1.

0 Concrete Overview
Concrete is a composite material that uses cement to bind together crushed stone, rock, and
sand (i.e., aggregate). Cement acts as a binder filling the space among the aggregate
particles and glues them together. The exact proportions of aggregate, cement, and water
vary depending on the type of concrete being made. The aggregate and cement are mixed
thoroughly with water, which starts the chemical reaction causing the cement to harden and
set. This chemical reaction is called hydration.

2.0 Concrete characteristics

 It should be constructible. This means concrete mix should be workable and placed
and consolidated with no difficulties. It should flow sluggishly without segregation of
the ingredients.
 It should gain the required strength after it is cured.
 It should be durable. This means during the service life; concrete should not develop
premature deterioration.

3.0 Concrete deterioration types

• Surface cracking (shrinkage cracks) caused by improper curing.
• Surface scaling caused by wetting and repeated freeze/thaw action.
• Surface scaling caused by de-icing salts.
• Chemical reaction caused by sulphate action or certain types of aggregate.
• Abrasion caused by traffic.
• Penetration of water and de-icing salts and subsequent corrosion of the reinforcing
steel.

4.0 Types of reinforced concrete deterioration

4.1 Cracking
Cracking can be found in almost all concrete bridge elements. The cracks may be vertically
oriented such as the column cracks, horizontally oriented following the rebar spacing, and
they can be full depth or partial depth such as deck cracks due to concrete plastic shrinkage
or restraint. Cracking can also be random based on the material deterioration as described
below.
4.2 Delamination
Detection of delamination’s (or the debonding of concrete from the reinforcing steel) includes
detection of predominantly horizontally oriented cracks, although substructure members may
exhibit delamination on vertical surfaces. Delamination occurs as a result of rebar corrosion,
overloading, or other type of deterioration. Delaminated concrete needs to be detected and
restored to original conditions. