CRACK REPAIR & INJECTION SYSTEMS

STEVEN NG, TMM ENGINEERED REFURBISHMENT

KEVIN OETIKER, TMM SEALING & BONDING
TABLE OF CONTENT

1 COMPANY PROFILE

2 REASON AND TYPES OF CRACKS

3 SURFACE CRACK REPAIR

4 THROUGH CRACK REPAIR

2
WHAT WE DO
BUILDING TRUST
Sika is a specialty chemicals company with a leading
position in the development and production of systems
and products for bonding, sealing, damping, reinforcing
and protecting in the building sector and motor vehicle
SIKA AT A GLANCE
industry. 25,000 EMPLOYEES
100 COUNTRIES
300+ PLANTS WORLDWIDE
6 NEW & EXPANDED PLANTS IN 2020
83 NEW PATENTS IN 2020
1 ACQUISITION IN 2020
7.88 BN NET SALES IN 2020 (IN CHF)

WE ARE THERE
Our products might not always be visible but
the results they achieve bring clear added
value to customers and society.
3
WHAT WE DO
CROSS-SELLING, LIFE-CYCLE MANAGEMENT, ONE STRONG BRAND

4
WHAT WE DO
CROSS-SELLING, LIFE-CYCLE MANAGEMENT, ONE STRONG BRAND
Concrete Waterproofing Roofing Building Finishing

Flooring & Coating Sealing & Bonding Refurbishment Industry

5
BUILDINGS MOVE
BUILDINGS MOVE
CRACKS ARE PART OF CONCRETE

 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
BUILDINGS MOVE
CAUSE OF CRACKS
HOW IT LOOKS ROOT CAUSE BUILDINGS MOVE and need
MOVEMENT JOINTS to prevent cracks
INTERNAL

Shrinkage, thermal
expansion, etc

EXTERNAL

Setting, weight, load

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BUILDINGS MOVE
TYPES OF MOVEMENT

Thermal cycling

Shrinkage

Causes
Settlement & Creep

Load Deflection

Wind

Seismic

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BUILDINGS MOVE
THERMAL MOVEMENT

Main cause of joint movement and is the

basis upon which joint size is calculated

Concrete = reacts only slowly to

daily changes in temperature,
affected more by annual
temperature variations

Lightweight cladding = responds

quickly to daily cycles of heating
and cooling

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BUILDINGS MOVE
SETTLEMENT AND CREEP

Settlement Creep

Occurs over
Occurs at a very
the first few
slow rate in
years causing
concrete structures
permanent
and provides only a
deformation
small contribution
of the
to joint movement
sealant.

11
BUILDINGS MOVE
SHRINKAGE

Solution
Shrinkage Best to wait as long as
possible after construction
Caused by loss of moisture from
before sealing joint.
construction materials, concrete,
blockwork, brick etc...... Leading to
permanent opening of the joint.

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BUILDINGS MOVE
SEISMIC ACTIVITY & BUILDING SETTLEMENT

Earthquakes create
omni-directional
movement

Static load deflection

Live load deflection

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BUILDINGS MOVE
WIND SWAY TALL BUILDINGS
ARE EXPOSED TO
STRONG WINDS

PETRONAS TOWERS MOVE

OVER UP TO 2 METERS
⇒BRIDGE IS NOT FIXED

14
BUILDINGS MOVE
IF WE DON’T PUT JOINTS, MOTHER NATURE WILL
Cracks Spalling & Tile Lift LEAKAGE of Water, Air, Sound and Fire

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ANALYZE THE CRACK
ANALYZE THE CRACK
CONDITION
WIDTH MOVEMENT
SURFACE CRACK (width change over time)
 Cosmetic issue
 Lower Durability

HOW DEEP IS YOUR CRACK CONDITIONS OF THE CRACK

THROUGH CRACK MOISTURE LEVEL
 Water tightness
 Strong impact on durability
(rebar corrosion!!)
 Potential risk to structural
strength

