CVLE 637

Concrete Repair Techniques

Submitted to Prof Jamal Khatib

Done by: Hadi El Chami
201802016
 Contents

01 02 03 04
Introduction Causes of Concrete Cracks Different Type of Surface Preparation
Cracks

06
05 Methods of Repair
07
Concrete Repair Materials used
Steps
08
Conclusion
Introduction

What is concrete repair?

Concrete repair is the process of fixing or restor-

ing damaged concrete structures that, over time,
has lost the ability to hold the binding concrete
materials together due to damage or environ-
mental exposure. Concrete repair is appropriate
for cracks, physical impacts, chipped out sur-
faces or surface scaling.
 Causes of Concrete Cracks

01 02 03 04
Mechanical Chemical Physical Thermal

05 06
Construction
Plastic
movement
 Curing Shrinkage

Fatigue
Plastic Settlement

Change in Temp/Humidity
Improper Installation
Causes of Cracks
that affect Con-
crete Structures Handling Practices

Settlement Corrosion

Creep
Carbonation Shrinkage
 Types of Cracks

According to (Winterbottom and Goodwin), cracks can To repair active cracks, we can use the following meth-
be classified into 3 main categories: ods:
• Active cracks: cracks that change in dimension with • Stitching
respect to time variation • Adding Reinforcement
• Passive or dead cracks: cracks that have stabi- • Drilling and Plugging
lized and do not change in dimension with time varia-
tion. To repair dormant cracks, we can use the following
• Dormant cracks: sleeping cracks which can be classi- methods:
fied as passive cracks that might become active after • Epoxy Injection
the repairing process. • Routing and Sealing
• Grouting
• Drilling and Plugging
• Dry Packing

• Surface preparation is an important step dur-
ing the repair of the concrete structure. This
helps to get a stronger bond between the con-
crete and the repairing materials. If the sur-
face is not prepared properly before applying
the repair material, it may not bond well with
the existing concrete, leading to failure. Im-
proper surface preparation for concrete may
cause such problems as low adhesion of coat-
ings or topping, weak durability, and unattrac-
tive outlook.
Surface Preparation
• In order to select the best and most suitable re-
pair method for the cracked surface, we should
measure the length and width of the cracks.
• To ensure the surface is well prepared, it is es-
sential to adopt appropriate procedures and
techniques depending on the types of cracks
formed on the concrete surface.
1. Sandblasting
2. Shot blasting
3. Grinding
4. Water-blasting
• Choose the appropriate material and technique
 Steps for the Start of Repair

01 02 03 04
Determine the cause of Assess the extent of the Evaluate the need for Select the suitable
concrete cracks damage concrete repair repair technique

05 06
Cure the repaired
Prepare damaged
concrete
structure for repair
 Methods of Repairing Concrete
Epoxy Injection
Epoxy is a liquid-like material which is injected
into cracks and voids in the concrete to seal them
and prevent further damage. This method is suitable
for narrow cracks 0.05 mm openings.
This technique can only be used for dead cracks or
dormant cracks as active cracks can still increase in
size. Simultaneously, this method is not suitable in
moist or wet environments as the epoxy will not
bond well.
Routing and Sealing
This is generally the easiest and simplest method for
concrete crack repair. This method is only applicable where
structural repair is not required. This process involves
making the cracks bigger then filling and sealing the cracks
with a joint sealant. The positive side of this technique is it
can be applied on cracks of all sizes (big and small cracks).
 Methods of Repairing Concrete

Stitching Adding Reinforcement

Stitching is the easiest long lasting method of
repairing concrete structures because of its
simplicity and good results. The process of stitching
involves drilling holes on each sides of the cracked
concrete surface then stitching it using U-shaped
wires well anchored and grouted.
For this technique to be applicable, the cause of cracks
needs to be due to the lack of sufficient reinforcements. This
method can be completed by either adding conventional
reinforcements or using pre-stressed steel bars. Choosing
between the two methods depends on the type of cracks, the
crack sizes and the structural member.
 Methods of Repairing Concrete

