Concrete Repair

Concrete Crack Repair

It’s crucial to assess each situation individually and choose the appropriate repair technique. We are proficient in various crack repair methods for both wet and dry conditions, meeting structural and non-structural requirements. Our current crack repair techniques include:

1. Polyurethane Injection Repair:

   • Used in waterproofing where flexibility is required, and cracks are non-structural.

2. Epoxy Injection Repair:

   • Employed for structural requirements in existing designs.

3. Surface Repairs (Fine Crack Repair):

   • Pour in epoxy grouts
   • Cementitious/Epoxy trowel repairs
   • Polyurethane caulking

4. Subsurface Repairs (In-depth Cracking):

   • Addressing issues like design errors, excessive loading, and corrosion-induced cracking.

Surface Preparation

1. Surface Preparation:

   • Put formwork
   • Pour non-shrink grout – Grade 50 minimum

2. Water Mark Presence – Chemical Grouting (Basic Injection Repair):

   • Types of chemical grouting according to the site situation:
     • Denepox 40 – underwater epoxy injection for concrete.
     • HA cut AF- 1 component polyurethane resin to stop water flow.

3. Chemical Grouting (Advanced Injection Repair):

   • Organasol XP – void fillings for large cavities.
   • IP 2C-Highflow: A 2-component high flow skid-mounted injection pump for polyurethane and organo-mineral resins.

Organasol XP

• Field of Application:

  • Injection of 2-component polyurethane and organo-mineral resins.
  • Tunnel and mining injections.

• Advantages:

  • High efficiency.
  • High flow rate and injection pressure.
  • Pneumatic drive, explosion-proof.
  • Skid-mounted for easy transportation.
  • Easy maintenance.

• Description:

  • Pneumatic 1/1 ratio high-performance piston injection pump.
  • Suitable for Rockstab polyurethane and Organosol organo-mineral resins.

Gelacryl Superflex AR

• Field of Application:

  • Waterproof to 7 bars.
  • Crack width starting from 0.1 mm.
  • Suitable for dry, damp, or wet conditions.

• Features and Advantages:

  • Solvent-free.
  • Good chemical resistance.
  • Easy to mix and work.
  • Forms a smooth even coating.

Denepox 40

• Field of Application:

  • Adhesion > 2 N/mm².
  • Crack width > 0.3 mm.
  • Suitable for dry or moist substrates.

• Features and Advantages:

  • Fast and easy to inject.
  • Excellent bonding to concrete and steel.
  • Non-corrosive to reinforcing steel.
  • Non-toxic and non-shrink.

Concrete Repair Protection

For Water Treatment Plants, Refineries, Chimneys, Road Structures, etc.

1. Anti-Carbonation Coating:

   • Matt finish surface for protection and embellishment.
   • Good water vapor permeability and resistance to weathering.

2. Hydrophobic Impregnation:

   • Water repellent treatment for absorbent substrates.
   • Reduces capillary water absorption.

3. Damp-proofing Injection:

   • Injectable water repellent cream for rising damp in masonry walls.
   • Forms a water repellent barrier.

4. Polymer-modified Mortar:

   • Fast repairs to horizontal or vertical surfaces.
   • Non-corrosive and high mechanical strength.

5. Chemical Resistant Coating:

   • Abrasion-resistant universal coating for chemical environments.
   • Suitable for storage tanks, silos, and water treatment plants.

6. Corrosion Inhibitor:

   • Protects steel-reinforced concrete structures from corrosion.
   • Easy to apply without changing the concrete appearance.

Spalling Concrete

Spalling concrete is a common issue for older buildings, typically caused by carbonation. Preventive measures include regular painting, proper sealing of cracks, and ensuring sufficient ventilation. If spalling occurs, timely repairs are essential to prevent further structural damage.

How to Prevent Spalling Concrete:

1. Paint ceilings regularly.
2. Seal cracks and holes properly.
3. Ensure sufficient ventilation to reduce humidity.

Repairing Spalling Concrete:

1. Remove the spalled concrete.
2. Clean and paint the corroded steel bars.
3. Patch the hacked area with a bonding agent and polymer-modified cement mortar.
4. Paint the repaired area to match the rest of the ceiling.

Concrete Crack Repair Checklist

1. Identification of Crack Types:

   • Structural or non-structural.
   • Wet or dry conditions.
   • Future intended use and location.

2. Selection of Repair Method:

   • Open crack and repair or injections.
   • Consideration of EN1504 standards.

3. Consideration of EN1504:

   • European standard defining repair methods and principles.
   • Specifies product performance levels and application guidelines.

Primary Criteria for Injection Resins

1. CE-Marking Consideration:

   • Applies to products used inside reinforced concrete.
   • Suitable for the repair method and application defined in EN1504.

2. Application Specifics:

   • Injectable for cracks > 0.5 mm.
   • Moisture condition (dry, damp, wet).
   • Optimum application temperature.

3. Glass Transition Temperature:

   • Important for structural injections.

Basic Injection Techniques

Primary Technique: Drill and Packer

• Common for waterproofing crack and joint injections.
• Monitor pressure carefully to avoid damage.

Confining Large Leaks and Voids

• Special techniques for specific scenarios.

Packer Installation:

• Use suitable packers related to leak size.
• Thoroughly tighten to prevent blowouts.
• Start flushing from the bottom of the crack.

Injection Equipment

Tailored injection equipment, such as packers, flushing pumps, and specialized injection pumps, is crucial for effective and controlled injections. It ensures precision, minimizes damage, and maximizes the success of the repair process.

At Rooflin, our commitment to quality and expertise in concrete repair enables us to deliver tailored solutions that not only address the visible issues but also ensure the longevity and structural integrity of the repaired structures. Contact us for specialized and reliable concrete repair services.