Concrete injection: why it is needed, necessary tools and choice of material, step-by-step instructions

In order to strengthen and repair concrete structures, concrete injection is a potent technique used in both construction and maintenance. In order to improve a structure’s durability and integrity, concrete injection is a dependable solution for cracks, voids, and compromised foundations. By using this technique, concrete’s lifespan is increased and its overall performance is enhanced in a variety of scenarios.

To ensure effectiveness, specific tools and materials are needed for the concrete injection process. In order to inject the material into the concrete, injection pumps, hoses, and packers are necessary equipment. Choosing the appropriate material is essential; popular options include polyurethane foams and epoxy resins, each of which is appropriate for a particular type of repair and set of environmental conditions.

There are specific steps involved in carrying out concrete injection. The area that needs to be fixed is first meticulously cleaned and ready. In order to enable the material to pass through the concrete, the injection ports are then installed. The selected injection material is then combined and pumped into the structure. Ultimately, the injected material is allowed to cure and solidify within the concrete, resulting in increased strength and stability.

For individuals working on building and repair projects, it can be very helpful to understand the necessity of concrete injection, the required equipment and supplies, and the detailed procedure. Professionals can guarantee successful results, effectively address structural issues, and increase the lifespan of concrete structures by adhering to these guidelines.

In what cases is injection performed

The following are the causes of the building elements’ structural violations:

1. Errors in the design of compositions.
2. Failure to comply with the standards and scheme for laying cement mixtures.
3. Concrete shrinkage during strength gain.
4. Uneven soil movements.
5. Tree roots.
6. Industrial waste.
7. Daily and seasonal temperature fluctuations.
8. Atmospheric humidity.
9. Weathering.
10. Corrosion.

These elements have the combined effect of creating cracks that allow moisture to slowly seep into the structure, causing the concrete to swell, losing its integrity, and ultimately destroying the building.

One approach to addressing the issue of concrete surface sealing and repair is to introduce specific compounds into structurally compromised areas.

The components that are most prone to errors are as follows:

• monolithic components of the building;
• expansion joints;
• cross-sections of columns, beams, etc.;
• areas of concentration of mechanical and impact loads.

Even in public buildings that are constantly exposed to water, the injection of cracks into the concrete allows for the restoration of damaged areas without the need for costly dismantling. This technique is in demand for hydraulic, subterranean, and joint sealing as well as void filling.

Materials for injection

The following functional characteristics ought to be present in the compositions used to restore damaged areas:

• high viability;
• optimal viscosity;
• low volume shrinkage;
• wear resistance;
• non-corrosive;
• compatibility with concrete.

Together with the restored base, the repair compound must be able to withstand all mechanical loads.

Epoxy resins

Is a clear, viscous liquid without any obvious inclusions. The material is low toxicity, highly fluid, and has good wetting qualities.

Epoxy resin-based compositions are distinguished by enhanced mechanical, adhesive, and physical properties, in addition to:

• moisture resistance;
• strength;
• heat resistance;
• low shrinkage;
• good compatibility with cement materials.

Two-component epoxy resins are used for injection into concrete structures. Due to their low viscosity, these composites can be injected into cracks as wide as 0.05 mm.

Use of polycement compositions

Polymer composites are added to mineral binders to create compositions for polycement. The following substances are added:

• water-soluble resins (epoxy, polyurethane);
• inorganic materials (synthetic rubbers, polyvinyl acetate and acrylic suspensions);
• Active chemical components.

To repair large surfaces and seal cracks, a polymer-cement mixture is injected.

• the required strength in the initial firmware;
• high mobility and plasticity of the solution;
• non -shaped material;
• wear resistance;
• durability.

Waterproofing compounds

Concrete surface invocation waterproofing eliminates the need for costly soil excavation and combines crack clasping and reinstating the supporting elements’ imperviousness.

Better waterproofing is achieved by forced injection of protective material into the concrete structure as opposed to free impregnation or bitumen composition coating of the foundation.

The following ingredients are used to make dry solutions or suspensions:

• epoxy or polyurethane resins;
• micro -cement;
• acrylate gels.

Using the materials on the list, injection waterproofing is utilized for:

1. Underground parts of buildings.
2. Elimination of active leaks.
3. Cut-off waterproofing.
4. Devices of anti-filtration curtains for load-bearing walls.

Stage injection

To achieve satisfactory results when utilizing injection technology to remove water intrusions in reinforced concrete structures, specific tools and equipment are required:

• pumps;
• control and shut-off valves;
• pipeline systems;
• perforator;
• injection devices.

In order to connect pipelines to them and introduce hydroactive mixtures into concrete defects, packers are devices that are placed in pre-drilled holes.

Structures are repaired in phases while adhering to guidelines for the application of the chosen material.

Preparing the surface

The surface is inspected for flaws and the kind and size of cracks are identified prior to surface preparation. Choose the materials and devices based on this.

