KHRI-Webinar (23-04-2020) - Injection Grouting For Concrete Repair-Shri S Seshadri (BASF)

- S Seshadri
Consultant
 Cracking in concrete
 Typification of cracks
 Crack repair methods
 Crack injection method
 Choosing right injection material
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Cracking In Concrete
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 Cracks occur when tensile load exceeds tensile strength
 True for any material!, not just concrete!
 Cracks can occur in different stages of concrete

 When just finished and stiffening starts
 Just after final setting
 Within a few weeks after setting
 In several years after setting
 Long time after - decades later
 The causes could be physical, chemical and mechanical
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After Hardening
 PHYSICAL
 Drying shrinkage
 Before hardening  Plastic settlement!

 Thermal cycles
 Moisture movement
 Chemical
 Plastic shrinkage  Sulphate attack
 Plastic settlement!  Alkali aggregate reaction
 Concrete movement  Corrosion

 Mechanical
 Thermal (hydration heat caused)
 Overload
 Formwork disturbance
 Impact
 Subgrade movement
Note:  Accidents / natural calamity
1. Circled causes result in structural cracks.
2. Many non –structural cracks can become structural  Fire
if untreated  Earthquake
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Typification Of Cracks
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 Repair method and material of depend on type of cracks
 Extent of crack
 Status of crack
 Condition of crack
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 Structural / non-structural
 Depends on percentage of load bearing area affected
 Structural if > 25% of bearing area affected

 Can be ascertained by cores or UPV or echo testing
 Dimensions
 Depth – shallow or deep. Shallow if < 1m deep
 Width : Hairline < 0.1mm, Fine <1mm , Medium < 3mm, Wide <6mm,. > 6mm is
considered fracture
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 Status
 Stable or active
 Active – variation of width or length or both with time
 Test using glass strip or crack monitor
 Glass strip: glue a thin glass strip across crack; breakage in 1-

3 days indicates active crack
 Crack monitor: Can see any movement of crack magnified
 Note:
 Only stable cracks can be repaired
 Active crack can be temporarily repaired for aesthetics
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 Condition – Wet (leaking) or Dry
 We will have
 Structural wet crack / dry crack
 Non-structural wet crack / dry crack
 Note: Wet cracks normally are

deep cracks
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Repair Of Cracks
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 Shallow cracks
 Open into a ‘V’ grove
 Seal with a rigid (non-shrink cementitious

mortar) or flexible sealant (PU sealant)
 Epoxy mortar not recommended
~ Coefficient of expansion
~ UV resistance (in exposed cracks)
 Deep / Structural cracks

 Injection grouting of cracks
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Codes, Guidelines and,
Some Reference
Literature
17 1912 ss / Rep / Injn / 01

 EN 1504-5:2001, Product and systems for protection and repair of concrete structures – definitions,
requirements, QC and evaluation for conformity
 Part 5 covers concrete injection
 EN 14068:2003, Products and systems for the protection and repair of concrete structures — Test
methods — Determination of watertightness of injected cracks without movement in concrete
 EN 12617-2:2004, Products and systems for the protection and repair of concrete structures — Test
methods
 Part 2 covers shrinkage of crack injection products based on polymer binder. Volumetric shrinkage
 JIS A 6024:2003, Epoxy injection adhesives for repairing in buildings
 ASTM C 881 – 90, Standard specification for epoxy resin based bonding systems for concrete
18 1912 ss / Rep / Injn / 01

 ASTM D 8109-17, guide to waterproof concrete floor, wall and ceilings
 Covers selection of chemical grouts; installation of selected grouts
 ACI 224.1R-07, Causes, evaluation, and repair of cracks in concrete

structures
 Injection systems and key properties
 What, where
 ICRI Guideline No. 330.1-2006, Guideline for the selection of

strengthening systems for concrete structures
19 1912 ss / Rep / Injn / 01

 ASTM D 8109-17, guide to waterproof concrete floor, wall and ceilings
 Covers selection of chemical grouts; installation of selected grouts
 ACI 224.1R-07, Causes, evaluation, and repair of cracks in concrete

structures
 Injection systems and key properties
 What, where
 ICRI Guideline No. 330.1-2006, Guideline for the selection of