17
ANALYZE THE CRACK
SOLUTION FLOW CHART

Structural Consultant to
Element Evaluate
Separating
Non-Structural Structural
Crack Element Crack Repair

Surface Crack
Surface
Repair

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SURFACE CRACKS
MOVING THROUGH CRACKS
WIDTH/DEPTH
< 4mm 4-10mm >10mm
MOVEMENT
(Flexible) Skim Coat
< 10%
(Flexible) Skim Coat Repair Mortar Repair Mortar
Static/Plastic Sealant

Flexible Skim Coat

10 – 25%
Waterproofing Flexible Sealant
Plastic-Elastic Sealant

MOVING CRACK/JOINT
>25%
Flexible Sealant Consult with Engineer
Elastic and Sika Specialist

19
SURFACE CRACKS
SIKA SOLUTIONS
WIDTH/DEPTH
< 4mm 4-10mm >10mm
MOVEMENT
SikaWall®-603 Acrylic SikaMonoTop®-412 MY SikaMonoTop®-412 MY
< 10%
Static/Plastic Sikadur-20 Crack Seal Sikaflex®-11 FC+ SikaMonoTop® R

SikaWall®-603 Acrylic
10 – 25%
Sikaflex®-11 FC+
Plastic-Elastic Sikaflex®-11 FC+

MOVING CRACK/JOINT
>25%
Sikaflex®-11 FC+ Consult with Engineer
Elastic and Joint Specialist

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SURFACE CRACKS
SIKAWALL®-603 ACRYLIC

 Ready-to-use white flexible skim coat

 Interior and exterior walls, columns and ceilings.
 Surface defect repair > grooves, seams and fine
cracks
 Application thickness 0.3-4.0mm
 Overcoating time 2 hours at 20°C

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 SURFACE CRACKS
HORIZONTAL ROOF CRACKS – SIKADUR®-20 CRACK SEAL

Solvent free, 2 component low viscosity and semi

elastic liquid, based on epoxy resins

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SURFACE CRACKS
SIKAFLEX-11 FC+ SWISS ARMY KNIFE OF ADHESIVE AND SEALANTS

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SURFACE CRACKS ON WALLS/FACADES

CRACK SEALING SOLUTIONS WITH SIKA INJECTION SYSTEMS

BASEMENT IN MALAYSIA

Photo taken in March 2017

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CRACK SEALING
SUCCESSFUL WATERPROOFING WITH INJECTION SYSTEMS
Injections are part of waterproofing
 No construction method and
waterproofing technology can provide
100% watertightness from the very
beginning. Material
 Injections are an important and necessary
part of all waterproofing technologies.

Minimum know-how requirement

 Construction basics
Method /
 Waterproofing basics in case of Equipment
performance failures Application
 Injection material know-how
 Injection application know-how

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CRACK SEALING
TYPICAL SOURCES OF LEAKS IN CONCRETE STRUCTURES

Products Leaking crack Leaking construction joint Leaking movement joint

Leaking compartment
Voids / Honeycomb Leaking area – i.e. wall tiles Leaking penetrations
membrane system

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SIKA INJECTION SYSTEMS
TECHNOLOGIES
SIKA INJECTION SYSTEMS
BEFORE YOU START ONSITE – STUDY THE DOCUMENTS
 Specification from Engineer
 Method Statements
 Product Data Sheets - know what product you are using
 QA
 SDS – Safe handling

29
SIKA INJECTION SYSTEMS
BEFORE YOU START ONSITE – STUDY THE DOCUMENTS
European Standard EN 1504
consists of 10 main parts (EN 1504-1 to EN 1504-10)
which covers about 65 standards for test methods for
atmospherically exposed, buried and submerged concrete
structures.

