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INTRODUCTION
Cracking is a phenomenon of “ a complete or incomplete
separation of either concrete or masonry into two or more parts produced by breaking or fracturing”. This definition is given by American Concrete Institute (ACI). A structure is subjected to cracking or crack formation due to one or more factors like:-
Temperature and plastic shrinkage.
Thermal variations. Drying shrinkage. Chemical reactions. Weathering process. Construction overload, and Poor construction practices like improper curing, inadequate water content in concrete mixture, inadequate formwork support, etc.
1 The development of cracks is a big deal if observed and examined from a structural perspective. Other than the structural aspects, it also affects the interior as well as the exterior aesthetics of the structure.
Cracks affect the structure in many ways. So it is
important to examine and repair the cracks as soon as possible. Crack repairs can be done by various methods, which depend upon the nature of cracks and the type of structure. There are many other factors on which suitable crack repair methods are chosen.
Concrete Crack Repair Methods
Crack repair can be done using different methods and techniques. They are as follows:-
1. Epoxy injection grouting
2. Routing and sealing 3. Flexible sealing 4. Stitching 5. Drilling and plugging 6. Grouting 7. Guiniting
2 1. Epoxy Injection Epoxy compounds possess properties like high compressive strength, tensile strength, and bond strength. They are widely used for making repair mortar. Epoxies can also be used on wet surfaces. Wet surfaces require some special grade of epoxy. It is way too costly than the normal epoxy compounds. Epoxy compounds can be used to seal cracks as narrow as 0.002 inch which is approximately 0.05 mm. It is an effective method for crack repair. The procedure for crack repair by epoxy injection grouting is as follows:-
Clean the cracks.
Seal the surfaces. Install the entry and venting points. Mix the epoxy compound. Inject the epoxy. Remove the surface seal.
3 2. Routing And Sealing This technique of crack repair is used in conditions where remedial repair is required and structural repair is not needed. In this method, the original crack formed on the surface is enlarged, which is known as routing, and then after the crack is sealed using a suitable joint sealant.
In this method, a groove of 6 mm to 25 mm depth is
prepared by means of concrete saw a hand tool or a pneumatic tool. Then the groove is cleaned by water blasting or air blasting.
The groove is allowed to dry. Once it is completely dried,
the sealant is placed in the groove and is allowed to cure. After the surface is cured properly, it can again be used.
The sealants used for the treatment of concrete may be of
several materials, including epoxies, silicones, and asphaltic materials.
4 3. Flexible Sealing In this method, a recess is cut along the line of the crack and it is filled up with a suitable flexible material. The breadth of recess and the sealant’s strength capacity determine the joint movement that can be accommodated.
So, the sealant bond must have a suitable width and
shape for the expected movement. A bond breaker should be used to prevent the sealing material from bonding to the bottom of the recess
4. Stitching Crack stitching is a permanent structural repair for cracked masonry and wall reinforcement. Simple and effective, our crack stitching repair process involves rods
5 that are grouted across cracks in walls in order to reconnect and strengthen masonry. A crack stitching repair provides excellent resilience against further cracking with minimal cost and little disruption. Crack stitching is used when a building starts to get vertical cracking. Typically crack stitching is perfect for cracked masonry, but it should only be applied once the cause of the crack has been determined.
Benefits of cracked stitching:
Quick, simple, effective and permanent. The grout combination provides an excellent bond. Masonry remains flexible enough to accommodate natural building movement. Non-disruptive structural stabilisation with no additional stress.
6 5. Drilling And Plugging This method includes drilling a 50-70mm hole near the crack. This hole must be large enough to cut across the crack along its full length and is filled with grout. The purpose of this technique is to prevent the crack from propagating further in the concrete. This approach is cost- and time-effective.
The grout key is responsible for preventing the transverse
movements of the concrete sections adjacent to the crack. The key also helps to reduce heavy water leakage through the cracks and loss of soil from behind the leaking wall.
If the priority is to make the structure more water resilient,
then the cavity is filled with a waterproof material of low modulus.
7 6. Grouting Based on grout material used, there are two methods for crack repair by grouting. They are as follows:-
1. Portland cement grouting
2. Chemical grouting
Portland Cement Grouting
Portland cement grout is used to repair wide cracks,
especially in structures like gravity dams and thick concrete walls. Portland cement grout prevents water leakage, but it does not bond the cracks structurally.
The procedure for this method is as follows:
• Clean the cracks by air jetting or water jetting.
• Installation of grout at suitable intervals and sealing of
the cracks with a suitable sealant.
• Grout the affected area with Portland cement grout and
let it dry.
• The Portland cement grout generally contains cement
and water or cement, water, and sand. Sometimes additives such as water reducers are added to the grout mixture to improve its properties.
8 Chemical Grouting
For chemical grouting, chemicals such as sodium silicate,
urethane, and acrylamide are used. Two or more chemicals are mixed to form a new chemical, which may be in the form of gel, a solid precipitate, or foam. The chemical grouts can be used in moist conditions also because of their properties to resist moisture.
9 7.Guniting Guniting is the process of using a spray gun for applying mortar or concrete to a surface. This process is mainly used for slope stability and specific rehabilitation purposes in building retaining walls, pools, tunnels, swimming, fluid tanks and some concrete restoration projects.
PROCEDURE Guniting, also called the dry-mix shotcrete technology, utilises a nozzle to transfer dry material from a machine to the application’s surface under high velocity and compressed pressure. Water is added to the nozzle to facilitate application, and the final mixture that emerges is a mixture of water and dry material. Both the water addition and the total water content were under the operator’s control. Depending on the application and regional restrictions, the cement mortar mix may need to be modified. The dry components are combined and kept in a cement gun in a bin. The dry mix is injected at high pressure and velocity, and water is supplied to the nozzle just before the dry mix bursts off during application. The nozzle receives water at sufficient pressure from a water supply pressure tank.
10 Equipment used for guniting
Guniting gun Concrete guniting machine Nozzle Hose Air compressor Admixture dispenser Pressure tank
Preventive Measures to Avoid Cracks
1) By creating slip joints under the support of RCC slab on walls, cracks by elastic deformation can be prevented.
11 2) Construct various joints such as expansion joints, construction joints, slip joints and control joints to prevent cracks from thermal movement.
3) Slab should be provided with thermal insulation.
4) Concrete should be of good quality. Use richer mix of
cement concrete 1:1.5:3 to prevent cracks.
5) In mixing of cement concrete or cement mortar, Use
minimum quantity of water, as per water cement ratio.
6) Do not use excessive cement in the mortar mix.
Because as a general rule, the richer the mix is, the greater the shrinkage will be. And shrinkage is one of the major causes of occurrence of cracks.
7) Use largest possible aggregate and the materials
should be of good grading and quality.
8) As soon as initial setting has taken place, the curing
should be started and be continued for at least seven to ten days. 9) Use good quality of building materials according to the specification. 10) The workmanship should be according to the prescribed norms and best practice in the building construction.
12 Conclusion
Repairing of cracks is very essential part in maintainance
of structure..Restoring the structural soundness and integrity of a concrete member,stopping water leaks etc is the main aim of crack repairs. Epoxy injection, Routing and sealing, Flexible sealing,Stiching,Drilling and plugging,Grouting,etc are the commonly used methods for crack repair.