strengthening systems for concrete structures
20 1912 ss / Rep / Injn / 01

Injection Grouting For
Crack Repair - Methods
21 1912 ss / Rep / Injn / 01

 A method of filling voids in a structure
 Completely
 Permanently
 Material used to fill voids is called a grout; process of

filling is called grouting
 Accessible, large voids: Gravity grouting – filling by force of gravity
 Inaccessible large / small voids: pressure grouting – filling by

pressure
 Accessible / inaccessible narrow voids: Injection grouting - filling

by applying pressure
22 1912 ss / Rep / Injn / 01

 The process of filling narrow voids (accessible or
inaccessible)
 Using low viscosity liquid grouts
 That set to harden into a gel / soft foam / rigid foam / hard solid
 Usually polymers; low viscosity
 By applying external pressure
 Low - <2 kg/cm2 to high - >20 kg/cm2
 Using machines / equipment
 Simple – a syringe - to sophisticated – High pressure twin line piston pumps
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24 1912 ss / Rep / Injn / 01
 To repair a structural crack and restore
structural integrity
 Wet (leaking) or dry; if wet, also to stop leakage
 To repair leaking joints and leaking non-

structural cracks to stop leakage
 Choice of grouts, method and equipment
depends on objective
 Two types of grouts – Bingham and Newtonian fluids
 Bingham fluids: e.g. cement slurry grout
 Newtonian fluids: e.g. chemical grouts, PU, acrylates, etc

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 Easy; in most cases
 No need to drill and inject
 Gravity filling is OK
26 1912 ss / Rep / Injn / 01

 Dry
 Restore structural integrity
 Inject with low viscosity, solvent free , epoxy resin conforming to

ASTM C 881
 200 to 350 CP
 Shallow crack – single line injection (mixed epoxy injected )
 Deep crack – Twin-line injection
 Resin and hardener pumped in separate hoses, get mixed at
injection nozzle
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 Wet
 First inject one component foaming PU to stop

leakage
 Temporary stoppage; does not restore structural integrity
 Follow-up with epoxy injection
 A weak foam gets compressed / punctured by injection

pressure
 Crack monitor: Can see any movement of crack magnified
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Below 0.2mm only products with
viscosity lower than 200 mpas are
applicable
Above 0.2mm products with more than
200 mpas are applicable
Above 0.5mm viscosity is not
important
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30 1912 ss / Rep / Injn / 01
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Some Resin Systems (Not Epoxy)
 Reacts with water to foam
instantly
 High increase in vol seals ingress
 Temporary stop – weak foam,

washes away when water
pressure builds up
 Does not restore structural
integrity
33 1912 ss / Rep / Injn / 01

 Clean surface, spray water and allow to dry to see cracks
 Surface usually covered by dust, algae, etc
 Water in cracks dry late and show up
 If PU foam first (wet crack) drill holes
 At 45º or more angle, to intercept crack plane
 @PCD = thickness of concrete, but max 1m
 Staggered on both sides of crack
 Fix appropriate type of packers
 Flush clean with copious water
 Inject using piston pump, hole after hole, until it appears at crack opening
 Clean up flush with surface with a knife
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35 1912 ss / Rep / Injn / 01
 Injection pressure
 Must monitor through pressure gauge attached to machine
 Up to 200 bar is fine; no worry about concrete damage
 Injection pressure gets dissipated inside concrete
 Start at low pressure – 3 bars, gradually increase as required
 Safety
 Must wear visor fitted helmet – splash of resin is dangerous
 Plus all other personal safety items – gloves, etc.
 If water is not stopping completely, drill relief holes

 Inject through them in the end
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 If leaking, only after stopping it with PU injection
 Clean sides of crack using hand grinder
 Very important – to stick epoxy seal later
 Seal crack opening with epoxy paste, leaving gaps at intervals
 To fix injection port later at those gaps
 If thin concrete member, can use injection port
 If thicker than 200mm, drill holes on crack and fix packers
 If thicker than 500mm, drill holes staggered at 45º and fix packers
 Don’t leave gap while sealing with epoxy paste
 Inject epoxy resin by single line or twin-line, as needed
 When the resin appears in next hole, stop, close cock, inject from next.
 For cracks on horizontal surface, no need to drill; gravity feed works.
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38 1912 ss / Rep / Injn / 01
39 1912 ss / Rep / Injn / 01
40 1912 ss / Rep / Injn / 01
41 1912 ss / Rep / Injn / 01
Repair Of Non-
Structural Crack To
Stop Leakage
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 PUs are highly reactive resin systems; can give exact desired properties
 Foaming properties / Hard resin properties / Flexible properties
 One component system
 Needs water to react
 Foam expansion factor and reaction time can be controlled with additives like accelerator
 For 1 component, high pressure pump – up to 200 bars
 Two component system
 Grout formed with 1:1 volume ratio; properties can be tailored to suit
 2 component high pressure pump required
 Chemistries
 Classical ‘pure’ PUs - methyl di-isocyanate + polyol + accelerator
 Organo-mineralic polyurethanes (MDI + Silicate + accelerator)
43 1912 ss / Rep / Injn / 01

