APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

Methodology of PQC Crack repair

1.0 Scope:
All pavements deteriorate with time. The rate of deterioration of concrete pavement is
comparatively much slower than the flexible pavement. The concrete pavements are
therefore expected to have a longer service life. Indicates the typical treatment which may
be considered with the age and condition of pavement.
2.0 Reference documents :
● Contract Agreement
● IRC SP 83 / IRC 15
3.0 Equipment :
The following equipment shall be deployed to carry out the operations.
● Drill Machine
● Diamond saw cutter
● Air Compressor
● Breaker – Jack Hammer
● Tools & Tackles
● Water Tankers
● Man Power
● NRV Grout Nozzle
● Grouting Pump
4.0 Material:
 low viscosity epoxy grout
 High strength Mortar grout >40Mpa

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

1. Repairing of plastic shrinkage Cracks:

(A) Clearing of cracks pressure air
(B) Injecting low viscosity epoxy materials into the cracks by fine nozzle injections or drilling
holes 6mm dia. and 50-75 mm deep@1m c/c to ease cleaning of cracks and static
penetration of epoxy materials into the crack.
(C) Superficially sealing the crack with Hand operated Gun.
(D) Making texturing on sealed material by actually brush.

2. Repairing of Partial depth Cracks:

(A) Cleaning of crack with pressure air.
(B) Drilling of holes 8 to 10 mm diameter 75 to 100 mm deep.
(C) Fixing off Injection nozzles @300 mm c/c sealing the periphery of nozzle with epoxy quartz
powder putty.
(D) Superficial sealing the cracks with low viscosity epoxy resin.
(E) Grounding of crack with low viscosity epoxy resin with epoxy grouting gun/pump as
specified and direction of engineer in charge
(F) Cutting and finishing of injection ports and texturing on whole repaired/sealed crack.

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

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 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

3. PQC JOINT REPAIR

1. Thoroughly clean the surface by wire brushing so as to expose the entire surface to be
repaired.
2. Remove all the loose particles and external material by chipping using a Suitable chipping
tool till the hard and strong concrete is exposed.
3. Wires brush the area again and clean the dust with blower.
4. Mix the epoxy with the recommended quantity of water and stir continuously for 3 minutes till
the consistency of the mixture is achieved.
5. Place the mortar into the groove and the holes and trowel it to the required shape. Make
sure that no air bubbles are trapped.
6. Next day saw cut the whole thing as per your widths and depths to accommodate the sealant.
7. The sealant can be applied after completing all the cleaning and drying formalities.

Page 4
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

4.Repairing of full depth cracks with cross

stitching method
(A) Clean the crack surface to V groove to a minimum depth of about 50 mm.
(B) Locate and mark centers of the holes on either side of the crack at a pitch distance of 300 mm
with an offset of 150 mm on the other side.
(C) The Perpendicular distance of the center of the hole from the crack shall be suitably selected
such that when the hole is drilled at 48 degrees, it will cross at the center of the PQC
thickness.
(D) The 20mm dia holes shall be drilled at an angle of 48 degrees with the horizontal with the help
of a suitable drilling machine and the fixture, so as to cross to the other side of the crack.
(E) The drilling shall be done for a suitable depth without reaching the bottom of the PQC.
(F) Water shall be used as coolant while drilling.
(G) After completing the entire drilling work, the holes are cleaned thoroughly with the help of
suitable tools and the water collected shall be removed.
(H)Each hole shall be inserted with a rod of 12 mm dia.
(I) The top of the rod shall be at least 25 mm below the surface of the panel.
(J) Suitable arrangement shall be made to maintain the rod at the center of the hole.
(K) Ecorock-tite is mixed thoroughly with the required quantity of water and poured into the holes
till the steel rod is completely covered.
(L) The Technopatch is poured along the crack and the top of the hole.
(M) Traffic can be allowed after 2 hours.

Page 5
 APCO INFRATECH PVT. LTD.

Construction of Nagpur – Mumbai Super Communication Expressway

(Package – 05) from Km.217+023 to Km. 259+900 on EPC mode

EMPLOYER: MAHARASHTRA STATE ROAD DEVELOPMENT CORPORATION LTD

5. Safety & Housekeeping

1. Take all the safety precautions during repairing & rehabilitation at work place.
2. Clean, remove all loose particles from surface & restore the location as per drawing
& standards specification.

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