through their thickness, spacing of
reinforcement, cover, and many more. The maximum size
for coarse aggregate is at about 80 mm, but that maximum
size should not be as large as possible and not more than 5
mm less than spacing of the reinforcement. Coarse
3
aggregate with size 20 mm are commonly used in the
making of concrete.
2.2.2. Fine Aggregate
Sand is the most popular material that being used for mix
design also known as standard of sand. Standard of sand
should be quartz, light grey and whitish color. Sand is one
of the fine aggregates. Sand is made up from a granular
form of silica. Sand is free from clay or silt, organic matter,
can pass through 850 μm and less than ten percent of 600
μm sieve. In order to use sand in the manufacturing of
concrete or building constructions, sand should possess at
least 85% of the strength of standard sand. Sand also has its
own function which is to strike the economy by its own use
as materials in concrete.
2.2.3 Water
Water is the most important material should present in the
mix design of a concrete. The purpose of water is to cause
hydration of the cement. This is because water act as glue
to combine the cement, coarse aggregate and fine aggregate
or sand and produced a workable and economical concrete,
without water, there will be no concrete. Unfortunately,
water should be added by using accurate calculation. If
there are excess of water, the water will leak through the
mould, resulting honeycombed concrete. On the other
hand, when there is lesser water can makes it difficult to
handle the concrete.
2.3 Water-cement ratio
Water cement ratio is the amount of the water that needs to
be added into the concrete mix that is design by the
engineer to get standard strength of concrete. Amount of
water that is used for concrete will affect the strength of the
concrete. More water is added in to the mix design, the
lower the compressive strength, weight and density of the
cubes. 0.65 above of water cement ratio can cause a
reduction in the compressive strength of the concrete.
However, the compressive strength of the concrete for each
water-cements ratio still increases by age of curing as
shown in the Table 2.1.
 Table 2.1 Variation of Weight, Density, and Compressive
Strength of concrete mixes with Water Cement Ratio.
Figure 2.2 Compressive Strength of Concrete Mixes VS.
Age
Moreover, it also will affect the workability of the concrete.
It can be seen from the fluidity of concrete. Water cement
ratios between 0.50 - 0.70 are still can be accepted because
it is still under the range of true slump, but sometime using
0.60 water ratio for concrete size 100x100x100 are not
suitable.
2.4 Compressive strength
Compressive strength of concrete is one of the factors of
concrete that is most important to make sure the
workability of concrete. The percentage of cement, sand,
aggregate and water in concrete mixture will be materials
that categorize the strength of the concrete. Concrete are
designed by an engineer to achieve a standard level of
strength. One of the ways to determine the compressive
strength of concrete is by using Compressive Strength Test
Machine (CS). The strength of the concrete are usually
increase rapidly up to 28 days. The reason the concrete
under curing for 28days is because it will achieve atleast
4
96% of strength. The compressive test against the curing is
shown in the Figure 2.2 below.
Figure 2.2 Compressive strength vs curing days
2.5 Test method
To study the compressive strength of different water
cement ratio used before and after applying epoxy. The
control mix was designed to achieve design strength of
30MPa. The cement, coarse aggregate, fine aggregate and
the water were mix together. The water cement ratio of
every five (5) concrete cubes was different which are 0.45,
0.50 and 0.60 to show the effect of compressive strength
before and after applying epoxy on cracks.
In this study, the concrete cube will be divided into five (5)
