MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

TSSM’s
Bhivarabai Sawant College of Engineering and Research (Polytechnic),
Narhe

Academic year: 2020-21

MICRO PROJECT

ON

Management

Program: code: CE6I

Course:- Diploma In Civil Engg.

Course code:22603

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 MAHARASHTRA STATEBOARD OF TECHNICAL EDUCATION

CERTIFICATE

This is to certify that Mr. Abhay Munnalal Vishwakarma Roll No-14 of 6th Semester of
Diploma in Civil Engineering of Institute, TSSM’s BSCOER POLYTECHNIC (Code:1606)
has completed the Micro Project satisfactorily in Subject –(Maintainance and Repair of
Structure) for the academic year 2023-24 as prescribed in the curriculum.

Place:Narhe,Pune Enrollment No: 2116060313

Date: 25/03/2024 Exam. Seat No:258020

Subject Teacher Head of the Department Principal

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 GROUP DETAILS

Sr.No Name of member Roll No Enrollment No Seat No

1 Abhay Munnalal Vishwakarma 14 2116060313 258020

2 Asolkar Suhani K. 15 2116060314 258019

Name of Guide

Prof. R.B. Ghavane

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  INDEX

SR.NO. CONTENTS PAGE NO.

1 ABSTRACT 5

2 INTRODUCTION 6

3 Objective 7

4 Case Study 8

5 Conclusion 10

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 Introduction: Concrete structures are susceptible to cracking due to various factors such as
shrinkage, temperature changes, and structural loads. These cracks can compromise the
integrity of the structure, leading to further deterioration if not addressed promptly. Epoxy
injection is a widely used technique for repairing cracks in concrete, providing a cost-
effective and durable solution.

Objective: This case study aims to illustrate the effectiveness of epoxy injection technique in
repairing cracks in a concrete structure.

Case Description: A multi-story parking garage, constructed 20 years ago, exhibited

extensive cracking in several structural elements, including beams, columns, and slabs. The
cracks varied in width from hairline cracks to wider fissures, indicating potential structural
issues and safety concerns.

Procedure:

1. Assessment: A team of structural engineers conducted a thorough assessment of the cracks

to determine their extent, cause, and severity. It was concluded that the cracks were primarily
due to shrinkage and cyclic loading.
2. Preparation: The cracked areas were cleaned thoroughly to remove debris, dust, and loose
concrete particles. Surface preparation is crucial for ensuring proper adhesion of the epoxy.
3. Injection: Epoxy injection was chosen as the repair method due to its ability to penetrate
deep into the cracks and bond with the concrete substrate effectively. Low-viscosity epoxy
resin was selected to ensure proper penetration into even the narrowest cracks. Injection ports
were installed along the length of the cracks at regular intervals.
4. Injection Process: The epoxy resin was mixed according to the manufacturer's specifications
and injected into the cracks using specialized equipment. Injection started from the lowest
port, and the resin was continuously injected until it flowed out from the next port, ensuring
complete filling of the crack.
5. Curing: After the injection process was completed, the epoxy resin was allowed to cure for
the specified duration. Curing time may vary depending on factors such as temperature and
humidity.
6. Surface Finishing: Once the epoxy had cured, any excess resin on the surface was removed,
and the repaired areas were polished to restore the aesthetic appearance of the structure.

Outcome: The epoxy injection technique effectively repaired the cracks in the concrete
structure, restoring its structural integrity and preventing further deterioration. The repaired
areas exhibited improved resistance to moisture ingress, chemical attack, and environmental
factors. Post-repair inspections confirmed that the cracks were adequately sealed, and the
structure was deemed safe for use.

Conclusion: The case study demonstrates the efficacy of epoxy injection technique in
repairing cracks in concrete structures. When implemented correctly, epoxy injection offers a
durable and cost-effective solution for addressing structural deficiencies and prolonging the
service life of concrete infrastructure. Regular inspection and maintenance are recommended
to ensure the long-term performance of repaired structures.

