Causes, Evaluation and

Repair of Cracks in
Concrete Structures
By
Suresh Chandra Pattanaik
Dr Fixit Institute of Structural
Protection & Rehabilitation,
Pidilite Industries Ltd,Mumbai
Construction Chemicals -Wide Range
 Broad Outline

• Introduction
• Causes
• Evaluation
• Repair Materials and Methodology
 Causes of cracks
Pre-hardening stage
•
Plastic shrinkage cracks
•
Drying shrinkage cracks
•
Settlement cracks
•
Movement of Formworks
•
Settlement of sub grades
•
Construction defects
Post-hardening stage
•
Bad quality of materials
•
Long term drying shrinkages
•
Thermal shrinkage cracks
•
Chemical and electrochemical corrosion related cracks
 PURPOSE OF REPAIR SYSTEM

•
To restore structural integrity
•
To arrest deterioration
•
To prevent future deterioration
•
To restore original profile
•
To restore integrity of sealed system eg. waterproofing
•
Aesthetic appearance
Cracking Delamination Spalling

Honeycomb Voids
Types of Deterioration

Carbonation attack Chloride attack

Reinforcement steel corrosion

Leaching and ef

Staining Popouts (ASR) >

Fire damage
Erosion
Acid and chemical attack
 Spalling
• Corrosion of reinforcement
• Impact
• Erosion
• Alaklli-aggregate reaction
• Freeze-thaw
• Fire exposure
 REPAIR CHEMICALS FOR
SPECIFIC APPLICATIONS
1 2
5 Injection grouts for
sealing cracks, pores
7 Sealing compounds
8 Putties
10
3
Low viscosity
monomers,
polyurethanes, etc.,
Epoxies, polyurethanes,
polysulphides, silicones
Cement, epoxy based
 A FEW TECHNIQUES FOR REPAIRS

Repair
Sl. Distress Materials
Techniqu
No. addressed Used
e
1 2 3 4

To seal cracks and pores Epoxies /

Injection in concrete. Monomers
1
grouting Polyurethane.
To Arrest leakages Cement slurry

Contd/…..
 REPAIR CHEMICALS FOR
SPECIFIC APPLICATIONS
Sl.
Application / purpose Specialty Chemicals
No.
1 2 3
3 Additives for grouting / Cement based
guniting, shotcreting chemicals

12
A Few Techniques for Repairs (Contd/…..)

1 2 3 4

General To densify porous

11 Non shrink grouts
grouting concrete members
Crack Repair
Permissible limits of Cracking as per IS 456-2000
Exposure conditions Width of
Cracking
Members where cracking is not 0.3 mm
harmful and does not have any
serious adverse effects on
reinforcement & durability
Members where cracking in tensile 0.2 mm
zone is harmful, exposed to
moisture/contact with soil or ground
water
Severe exposure conditions 0.1 mm
 Detection of cracks

• Voids and Honey comb : UPV

• Crack width measurement: Crack gauge,
Crack microscope
• Active crack monitoring :Crack monitor
• Crack depth: UPV
• Crack detection(inside concrete):concrete
endoscope
• Leakage cracks: Thermal imaging
Measurement of crack by gauge Taking of core sample
SELECTION OF CRACK REPAIR SYSTEM
mm wide. The method is suitable for sealing both fine pattern cracks and larger isolated defects. The crack is routed out, cleaned and flushed out before filling it with ready to use crack filling material. It should be ensured that the crack is filled completely. Where ever a cementitious ma

•It is a single pack, ready to use flexible putty

for filling the cracks up to 5 mm wide.
•The method is suitable for sealing both fine
pattern cracks and larger isolated defects.
The crack is routed out, cleaned and flushed
out before filling it with ready to use crack
filling material.
• It should be ensured that the crack is filled
completely. Where ever a cementitious
material is being used, dry or moist crack
edges must be wetted thoroughly.
• Surface must be free from dust, oil, grease, and loose
particles etc. Moisten the surface before applying Dr.
Fixit Crack-X Paste.
• For porous surfaces, apply primer coat prepared with
Dr. Fixit Crack-X Paste and water in 1:1 proportion
over the crack.
• Fill Dr. Fixit Crack-X Paste when the surface is tacky
and not dried completely.
• Press Dr. Fixit Crack-X Paste firmly into the crack
with a spatula or putty knifes and level with the surface
• Care must be taken to avoid formation of cavities or
bubbles during application.
• Allow it set for 24 hours and then apply another coat of
Dr. Fixit Crack-X Paste
 Repair by injection grouting with
low viscous epoxy injection grout

•
Used for grouting the cracks having width
0.5 mm to 2 mm
•
Epoxy resins cure to form solids with high
strength and relatively high moduli of
elasticity.
•
Can be applied on negative side.
•
Can penetrate deep into the cracks
•
Do not cure very quickly particularly at low
temperatures
•
Surface preparation:Injecting compressed
air,water is used for flushing and cleaning
cracks. It can have better bond with dry
surface than wet surface.
•
Materials:100% solid resinous solvents or
nonreactive diluent should be in the resin 21
 Cont.
•
Injection equipment:single
component pump for small
repair jobs.
•
Injection port location
established.
•
If cracks are clearly
visible,injection ports can be
installed at appropriate
interval by drilling directly into
the crack surface.
•
The surface of the crack
between ports is allowed to
cure.
•
It begins with lowest
elevation port and proceeds 22
along
PU Injection

Injection continues
1. Fixing of nozzles @ 500 no 400 120 48,000
mm c/c alternatively on
both faces of beam
bottom using suitable drill
machine at least 150mm
in depth and sealing the
nozzles with epoxy putty.

2. Injecting with Pagel ZS 10 kg 600 250 1,50,000

cementitious grouts in
beam
3. Injecting Dr Fixit Epoxy Kg 1200 750 9,00,000
Injection Grouts – two
components low viscous
high strength ( 7 days comp
strength 800 kg / cm2 )
epoxy resin based injection
grout complies with ASTM
C-881 through the above
nozzles to fill the cracks /
voids using compressor
machine.
4. Filling of non-structural m 90 90 8,100
cracks up to 5mm with Dr
Fixit Crack X paste
5. Filling of non-structural m 50 120 6,000
cracks between 5 to 10mm
with Dr Fixit Crack X Shrink
free by widening and
making ‘V’ grove including
cleaning, wetting , applying
and leveling the crack with
crack filling material
6. Filling of non-structural m 130 70 9,100
cracks more than 10mm
wide, all separation cracks
between masonry and
column and between
masonry and beam with
polymer modified mortar
with Dr Fixit URP by widening
the gap up to 15 mm,
cleaning wetting and filling at
Protection with a Protective Coating
Safety,Health & Environemnt
 suresh.pattanaik@pidilite.co.in
Telephone:022-28357973(O) / 09987355816(M)
Toll Free No:1800-225502
Web site: www.drfixitinstitute.com

THANKS