 Most steps are same as injecting structural cracks
 Cleaning and marking cracks
 Drilling holes; fixing packers
 Do not seal crack opening

 PU systems don’t need sealing
 Necessary to relieve pressure and see PU issuing out
 One component PU forms soft foam; foam strength can be enhanced using right grade of PU
(check with manufacturers)
 Two component of PU react to form soft to hard seal

 Hard seal forming PU if leakage pressure high
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Foam with maximum possible expansion and shortest reaction time to be used
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 Cracks are common in concrete due to different causes
 Some are structural and some non-structural; dry and leaking; stable and active.
 Structural crack repair – wet / dry must restore structural integrity
 Non-structural leaking cracks must be repaired to stop leaks
 The type of resin system, the method and machines to be chosen carefully
 The grouting process is a scientifically designed procedure; must follow it for

effectiveness.
 Expert advice is needed in complex situations.
54 1912 ss / Rep / Injn / 01

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- S Seshadri

 Crack repair methods

 Crack injection method

 Choosing right injection material

2 1912 ss / Rep / Injn / 01

3 1912 ss / Rep / Injn / 01

 Cracks can occur in different stages of concrete

 Just after final setting

 Within a few weeks after setting

 In several years after setting

 Long time after - decades later

 The causes could be physical, chemical and mechanical

4 1912 ss / Rep / Injn / 01

 Before hardening  Plastic settlement!

 Concrete movement  Corrosion

9 1912 ss / Rep / Injn / 01

10 1912 ss / Rep / Injn / 01

 Structural if > 25% of bearing area affected

11 1912 ss / Rep / Injn / 01

 Active – variation of width or length or both with time

 Test using glass strip or crack monitor

 Glass strip: glue a thin glass strip across crack; breakage in 1-

 Crack monitor: Can see any movement of crack magnified

 Active crack can be temporarily repaired for aesthetics

13 1912 ss / Rep / Injn / 01

 Structural wet crack / dry crack

 Non-structural wet crack / dry crack

 Note: Wet cracks normally are

14 1912 ss / Rep / Injn / 01

15 1912 ss / Rep / Injn / 01

 Seal with a rigid (non-shrink cementitious

 Deep / Structural cracks

16 1912 ss / Rep / Injn / 01

17 1912 ss / Rep / Injn / 01

 JIS A 6024:2003, Epoxy injection adhesives for repairing in buildings

18 1912 ss / Rep / Injn / 01

 ACI 224.1R-07, Causes, evaluation, and repair of cracks in concrete

 ICRI Guideline No. 330.1-2006, Guideline for the selection of

19 1912 ss / Rep / Injn / 01

 ACI 224.1R-07, Causes, evaluation, and repair of cracks in concrete

 ICRI Guideline No. 330.1-2006, Guideline for the selection of

20 1912 ss / Rep / Injn / 01

21 1912 ss / Rep / Injn / 01

 Material used to fill voids is called a grout; process of

 Inaccessible large / small voids: pressure grouting – filling by

 Accessible / inaccessible narrow voids: Injection grouting - filling

22 1912 ss / Rep / Injn / 01

 Usually polymers; low viscosity

 By applying external pressure

 Low - <2 kg/cm2 to high - >20 kg/cm2

 Using machines / equipment

 Simple – a syringe - to sophisticated – High pressure twin line piston pumps

23 1912 ss / Rep / Injn / 01

 To repair leaking joints and leaking non-

 Bingham fluids: e.g. cement slurry grout

 Newtonian fluids: e.g. chemical grouts, PU, acrylates, etc

 No need to drill and inject

26 1912 ss / Rep / Injn / 01

 Restore structural integrity