AMERICAN CONCRETE INSTITUTE

ACI 503.7-07
Specification for Crack Repair by Epoxy Injection

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SIKA INJECTION SYSTEMS
STAGES OF MOISTURE
Dry / Damp Wet Flowing water Pressure

(temporarily) Dry/Damp Wet cracks Cracks with flowing water Cracks with flowing water
cracks (standing water) without pressure under pressure

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INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES
Acrylate Gel
for WET cracks in contact
with Earth

 SikaFix®-301
 Sika® Injection-304
 Sika® Injection-310
Acrylate gel

Silane / siloxane
for Hydrophobic
Surface Treatment

 SikaMur® InjectoCream-
100
Silane / siloxane

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INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES

Epoxy Resin
for DRY/DAMP injection
or pour

 Sikadur®-52 MY
Acrylate resin Epoxy resin

Microfine cement
for WET cracks

 Sika® InjectoCem-190

Silane / siloxane Microfine cement

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INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES
PU Resin
for PERMANENT joint
and crack sealing

 Sika® Injection-107
 Sika® Injection-201 CE
Acrylate resin Epoxy resin Polyurethane resin

PU Foam
for TEMPORARY initial
stop of water flow

 Sika® Injection-101 RC
 Sika® Injection-125 MY
Silane / siloxane Cement suspension Polyurethane foam

34
INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES
Sika Injection®-101 RC Sika Injection®-107
Material base PU PU
Components 2 1
Viscosity ~150 ~250
Foaming factor ~35-40 times ~20-25 times
Expansion (Start/end) ~16/70 sec ~25/130 sec
Acceleration Sika Injection-AC10 (Sika Injection-AC10)
Inj. Quality Temporary, secondary injection with Permanent (second inj. of same material
Sika Injection-201 CE is necessary) necessary during gel time)
Certifications Drinking water CE Marked (acc. EN 1504-5)
CE not possible (due to tempo. inj.)
Use Use for cracks with middle-high Use for cracks with low-middle
hydrostatic pressure hydrostatic pressure

EASY AND
EFFICIENT

35
INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES
Sika® Injection-201 CE
Material base PU
Components 2
Viscosity ~150
Pot life (20 °C) 2h / 2-3 min (react. water contact)
Acceleration Sika Injection-AC20
Injection Quality Permanent waterproof
Certifications CE marked (EN 1504-5), Drinking water
Use Cracks, joints, honeycombs, hoses low-
middle hydrostatic pressure
Benefit Very efficient

36
INJECTION MATERIALS
INJECTION MATERIAL TECHNOLOGIES
Sika Injection-304 Sika Injection-310
Material base Acrylate Acrylate
Components 3 1
Viscosity ~6 ~15
Pot life (20 °C) 20 sec – 3 min (adjustable) ~45 min
Accelerator Component A2 Sika® Injection-300 BOOST
Injection Target/Quality Permanent Permanent
Certifications Drinking water, soil (Drinking water, CE at work)
Use Curtain injections, joints, middle Joints, compartments
hydrostatic pressure low-middle hydrost. pressure
Special Benefits Very fast, adjustable 1-C-Powder  easy to use

INNOVATION

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INJECTION MATERIALS
FOR DIFFERENT OBJECTIVES
Stage of moisture

Objectives Flowing water

Dry & wet
No pressure Under pressure
Sika® Injection-101 RC (PU foam)
Closing
Sika® Injection-201 CE (PU resin) PLUS
Sika® Injection-201 CE (PU resin) or
Sika® Injection-107 (PU foam resin) Sika® Injection-201 CE (PU resin)
Waterproofing or
Sika® Injection-310 (Acrylate resin)

Structural repair Sikadur®-52 MY (Epoxy resin) Sika® Injection-216 (PU resin) Not possible

Flexible repair Sika® Injection-201 CE (PU resin) Sika® Injection-304 (Acrylate resin)

All Sika injection materials for crack repair can be injected with one-component pumps

