Injecting cracks in a concrete surface

Although concrete is a strong and adaptable material that is frequently used in construction, it is not impervious to cracking. Concrete surfaces may crack over time as a result of structural stress, shrinkage, or temperature variations. If these cracks are not fixed right away, they could cause more damage by jeopardizing the concrete’s integrity and appearance.

One efficient way to restore and repair concrete surfaces is to inject cracks. Using specialized materials that bond with the existing concrete, this technique fills in the cracks to seal the gaps and stop water infiltration and further deterioration. Injecting cracks prolongs the life of the concrete while also improving its strength and stability.

Depending on the kind and extent of the cracks as well as the particular needs of the project, there are several ways to inject cracks. Selecting the appropriate injection material and technique is essential to attaining favorable outcomes. Knowing the fundamentals of crack injection can help ensure a long-lasting repair, regardless of the severity of your structural damage or hairline cracks.

The various techniques and materials for creating cracks in concrete surfaces will be discussed in this article. Along with offering advice on how to properly diagnose and treat cracks, we will also go over the advantages of crack injection. By the time it’s all through, you’ll know more about how to take care of and fix concrete buildings so that their strength and beauty last for many years.

Step Description
1. Clean the Crack Remove dirt and loose debris from the crack using a wire brush or a vacuum.
2. Prepare the Crack Widen the crack slightly with a chisel or grinder to ensure better adhesion.
3. Apply a Primer Use a concrete primer to help the filler bond with the concrete.
4. Inject the Filler Fill the crack with a suitable injection material, like epoxy or polyurethane foam, using a caulking gun or specialized injection tool.
5. Seal the Surface Once the filler has cured, smooth the surface and apply a concrete sealant to protect the repair.

When is injection performed?

For waterproofing tunnels or basements, concrete injection is frequently utilized. This is particularly valid when surface leaks occur.

Furthermore, the injection method of work is appropriate for caulking wall, ceiling, and floor screed cracks. If "cold joints" were made when the foundation was built, this technique is also important to use when restoring it. It is important to keep in mind that debris frequently accumulates between the adjoining sections of the foundation, negatively affecting the building’s ability to adhere to surfaces and resist water.

Block foundations can also have their waterproofing qualities improved with a similar process. In this instance, a reinforced concrete or concrete monolith’s smallest cracks and voids are filled by the injection compound.

Additionally, during foundation repairs, a similar process is used to strengthen piles.

Additionally, when joints are deformed, crack injection is carried out. This typically occurs with subterranean passageways or parking lot foundations.

The many benefits of concrete injection have led to its increasing use in society:

  • the ability to instantly waterproof and seal;
  • maintaining the integrity of the structure without disturbing the design of the building;
  • the ability to restore even the most inaccessible areas of the structure;
  • no need to carry out excavation work;
  • the ability to carry out work all year round.

It is important to remember, though, that the material chosen to inject cracks in concrete directly affects the quality of the work.

Compositions for injection

Mixtures used to inject cracks into concrete or brickwork must adhere to specific specifications, which require the compositions to be identified by:

  • reduced viscosity;
  • high penetrating ability (this means that the composition must fill even the most microscopic cracks);
  • high adhesion (adhere well to various building materials);
  • corrosion resistance;
  • minimal shrinkage after complete hardening of the mixture;
  • long service life.

Epoxy or polyurethane resins, polycement materials (microcements), and specialty waterproofing solutions are the three types of compounds that satisfy all these requirements.

Resins

If the crack thickness is less than 0.5 mm, resin injection is used to treat walls and other bases. Because of this material’s ability to swiftly fill tiny pores, concrete’s strength and bearing capacity are fully restored following reconstruction.

Two categories of resins exist:

Polyurethane

This resin not only fills in cracks but also enables you to add more waterproofing. Polyurethane compound crack injection is typically used for processing wet joints and for rebuilding concrete and reinforced concrete monolithic structures. These kinds of resins are also used in the waterproofing process to prevent non-pressure or pressured water inflow.

The two components that make up polyurethane resin are component B (hardener) and component A (base). Only after they are blended until completely blended does the resin acquire its characteristics. In this instance, mixing can take place inside the injection pump head directly or beforehand.

Epoxy

This kind of resin sets fairly quickly and has a higher chemical resistance, making it a durable material. Epoxy compounds are typically injected into seams or dry cracks. In this instance, the structure’s ability to support weight is fully restored. The epoxy can expand its volume by two to three times when it comes into contact with water, creating a waterproofing layer in the process.

The lack of solvents in the composition and excellent adherence to a wide range of materials are two more benefits of epoxy resins.

Polycement materials

If the damage is more extensive, using such compounds is advised. Portland cement, which was created for injection, is known as polycement materials or microcement. These compositions stand out for having a unique level of grinding, which allows them to effectively fill in all formed pores, crevices, and cavities.

