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Repair Leaking Cracks in Walls Liquid Containment Structures
Repair Leaking Cracks in Walls Liquid Containment Structures
Repair Leaking Cracks in Walls Liquid Containment Structures
CoNTAINMENT ST RUCTURES
Keywords: chemical grout; concrete repair; crack injection; epoxy; leak; repair; rout and seal; wall; water tank.
Introduction
Nonprestressed reinforced concrete liquid contain
ment structures-in particular, noncircular tanks-often
exhibit vertical and diagonal cracks that are aestheti
cally objectionable. More importantly, cracks could
result in loss of stored liquids, leakage of hazardous
materials, concrete deterioration, and corrosion of rein
forcing bars. Such cracks, however, are seldom indica
tive of structural failure. This TechNote reviews the
methodology of repair in liquid containment structures.
Question
What are the typical causes of, and best practices to
repair, vertical and diagonal cracks in liquid contain
ment structures?
In the absence of corrosion, dormant but leaking cracks are typically repaired by pressure injection of epoxy
or chemical grout, vacuum injection, or routing and sealing on the interior or exterior wall surfaces, or both.
Active cracks are repaired by pressure injection with chemical grouts; by routing and sealing with a flexible
sealant on the interior or exterior wall surfaces, or both; or by application of a flexible barrier membrane on the
liquid retention side of the wall. ACI Concrete Terminology (ACI CT-13) defines an active crack as one whose
width changes with time, and a dormant crack as the opposite-one whose width does not change with time.
Not all cracks require repair. Refer to ACI 224R, Table 4.1, for crack widths that require repair or remediation.
Discussion
Liquid containment structures, such as large rectangular tanks, often exhibit vertical and diagonal cracks that
are usually the result of restrained concrete shrinkage and thermal contraction, typically spaced 4 to 10 ft (1.2
to 3 m) apart (Fig. 1). These cracks generally have an insignificant effect on the structural integrity. Cracking,
however, can affect the performance, serviceability, or both, of a structure, making repairs necessary to assure
liquid-tightness and long-term durability (ACI 350). Liquid containment concrete structures could have concrete
roof slabs that should be kept liquid-tight to prevent contamination of the contents by exterior exposure. In
these cases, differential shrinkage and thermal deformation of the concrete could result in significant wall and
roof cracking if the appropriate expansion or contraction (movement joints) are not provided. Structures with
movement joints in the walls and without matching joints in the base slab are prone to crack development,
not only in the walls adjacent to the joint, but in the base slab below the movement joint. The cracks typically
For more concrete repair guidance, refer to ACI 562, ACI 546R,
ACI 224.1R, and ICRI Guideline No. 340.1. Refer to ACI 224. 1R for
an assessment of the intrinsic nature of cracks. Before selecting a
repair methodology, the licensed design professional should deter
mine the cause of the cracks-if they are active or dormant and if
corrosion is active in cracked areas. Because shrinkage of concrete
continues over an extended period of time, resulting cracks should
be considered active, especially if the structure is subjected to
cycles of wet and dry periods. Dormant cracks usually result from
an event of limited duration, such as temporary overload condi
tions during construction.
For dormant cracks, injecting a rigid epoxy product restores the Fig. 2-Example of an active crack improperly
structural integrity of the member (ACI 503.7; RAP-1; ASTM C881/ repaired.
CM881).
Conversely, except where it is needed for load-transfer purposes, rigid epoxy products should not be used in
active cracks (Fig. 2). If the conditions that cracked the wall initially are not, or cannot, be changed, the wall will
crack again near the same location if the wall is structurally bonded back together. A repair technique incorpo
rating flexibility across the crack is the correct approach for this type of condition (ACI 224.1R). Crack injection
should not be used to repair cracks caused by corrosion of steel reinforcement unless supplemental means are
used to mitigate the cause of the cracks and corrosion.
If corrosion is present, it should be evaluated before making repairs. This TechNote does not cover repair of
cracks resulting from steel corrosion. There are various methods to mitigate, prevent, and control corrosion of
reinforcing steel in concrete (ACI 222R).
Active cracks can be repaired by: 1) pressure injecting of chemical grouts; 2) routing and sealing of cracks;
and 3) installing a flexible barrier system (ACI 224.1R). These methods are considered serviceability repairs and
not structural.
1) Chemical grout injection -Flexible hydrophobic polyurethane foam grout material is often used for the
crack repair in containment structures. Polyurethane foam retains most of its volume after curing, even if the
surrounding concrete should become dry, which is advantageous for repairing active cracks (Fig. 3 and 4).