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 Abstract: Concrete structures are ubiquitous in modern infrastructure, but they are
prone to cracking, which compromises their structural integrity over time. Epoxy
injection has emerged as a widely employed technique for repairing cracks in
concrete, offering durability, cost-effectiveness, and structural reinforcement. This
comprehensive study delves into the principles, procedures, applications, and
outcomes of epoxy injection, providing valuable insights into its effectiveness in
enhancing the longevity and performance of concrete structures.

Introduction: Concrete, despite its widespread use and inherent strength, is

susceptible to cracking due to various factors such as shrinkage, thermal fluctuations,
chemical exposure, and structural loading. These cracks, if left unaddressed, can
propagate, leading to structural deterioration, reduced load-bearing capacity, and
safety hazards. Epoxy injection has emerged as a preferred method for repairing
cracks in concrete structures due to its ability to penetrate and bond with the
substrate, effectively sealing the cracks and restoring structural integrity.

Principles of Epoxy Injection: Epoxy injection involves the application of epoxy

resin into concrete cracks under pressure, ensuring deep penetration and effective
bonding with the substrate. The key principles underlying epoxy injection include
surface preparation, crack assessment, selection of appropriate epoxy resin, injection
equipment, and curing process. Proper surface preparation is crucial for ensuring
adhesion and penetration of the epoxy into the cracks, while crack assessment helps
determine the extent and severity of the damage.

Procedures and Techniques: The epoxy injection process typically involves the
following steps:

1. Surface Preparation: Cleaning the cracked area to remove debris, dust, and
contaminants.
2. Crack Assessment: Evaluating the size, width, depth, and orientation of cracks to
determine the appropriate repair technique.
3. Injection Port Installation: Installing injection ports along the length of the cracks
at regular intervals.
4. Epoxy Mixing: Preparing the epoxy resin according to the manufacturer's
instructions, ensuring proper viscosity and consistency.
5. Injection Process: Injecting the epoxy resin into the cracks using specialized
equipment, starting from the lowest port and progressing upward.
6. Curing: Allowing the epoxy resin to cure for the specified duration, typically 24 to 48
hours, depending on environmental conditions.
7. Surface Finishing: Removing any excess epoxy resin and polishing the surface to
restore its aesthetic appearance.

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Applications and Case Studies: Epoxy injection finds extensive applications in
various concrete structures, including buildings, bridges, dams, tunnels, and parking
garages. Case studies highlight the efficacy of epoxy injection in repairing cracks,
restoring structural integrity, and extending the service life of concrete infrastructure.
For instance, a multi-story parking garage exhibiting extensive cracking underwent
epoxy injection repairs, resulting in enhanced durability and safety.

Outcomes and Benefits: The outcomes of epoxy injection repairs are manifold,
including improved structural stability, enhanced resistance to moisture ingress and
chemical attack, prevention of further crack propagation, and restoration of aesthetic
appearance. Moreover, epoxy injection offers several benefits such as cost-
effectiveness, minimal disruption to operations, and rapid turnaround time, making it
a preferred choice for concrete crack repair.

Challenges and Limitations: Despite its effectiveness, epoxy injection may

encounter challenges such as inadequate surface preparation, improper crack
assessment, insufficient resin penetration, and curing issues. Moreover, epoxy
injection may not be suitable for certain types of cracks, such as those resulting from
structural settlement or expansive soil conditions.

Future Directions and Recommendations: Continued research and development

are essential to further enhance the efficacy and applicability of epoxy injection
technique for concrete crack repair. Future studies may focus on optimizing epoxy
formulations, improving injection equipment, developing advanced monitoring and
quality control techniques, and exploring alternative repair methods. Additionally,
ongoing education and training programs for engineers, contractors, and inspectors
are crucial to ensure proper implementation and quality assurance.

Conclusion: Epoxy injection technique represents a versatile, efficient, and reliable

solution for repairing cracks in concrete structures, mitigating structural deficiencies,
and prolonging the service life of infrastructure assets. By understanding the
principles, procedures, applications, and outcomes of epoxy injection, engineers and
practitioners can make informed decisions and effectively address concrete cracking
issues, ensuring the long-term performance and safety of built environments.