These materials might also include extra ingredients. For instance, lime, carbonate-quartz filler, white portland cement, and other additives are included in Runit injection mortar for masonry. This leads to the ability to regulate the composition’s hardening time, which eliminates the need for breaks during work.

Most frequently, reinforced concrete columns in older buildings are strengthened with microcement. We call this process "injector piles with bored injections for strengthening foundations." It is carried out by installing unique concrete structures in the ground at up to 45 degrees of angle. This is accomplished by drilling wells first, then filling them with high-pressure injected microcement.

In order to prevent water inflows and shrinkage cracks, this material is also utilized.

Waterproofing compounds

The most common material used for injection waterproofing is polyurethane because it completely withstands moisture infiltration. It is employed in the restoration of wet areas, in the treatment of seams and joints between monolithic elements, and in the isolation of holes and cracks in water supply and sewer networks.

Acrylic gels, which have a low viscosity and the capacity to expand in volume in a humid atmosphere, are also utilized for waterproofing. These compositions have good fluidity, which enables them to form waterproof barriers fast. Gels also dry the area around cracks in addition to filling them.

Using specialized tools, any of the compositions mentioned above is injected into a concrete monolith.

Equipment used and its cost

When it comes to concrete injection equipment, the following items are typically utilized for this purpose:

  • Injection pumps. Their cost depends on the composition used. For example, a KSG-700 pump for cement mortars will cost about 82,000 rubles. For polyurethane and epoxy resins, the KSG 900 model is suitable, costing 48,000 rubles. Also, you can find manual injection pumps on sale at a lower cost.
  • Injection packers. These elements are special tubes through which the solution is fed into the concrete base. Currently, 1 injection packer costs about 50 rubles (however, everything depends on its size).

One kilogram of resin costs roughly 800 rubles, while one kilogram of acrylic gel costs roughly 600 rubles. You will also need to purchase protective tape, which comes in rolls that cost roughly 400 rubles.

All you need to do is inject after you’ve made all the necessary purchases.

Execution of work

Everything about injecting is contingent upon the nature of the damage. In the event that a crack develops in the concrete monolith, the following steps are taken:

  1. The crack is expanded using a grinder.
  2. Parkers are inserted into the hole.
  3. Protective tape is glued on both sides of the crack.
  4. The crack and the tubes installed in it are filled with mortar, after which the injection compound is fed through the holes into the concrete layer.
  5. The parkers are removed and the surface is cleaned.

When discussing sealing injections on damp surface areas, the process will be as follows:

  1. Holes are drilled on the sides of the crack (in a checkerboard pattern) from which dust and concrete particles are removed using a vacuum cleaner.
  2. Parkers are installed in the holes and the compound is injected.
  3. The tubes are removed and the surface is covered with mortar.

Injection work is done exactly the same way when sealing pressure leaks; the only difference is that special compounds that expand well and harden quickly must be used in this situation.

Injecting concrete surface cracks back together is a dependable way to repair them and restore their strength and appearance. This method guarantees that the structure will remain intact and continue to function as intended. When the proper materials and methods are used, injected cracks become almost undetectable, offering a long-lasting solution.

It is essential to identify the root cause of the cracks before attempting injection repairs. Determining problems like settling, temperature swings, or structural stress makes it easier to customize the repair strategy and avoid more damage. Concrete stays more stable for longer periods of time and the injection process is more effective when these underlying causes are addressed.

Successful repairs require the use of premium injection materials, such as polyurethane or epoxy. Because of their great strength, epoxy injections work well for structural repairs, whereas polyurethane injections work better for sealing cracks in damp environments or when flexibility is needed. Selecting the right material guarantees that the repair properly fits the unique requirements of the concrete structure.

Frequent upkeep and inspections can aid in the early detection of cracks, enabling prompt repairs before they worsen. Property owners can prolong the life of their concrete structures and avoid expensive future repairs by being proactive and fixing cracks as soon as they arise. Injecting cracks into concrete, whether for residential, commercial, or industrial projects, is a workable solution that promotes the longevity and security of buildings.

In order to prolong the life of concrete structures, repair and restore structural integrity, and stop additional deterioration, it is essential to inject cracks into the surface of the concrete. Using specialized materials to fill in cracks and fuse the concrete back together, this technique effectively seals off the damaged area from moisture and other impurities. You can prevent more serious structural problems later on, save money on expensive repairs, and guarantee the longevity and safety of your concrete surfaces by taking immediate action to address cracks. Successful concrete repair depends on knowing the injection procedure and selecting the appropriate materials, regardless of the size of the cracks.

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Anna Vasilieva

Journalist with a technical education, specializing in construction topics. I can explain complex technical topics in simple and accessible language.

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