Work process:

1. Clean the coating from dirt, wipe with a clean rag and blow with air.
2. Check and install the equipment.
3. Using a tape measure and a marker, mark the points for installing the packers.
4. Considering the marking scheme, use a hammer drill to drill holes in places with the highest concentration of defective areas.
5. The boreholes are distributed in a checkerboard pattern. The interval between drilling points is 0.7-1.0 m.
6. The depth of the holes should be 5-10 mm greater than the size of the injector.
7. Upon completion of the work, all holes are cleaned with compressed air.

Fill the voids in the cracks

1. Injectors are installed in the prepared boreholes.
2. Prepare the repair compound.
3. Injection of mixtures is carried out from the bottom up.
4. A pipeline is connected to the first device, and the check valve is removed on the next one. Start pumping the solution. When the composition appears at the outlet of the second packer, the valve is returned to it and the process continues.
5. Such operations are performed sequentially with other devices until the entire volume of the crack is filled with sealant.

Apply the last layer

After the work is finished, disconnect the pipelines, remove the injectors, turn off the pump, and use a repair mixture to fill the holes with cement-sand mortar. Next, put the repaired surface back in place:

1. In the case of an insulating coating, restore the protective layer by applying mastic or gluing sheets of aquaizol.
2. If work was carried out to strengthen the structures of walls, columns, beams, then prime and putty the surface, apply a decorative layer of appropriate finishing materials.

In order to ensure the longevity and stability of existing structures, concrete injection is an essential technique for strengthening them and filling in cracks. Depending on the type of repair, this technique calls for specialized equipment like packers and injection pumps. Materials like epoxy or polyurethane can be used. We’ll walk you through every step of the procedure in this post, from site preparation to concrete injection and completion, making it simple for experts and do-it-yourselfers to follow and complete successfully.

Subtleties of waterproofing work

The basic idea behind waterproofing a structure is to use packers to inject a water-resistant mixture into any crevices, cracks, or seams. This composition then reacts chemically with the concrete to form a long-lasting impermeable material. Because of the generated excess pressure, the introduced mixture fills the spaces across the thickness of the structure.

Building components can be waterproofed in three ways:

• external waterproofing – compaction of the wall-soil sector;
• internal – from the basement or ground floor;
• strengthening the structure of the structure (pores, capillaries).

The degree of mobility of the affected area (seam, crack), the kind of loads, the temperature regime, the accessibility of the damage, and the characteristics of the repair composition utilized all influence the choice of solution.

The most common method involves injecting insulating mixtures from basements into the ground contact zone through the foundation’s thickness. An impermeable film known as a membrane is formed on the surface of the structure when the pumped suspension is equally distributed over its outer base.

The life of a screen like this is the same as the foundation’s, and penetrating waterproofing eliminates the need to add another layer of protection to the concrete surface.

Topic	Details
Why Concrete Injection is Needed	Concrete injection is used to repair cracks, fill voids, and strengthen structures. It"s essential for maintaining structural integrity and preventing further damage.
Necessary Tools	You will need an injection pump, resin or grout, injection ports, a drill, and a crack cleaner. These tools help ensure the material is properly injected and bonds well.
Choice of Material	Choose between epoxy or polyurethane resin. Epoxy is strong and durable, ideal for structural repairs. Polyurethane is flexible and good for sealing cracks that may move.
Step-by-Step Instructions	1. Clean the crack and drill holes for injection ports. 2. Install the ports and seal the surface. 3. Mix the resin or grout. 4. Inject the material starting from the lowest port. 5. Remove ports and seal holes once the material has cured.

Injecting concrete is essential to preserving and improving a structure’s durability. It contributes to the integrity restoration of concrete components, preventing additional damage and prolonging their lifespan, by caulking gaps and cracks. Knowing the goal and advantages of concrete injection will help you maintain the longevity and security of your structures, whether you’re working on small fixes or large restoration projects.

The proper equipment and supplies are necessary for a concrete injection to be successful. Whether to use epoxy, polyurethane, or another compound for injection depends on the particular requirements of your project. Having the right tools, like ports, sealing materials, and injection pumps, will help ensure a seamless and efficient repair procedure.

An easy-to-follow, step-by-step manual guarantees proper execution of the injection procedure. Every stage is necessary to achieve a long-lasting repair, from priming the surface and caulking the cracks to combining the injection material and applying it methodically. Every step of the process can be carefully planned out to avoid common problems and guarantee that the concrete regains its original strength and stability.

Understanding the significance of concrete injection and adhering to the right protocols will enable you to quickly and successfully resolve structural problems. Long-term cost savings and increased safety are also benefits of this proactive approach, which also protects the structural integrity of your concrete components. By adopting these habits, you’ll be able to handle concrete repairs with assurance and skill.

Video on the topic

Concrete injection.

Foundation waterproofing by injection.

Resin injection. Foundation waterproofing.