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 Epoxy Injection Technique: Enhancing Structural Integrity and Durability of
Concrete

Introduction:

Concrete structures are integral to modern infrastructure, providing essential support

for buildings, bridges, dams, and other civil engineering projects. However, over time,
these structures can develop cracks due to various factors such as shrinkage, thermal
cycling, chemical exposure, and structural overloading. Left unaddressed, these
cracks can compromise the structural integrity, leading to safety hazards and costly
repairs. Epoxy injection has emerged as a highly effective method for repairing cracks
in concrete, offering a durable, cost-effective, and minimally invasive solution. This
comprehensive analysis delves deeper into the principles, procedures, applications,
benefits, and future prospects of epoxy injection technique in concrete crack repair.

Principles of Epoxy Injection:

Epoxy injection relies on the use of epoxy resins, which are highly viscous materials
capable of penetrating deep into concrete cracks. The key principles guiding epoxy
injection include:

 Surface Preparation: Thorough cleaning of the crack surface to remove debris,

contaminants, and loose particles, ensuring optimal adhesion of the epoxy resin.
 Crack Assessment: Detailed evaluation of crack characteristics such as width, depth,
length, and orientation to determine the most suitable repair approach.
 Epoxy Selection: Choosing the appropriate epoxy resin based on factors such as
crack width, environmental conditions, and desired performance characteristics.
 Injection Equipment: Utilizing specialized injection pumps, ports, and accessories to
deliver the epoxy resin into the cracks under pressure, ensuring thorough
penetration and filling.
 Curing Process: Allowing the epoxy resin to cure and harden within the crack,
forming a strong bond with the concrete substrate and sealing off moisture and
contaminants.
 Quality Control: Implementing rigorous quality control measures to ensure proper
mixing, injection, and curing of the epoxy resin, as well as post-repair inspection to
verify effectiveness.

Procedures and Techniques:

The epoxy injection process typically involves the following steps:

1. Surface Preparation: Cleaning the cracked area using wire brushes, compressed air,
or water blasting to remove all loose materials and contaminants.

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2. Installation of Injection Ports: Placing injection ports along the crack at regular
intervals, typically spaced every 6 to 12 inches, and sealing them with epoxy
adhesive.
3. Epoxy Mixing: Preparing the epoxy resin by mixing the resin and hardener
components in the correct proportions, ensuring uniform consistency and adequate
pot life.
4. Injection Process: Injecting the epoxy resin into the crack using injection pumps or
pressure dispensing equipment, starting from the lowest injection port and
progressing upward.
5. Monitoring and Control: Monitoring the injection process to ensure proper resin
flow and distribution, adjusting pressure and flow rates as needed to optimize
penetration and filling.
6. Curing and Post-Repair: Allowing sufficient time for the epoxy resin to cure and
harden, typically 24 to 48 hours, before removing the injection ports and performing
any necessary surface finishing or cosmetic repairs.

Applications and Case Studies:

Epoxy injection technique finds widespread applications in various concrete

structures, including:

 Buildings: Repairing cracks in concrete walls, floors, and foundations to maintain

structural integrity and prevent water infiltration.
 Bridges and Highways: Restoring deteriorated concrete bridge decks, abutments,
and piers to extend service life and ensure safe transportation.
 Dams and Reservoirs: Sealing cracks in dam structures to prevent leakage and
preserve water storage capacity.
 Tunnels and Underground Structures: Reinforcing concrete tunnel linings and
underground utility vaults to withstand ground movements and environmental
stresses.

Case studies demonstrate the effectiveness of epoxy injection technique in real-

world scenarios. For instance, a historic bridge suffering from extensive concrete
cracking underwent epoxy injection repairs, resulting in restored structural stability
and enhanced durability. Similarly, a commercial building plagued by water
infiltration issues due to concrete cracks was successfully repaired using epoxy
injection, eliminating moisture ingress and protecting interior finishes.