Grouting Dry Packing

Grouting is a technique used to fill void gaps by
pumping Portland cement grout under pressure.
This method is mainly used where water leaks are
involved. For wide cracks such as dams, Portland
cement grout can be very effective.
This process involves applying a thin layer of grout usually
mortar with a low water content on cracks followed by
ramming in order to make a good bond between the existing
concrete and the new thin layer of grout. The presence of
low water content allows low shrinkage while also
providing a good strength and durability.
 Methods of Repairing Concrete

Drilling and Plugging

This technique involves drilling the length of the

crack then grouting it in the shape of a key as
shown in figure. The drilling and plugging method
is used to repair cracks that are vertical and run in a
straight line while being accessible from one end.
 Repair Materials

Portland Cement Dry Pack Mortar

Portland Cement or concrete is one of the most
common material used due to its wide availability
worldwide and low cost. Another big advantage is
that it is easy to use as it doesn’t require a high
skill to place and cure
Portland cement has good characteristics in terms
of stiffness and thermal expansion. Portland
cement can also be used effectively in humid and
moist environments as less shrinkage is prone to
occur.
One of the materials popularly used in repair of concrete,
especially where one needs a dense and strong repair
material, is dry-pack mortar. Mostly, dry-pack mortar consists
of Portland cement, fine aggregate (like sand), with very little
water. Attaining moisture that will lead to dry consistency
sufficient for shaping while compacting well is crucial.
 Repair Materials

Epoxy Resin Shotcrete

One of the most commonly used materials in Shotcrete can be an effective material for crack repair,
concrete repair is epoxy resin because of its strong especially in situations where traditional casting or formwork
bonding abilities, high strength, as well as may be challenging, or when repairs need to be performed on
durability. It is a versatile material that is often vertical or overhead surfaces. Shotcrete is a mix of cement,
employed for patching up cracks, strengthening aggregates, and water
structural elements, or protecting concrete
surfaces. In most cases crack injection involves
using epoxy resin to strengthen or rebuild damaged
parts of the concrete structure. This is a process
that entails introducing epoxy into the fissures so
as to seal them off to avoid future damage.
 Repair Materials

Polymer-Modified Concrete

A type of concrete that incorporates polymers,

such as latexes or resins, to enhance its
performance properties. Because of its enhanced
toughness, adhesion, elasticity and resistance to
different environmental situations, it is often
applied on repairing and restoring concrete.
 Conclusion

There are many reasons to why cracks occur. It is

important to find the reason first before repairing
the structure. We have many different techniques
and materials to use to repair the structure so it is
important to consider the cost, time and
effectiveness to decide on which technique and
materials to use.
 Knowledge Gap

Concrete repair is an evolving field, and opportunities for new research abound.
We can investigate and develop sustainable repair materials, such as eco-friendly
binders, recycled aggregates to reduce the environmental impact of concrete repairs.
The use of eco-friendly binders and recycled aggregates in concrete repair has gained
increased attention in recent years, reflecting a growing emphasis on sustainability
and environmental responsibility in the construction industry. While the concept of
incorporating these materials into concrete repair has been around for some time, the
broader adoption and recognition of their benefits have become more prominent in
the last couple of decades.
 Knowledge Gap
Eco-Friendly Binder
Recent Years (approximately past 10-20 years):
The development and use of eco-friendly binders,
such as geopolymers and alkali-activated
materials, have seen increased interest and
research. These binders often utilize industrial by-
products or waste materials as precursors, reducing
the reliance on traditional Portland cement.
Researchers and industry practitioners have been
exploring their application in concrete repair and
construction projects to decrease the carbon
footprint of the built environment.
Recycled Aggregates
Recent 20 years: The use of recycled aggregates, which
involve incorporating crushed concrete, reclaimed asphalt
pavement (RAP), or other recycled materials in lieu of
traditional aggregates, has been actively researched and
implemented in concrete repair projects. Over the past couple
of decades, there has been a greater recognition of the
potential environmental and economic benefits of using
recycled aggregates, leading to increased adoption in
sustainable construction practices.
 Knowledge Gap

While the use of these materials in concrete repair is gaining momentum, challenges
remain, including the need for further research, standardization, and market
acceptance. As sustainability becomes an increasingly central consideration in the
construction industry, it is likely that the use of eco-friendly binders and recycled
aggregates will continue to evolve and become more widespread in concrete repair
practices.
Thank YOU!