Hydrophilic grouts tend to shrink when allowed to dry out and lose volume, resulting in active leaking when the
liquid is reintroduced at a later time. Note that some of these grouts might not re-swell sufficiently upon rewet
ting to fully prevent future leakage. Both types of chemical grouts can be used to mitigate leaking cracks with
injection performed from the exterior side of a liquid containment structure so the tanks need not be emptied.
Interior injection can also be accomplished without draining the tank by experienced divers performing the
work underwater. Some excavation could be required to access cracks below grade. For extensive cracking
below grade, the application of a waterproofing system might be necessary.
There are conditions, however, where injection from the inside wall face is recommended to prevent liquid
exfiltration, which could require the tank be emptied. Injection from the inside, however, provides access for
crack repair below grade for buried or partially buried structures without excavation.
The proper climatic condition is crucial for successful crack injection, especially if polyurethane chemical
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REPAIR OF LEAKING CRACKS IN WALLS OF LIQUID CONTAINMENT STRUCTURES (ACI364.12T-15) 3
Another method for crack repair is actual depth of penetration and effectiveness in filling the
2) Rout and seal -
routing and sealing cracks with a flexible sealant, incor entire crack width.
porating details that permit some movement. Because
routing and sealing are performed on the liquid side of the containment structure for tank leakage, the structure
should be emptied. In some cases, routing and sealing cracks on the exterior side can be used to reduce the
potential for contaminants penetrating the containment structure.
3) Flexible barrier system-A flexible barrier system can also prevent containment structures from leaking. This
method may be preferred if there is a large quantity of leaking cracks. One should completely empty the contain
ment for an extended length of time to allow the tank to dry before application of the barrier system. The construc
tion details for active cracks or joints should be reviewed and confirmed by a lining product manufacturer.
Considerations for tanks containing aggressive m aterials When chemicals such as acids, alkalis, or process
-
contaminants are present in the liquid contained by the structure, the materials used to inject the cracks should
be carefully selected for compatibility (ACI 503. 7R) and chemical resistance (EPA 9090A). The sensitivity of mate
rials to acid- and alkali-driven chemical attack depends on their composition, the containment chemistry (ACI 350;
515 .2R), and the severity of exposure conditions, such as concentration and temperature. Repair materials are
prone to deterioration by permeation if solvents in the tank are close to the solubility of the repair material. The
lower the molecular weight of the solvent, the more rapidly it diffuses into the repair material. Crack repair mate
rial should be resistant to chemical attacks and other detrimental effects to avoid corrosion. Testing, consultation
with the material supplier, or both, is recommended to address chemical compatibility and chemical resistance.
When liquids being contained are corrosive and chemical deterioration of the crack repair materials is expected,
additional barrier linings may be required to assure long-term performance of the repair.
Summary
Treatment of vertical and diagonal nonstructural cracks often found in ordinary reinforced concrete liquid
containment structures depends on if they are active or dormant. Dormant but leaking cracks are typically
repaired with a rigid material, either by pressure injection or routing. Active cracks are repaired by pressure
injection with chemical grouts, by routing and sealing with a flexible sealant on the interior or exterior wall
surface, or both, or by application of a flexible barrier membrane on the liquid retention side of the wall.
References
American Concrete Institute (ACI)
ACI 222R-01(1 0)-Protection of Metals in Concrete Against Corrosion
ACI 224.1R-07-Causes, Evaluation, and Repair of Cracks in Concrete Structures
ACI 224R-01-Control of Cracking in Concrete Structures
ACI 350-06-Code Requirements for Environmental Engineering Concrete Structures and Commentary
ACI 503. 7- 07-Specification for Crack Repair by Epoxy Injection
ACI 515.2R-13-Guide to Selecting Protective Treatments for Concrete
ACI 546R-14-Guide to Concrete Repair
ACI 562-13-Concrete Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings and
Commentary
ACI RAP-1-Structural Crack Repair by Epoxy Injection
ACI CT-13-ACI Concrete Terminology (web access)
ASTM International
ASTM C881/C881M-10-Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete
Authored documents
Vrignaud, J. P.; Ballivy, G.; Perret, S.; and Fernagu, E., 2003, "Selection Criteria of Polyurethane Resins to Seal
Concrete Joints in Underwater Road Tunnels in the Montreal Area," Grouting and Ground Treatment, Third Inter
national Conference on Grouting and Ground Treatment, New Orleans, LA., Feb. 1 0-12, pp. 1338-1346.
�m - e with ACI
Provided by I
American Concrete Institute- Copyright� @fMafe1'11fi'121�WW.&mcrete.org
No reproducti r� mg permitted without license from tHS
REPAIR OF LEAKING CRACKS IN WALLS OF LIQUID CONTAINMENT STRUCTURES (ACI364.12T-15) 5
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