Benefits and Advantages:

Epoxy injection offers numerous benefits compared to traditional repair methods:

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 Strength and Durability: Epoxy resins provide high-strength, durable repairs that
resist further cracking and deterioration.
 Waterproofing: Epoxy injection seals cracks effectively, preventing water infiltration
and corrosion of embedded reinforcement.
 Minimal Disruption: Epoxy injection is a non-disruptive repair method that
minimizes downtime and inconvenience to building occupants or traffic flow.
 Cost-Effectiveness: Epoxy injection repairs are often more cost-effective than
traditional tear-out and replacement methods, saving time and resources.
 Versatility: Epoxy injection can be used to repair cracks of various sizes and
orientations in both horizontal and vertical concrete surfaces.

Challenges and Limitations:

Despite its effectiveness, epoxy injection may face certain challenges and limitations:

 Crack Width: Epoxy injection may not be suitable for very narrow cracks (< 0.005
inches) or excessively wide cracks (> 0.5 inches), requiring alternative repair methods.
 Structural Movement: Epoxy injection may not be effective for cracks caused by
ongoing structural movement or settlement, necessitating additional stabilization
measures.
 Chemical Resistance: Some epoxy resins may be susceptible to chemical attack in
aggressive environments, requiring compatibility testing and specialized
formulations.
 Quality Assurance: Proper execution of epoxy injection requires skilled personnel,
quality materials, and adherence to strict procedures to ensure long-term
performance.

Future Directions and Recommendations:

Continued research and innovation are essential to advancing the effectiveness and
applicability of epoxy injection technique:

 Material Development: Research into new epoxy formulations with enhanced

properties such as rapid curing, increased flexibility, and improved chemical
resistance.
 Injection Technology: Development of advanced injection equipment and
techniques for better control, monitoring, and optimization of epoxy injection
processes.
 Quality Control: Implementation of standardized procedures, guidelines, and
training programs to ensure consistent quality and reliability of epoxy injection
repairs.

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 Sustainability: Exploration of environmentally friendly epoxy formulations and
recycling methods to reduce the environmental impact of repair materials and
processes.

Conclusion:

Epoxy injection technique represents a valuable tool in the arsenal of concrete repair
methods, offering a versatile, efficient, and durable solution for addressing cracks
and enhancing the longevity of concrete structures. By understanding the principles,
procedures, applications, benefits, and challenges of epoxy injection, engineers,
contractors, and facility managers can make informed decisions and effectively
manage concrete cracking issues, ensuring the safety, durability, and sustainability of
built environments for generations to come.

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WEEKLY PROGRESS REPORT

SR.NO. WEEK ACTIVITY PERFORMED SIGN OF DATE

GUIDE

1. 1st Discussion and finalization of topic

2. 2nd Preparation and submission of Abstract

3. 3rd Collection of Data

4. 4th Discussion and outline of Content

5. 5th Formulation of Content

6. 6th Editing and proof Reading ofContent

7. 7th Compilation of Report and Presentation

8. 8th Seminar / Viva voce

9. 9th Final submission of Micro Project

Sign of the student Sign of the faculty

ANEEXURE II

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 Evaluation Sheet for the Micro Project
Academic Year: 2023-24 Name of the Faculty: -Prof R B Ghavane

Course: CE6I Course code: 22603

Semester: 6

CO’s addressed by the Micro Project:

C414.1 : configure various networking devices

Major Learning outcomes achieved by students by doing the Project:

(a)Practical Outcome
Pro-1:Configure peer-to peer Network with at least three hosts.

Pro-10:Configure client to file server and use file services.

(b)Unit Outcomes in cognitive Domain
1.d. Classify computer networks on the specified parameter.
5a. Identify function and feautures of the given layers of OSI Refrence model.
5b.Compare the specified service on the given parameters
1.c. Explain the process of data
for the given situation with justification.

(c)Outcomes in affective Domain

1.a.Describe role of the given component in the process of data communication
1e.Select network architecture for the given situation with justification

Marks out of 6 marks out of

Roll Student Name for performance 4for Total out of
No in group activity performance in 10
(D5 Col.8) oral/
presentation

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 (D5 Col.9)
14 Abhay Munnalal
Vishwakarma

(Signature of Faculty)
Prof.R.B. Ghavane

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