concrete cubes for every each water cement ratio.
All these samples will be cured in curing water up to 28
days as shown in the figure 2.1 below. Thus, after 28 days,
all the cubes will be tested by using the compressive
strength test machine to create cracks. Once the cracks
seen, the stop button will be immediately pushed before it
achieved to failed cubes. The cracks on the cube are shown
in the figure 2.2 below. Only one (1) cube was left to test
until it failed. The compressive strength for every cube was
recorded. These steps will be repeated for other water
cement ratio.
Next, the epoxy or Sikadur 31SBA S08 (figure 2.3) were
used. The component A and B will be mixed together in
order to get grey in color by using 1 to 3 ratio. After being
mixed together, the cracks that occurred before will be
injected with epoxy inside to act as glued as shown in the
figure 2.4 and figure 2.5 below. Although the cracks are
hair line cracks, the epoxy are forcedly injected in the small
cracks and then being apply around the surface of the cube.
Once the cracks are done being injected and covered, those
cubes will be left for 1 day to dry up. The next day, those
cubes were tested again in order to get the strength after
applying epoxy. These steps were repeated for other water
cement ratio and the data were recorded.
 Figure 2.1 curing
Figure 2.2 Cracks occur
Figure 2.3 Sikadur 31 SBA S08
5
Figure 2.4 Epoxy injection
Figure 2.5 Covered with epoxy
3. RESULT & DISCUSSION
3.1. Intoduction
This chapter will discuss about all the results from testing
and laboratory works that had been done. Compressive
strength, water-cement ratio, epoxy (Sikadur 31SBA S08)
and percentages of reduction strength had been discussed in
this chapter. There are different water-cement ratio that had
been used which was 0.45, 0.50 and 0.60. Every each of
these water-cement ratios had 5 samples of concrete cubes
150 x 150 x 150 in size. In this research, it could not mimic
earthquake to cause crack. Regarding to the place of the
experiment had been done; the only machine that was very
suitable to be used was compressive strength test machine.
The only problem of using this machine was the crack
occurred only a small crack before it achieved the failure
limit.
3.2 Epoxy (Sikadur 31 SBA S08)
Table 3.1 Control samples
Epoxy resin used was in the form of sticky-liquid form.
Epoxy resins are also known as polyepoxides, there are in a Water-cement ratio Failed (Stress), KN
class of reactive pre-polymers and polymers which include
epoxide groups. In this reseach, sikadur 31SBA S08 had 0.45 53.21
been used. Sikadur 31 SBA has many different types of
grade. This sikadur has high modulus, high strength, 0.50 42.33
structural epoxy paste and to harden concrete. It can be
used for a sealant agent, used for erection and for bridges. 0.60 36.78
The surface must be cleaned before applying the epoxy at
the concrete. Sikadur 31SBA S08 have two components
which are component A and component B. Component A is Graph 3.1 Water cement ratio VS Failed stress, KN
black in color. This part is quite dangerous to human relationship
system if the precaution did not emphasize and can cause a
lot of problem which are skin sensitization, skin or eye
irritant, respiratory problem, and liver injury. Meanwhile,
component B is corrosive. It contains amines and this
component can cause burns. If these happen, for example,
it contact with eye, quickly hold the eyelids and wash it for
15 minutes. Moreover, when it contact with skin, quickly
remove contaminated cloth and wash the skin with water
and soap for 15 minutes.
It is very easy to handle by mixing both
component A and component B until it turns into grey
color and mix them for about 3 minutes by using a scraper
at low speed. By leaving the container of component A and
B at about 20 minutes can cause the reduction of
consistency and workability because it undergoes the
process of curing.