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CRACK INJECTION
EQUIPMENT AND PACKERS
CRACK INJECTION
HANDLING AND PSE
Handling
 Read and Observe relevant handling
information in the SDS (Safety Data Sheet) and
PDS (Product Data Sheet)
 Two people handling

Application
Most two component systems have exothermic
(hot) reactions and need protection
 Full skin coverage
 Gloves – Nitril, gauntlet, two layers
 Safety Goggles
 Hard Hat with Visor
 Safety Boots
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CRACK INJECTION
MIXING EQUIPMENT
All Sika Injections can use
either 1- or 2-component
mixers.
Storage Storage
container container
Storage
container Pot life begins when
mixing together

Pot life begins when

start pumping

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INJECTION MATERIALS
ACCESSORIES – COMMON INJECTION PACKERS

42
CRACK INJECTION
PACKERS
MPS

MPR

MPC

SP

43
CRACK INJECTION
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

44
CRACK INJECTION
APPLICATION OF A DRILL-HOLE PACKER
WORST CASE SCENARIO 

↓ WRONG ↓ RIGHT

45
CRACK INJECTION
APPLICATION OF A DRILL-HOLE PACKER

46
CRACK INJECTION
APPLICATION OF A SURFACE PACKER
Step 1 Step 2 Step 3 Step 4

 Clean and stable  Packers spaced at  Patching crack with  Coverage at least
surface crack/element depth Sikadur®-31 CF Normal 100mm wide and cure
for 24h
 Nail in packer to keep
hole open  0.5kg/meter

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CRACK INJECTION
INJECTION PRESSURE

𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺 𝒙𝒙 𝟏𝟏𝟏𝟏

𝑷𝑷𝑷𝑷𝑷𝑷𝑷𝑷(𝒃𝒃𝒃𝒃𝒃𝒃) =
𝟑𝟑𝒙𝒙 𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺𝑺 𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭

Example:
Concrete strength: 30 N/mm² (Class C25/30, EN 206-1)
Safety factor: 4 (commonly used)

Pmax = (30 x 10) / 3 x 4

= 300 / 12
= 25 bar

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CRACK INJECTION METHODS
BY CRACK TYPE
CRACK SEALING
TYPICAL SOURCES OF LEAKS IN CONCRETE STRUCTURES

Products Leaking crack Leaking construction joint Leaking movement joint

Leaking compartment
Voids / Honeycomb Leaking area – i.e. wall tiles Leaking penetrations
membrane system

50
Sika® Injection-107
VIDEO
 Easy to use, one
component, low-viscous,
flexible polyurethane
injection foaming/resin
for permanent
waterproof sealing.
Especially for leaks in
basement structures.

 Sika Injection 107

Waterproofing crack
resin – YouTube

51
CRACK INJECTION METHODS
BASIC CRACKS/JOINTS
Construction Joint Repair Works

52
CRACK INJECTION METHODS
GRID INJECTION – SIKA INJECTION-304/-310 (ACRYLIC GEL)
 Packers placed in a GRID with 30-50cm spacing
(must be tested first)

 Depth of holes = 2/3 total element

 Construction must be injectable

Grid
injection

53
CRACK INJECTION METHODS
GRID INJECTION – SIKA INJECTION-304/-310 (ACRYLIC GEL)

54
CRACK INJECTION METHODS
CURTAIN INJECTION – SIKA INJECTION-304 (ACRYLIC GEL)
 When positive side waterproofing is not
possible
 Last resort
 Expensive
 Success difficult to control
Excavation Excavation
possible not possible

55
CRACK INJECTION METHODS
CURTAIN INJECTION – SIKA INJECTION-304 (ACRYLIC GEL)
 Packers placed in a GRID with 30-50cm spacing
(must be tested first)

 Detailed soil information required to choose

right material, right packer distance and right
application method

Curtain injection

56
CRACK INJECTION METHODS
CURTAIN INJECTION

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THANK YOU

Our most current general sales conditions shall apply. Please consult the most current local product data sheet prior to any use.