3.3 Compressive strength test

The test was conducted to identify the compressive strength
of each samples with different water-cement ratio. The
testing was conducted to get the strength of each samples
once cracks seen. Once the cracks seen, the epoxy had been
applied and tested again using the compressive strength test
machine. From the observed, it noticed that the total time
taken before cracks was observed within 5 to 7 minutes,
whereas the total time observed after applying the epoxy on
cracks and upon testing was within 4-5 minutes.
The table 3.1 shows that the strength of each sample for each
water-cement ratio. For 0.45, 0.50 and 0.60, the failure limits
were at 53.21 KN, 42.33 KN, and 36.78 KN. These samples
were the control samples in order to know the limit of their
strength and to make the conclusion of this research. From the
table, the graph had been plot as shown in the graph 3.1.

This shows that the time after applying epoxy on the cracks
is fast compared before applying the epoxy. This is
because, it noticed that the time difference of failure after
applying epoxy and before applying epoxy had some major
differences because by applying epoxy on the cracks, most
of the particles inside lost their elastic bond properties
between cement, aggregate and sand. Therefore, upon
applying epoxy, the epoxy itself acted as an external glue to
rebond the loosen particles. These epoxy glue acted as a
medium to sustain the strength of the concrete. The
differences between compressive strength and the water-
cement ratio before and after applying epoxy had been
recorded in the result below.

6
 Table 3.2 Water-cement ratio of 0.45 Table 3.3 Water-cement ratio of 0.50

Compressive Strength Machine Percentages Compressive Strength Machine Percentages

No. (Stress), KN of No. (Stress), KN of
Before After applying reduction Before After applying reduction
applying epoxy epoxy on crack strength, applying epoxy epoxy on crack strength,
on crack % %
on crack
1 47.01 36.25 22.89 1 37.97 30.46 19.77

2 40.07 37.05 8.97 2 38.30 33.53 12.45

3 49.58 42.92 13.08 3 38.70 33.20 14.21

4 47.65 41.97 11.92 4 39.68 30.99 21.90

Average 46.19 39.55 14.22 Average 35.53 32.05 17.08

Figure 3.2 Compressive strength of 0.45 water-cement ratio Figure 3.3 Compressive strength of 0.50 water-cement ratio

From the table above, it shows that the first samples before
applying the epoxy and after applying epoxy are 47.01 KN
and 36.25 KN. Moreover, the second samples before applying
epoxy and after applying epoxy are 40.70 KN and 37.05 KN.
Followed by the third samples before applying the epoxy and
after applying epoxy are 49.38 KN and 42.92 KN. The last
samples before applying epoxy and after applying epoxy are
47.65 KN and 41.97 KN. From these strength, the average
were taken for before applying epoxy and after applying
epoxy which are 46.19 KN and 39.55 KN. Regarding to the
results, the differences between these two are calculated and
manage to get the percentages of the reduction. For 0.45 water
cement ratio, only 14.22% reduction was calculated.
7
From the table above, it shows that the first samples before
applying the epoxy and after applying epoxy are 37.97 KN
and 30.46 KN. Moreover, the second samples before applying
epoxy and after applying epoxy are 38.30 KN and 33.53 KN.
Followed by the third samples before applying the epoxy and
after applying epoxy are 38.70 KN and 33.20 KN. The last
samples before applying epoxy and after applying epoxy are
39.68 KN and 30.99 KN. From these strength, the average
were taken for before applying epoxy and after applying
epoxy which are 35.53 KN and 32.05 KN. Regarding to the
results, the differences between these two are calculated and
manage to get the percentages of the reduction. For 0.50 water
cement ratio, only 17.08% reduction was calculated.
 Table 3.4 Water-cement ratio of 0.60 Figure 3.5 Average stress VS water-cement ratio

Compressive Strength Machine Percentages

No. (Stress), KN of
Before After applying reduction
applying epoxy epoxy on crack strength,
on crack %
1 29.51 23.79 19.38

2 33.26 26.97 18.91

3 30.72 22.20 27.73

4 28.19 23.78 15.64

Average 30.42 24.19 20.42

Figure 3.4 Compressive strength of 0.60 water-cement ratio Figure 3.6 Average percentages of reduction strength
according to water cement ratio

From the table above, it shows that the first samples before
applying the epoxy and after applying epoxy are 29.51 KN
and 23.79 KN. Moreover, the second samples before applying
4. CONCLUSION AND RECOMMEDATION
epoxy and after applying epoxy are 33.26 KN and 26.97 KN.
Followed by the third samples before applying the epoxy and
4.1 Conclusion
after applying epoxy are 30.72 KN and 22.20 KN. The last
samples before applying epoxy and after applying epoxy are
From this researches, the conclusion that can be made based
28.19 KN and 23.78 KN. From these strength, the average
on the test results that obtained from the test are the maximum
were taken for before applying epoxy and after applying
strength achieved at crack initiation for different water cement
epoxy which are 30.42 KN and 24.19 KN. Regarding to the
ratio was observed. The higher the water cement ratio, the
results, the differences between these two are calculated and
lower the maximum strength achieved. For example, for 0.60
manage to get the percentages of the reduction. For 0.60 water
water cement ratio, it only achieved 30.42 KN, while for 0.45
cement ratio, only 20.42% reduction was calculated.
water cement ratio, it achieved at about 46.19 KN whereas the
failure limit of 0.60 and 0.45 water cement ratio are at 36.78
KN and 53.21 KN. This is because the water content inside the
concrete affect the strength itself. In order to have good
quality of concrete, water cement ratio is very important to be
considered to have strong and safe building.

8

Moreover, this research shows the repairing of concrete cracks
using epoxy (Sikadur 31 SBA S08). The used of epoxy as a
crack sealant can save the cost of maintenance of a building.
In addition, epoxy was applied at the crack in order to
combine back the concrete by using injection method.
ACI Committee 224.1R-93. Causes, evualation, and repairs of
cracks in concrete structures. MI: American Concrete
Institute; 1993.
ACI, C. (1993). Cause, evaluation, and repair of cracks in
concrete structures. America: American Concrete Institute.

Furthermore, the cracks had been injected with the epoxy and
had been tested using the compressive strength test machine.
From this research, the strength of repaired concrete after
applying epoxy are quite relevent. As in the result above, the
percentages reduction of concrete strength before and after
applying epoxy is only at range of 14 to 21%.
Issa, C. A., & Debs, P. (2007). Experimental study of epoxy
repairing of cracks in concrete. Construction and Building
Materials , 157-163.
R., F., & V.H., D. D. (2009). Cracked concrete repair with
epoxy-resin infiltration. Concrete repair, rehabilitation and
retrofitting II , 783-789.

El-Hawary, M., Al-Khaiat, H., & Fereig, S. (1998). Effect of

sea water on epoxy-repaired concrete. Cement and Concrete
Composites , 41-52.

4.2 Recommendation Tittelboom, K. V., Belie, N. D., Muynck, W. D., & Verstraete,
W. (2010). Use of bacteria to repair cracks in concrete.
From the research, the recommendation for the further Cement and Concrete Research , 157-166.
research and also for better understanding of matters related to
concrete cracks repair using epoxy resin and their compressive Song, X. F., Wei, J. F., & He, T. S. (2009). A method to repair
strength are as follows: concrete leakage through cracks by synthesizing super-
absorbent resin in situ. Construction and Building Materials ,
I. A higher bonding agent or higher grade of sikadur 386-391.
(epoxy) could possibly improvised the strength of the
crack concrete. Nossoni, G., & Harichandran, R. S. (2010). Improve repair of
II. A proper equipment or injection method could be concrete structures using Polymer concrete patch and FRP
used that can penetrates as much as epoxy into the overlay. Materials in Civil Engineering , 314-323
cracks.
III. Make sure when mixing the epoxy, scrape down the
sides of the container to enhance that there are no
unmixed of epoxy.
IV. This repair method could be extensively extended to
other materials in order to study the strenght
retension.

5. REFERENCES

Ekenel, M., & Myers, J. J. (2007). Durability performance of

RC beams strengthen with epoxy injection and CFRP fabrics.
Construction and bulding materials , 1182- 1190.

Mindness, S., & Young, J. F. (1981). Concrete. Englewood

Cliffs, N.J.: Prentice-Hall.

Duggal, S. (1998). Building Materials. Rotterdam, Netherland:

A.A Balkema.

Alawode, O., & Idowu, O. (2011). Effects of water-cement

ratios on compressive strength and workability of concrete and
lateric concrete mixes. Nigeria: Department of Civil
Engineering, University of Ado-Ekiti.

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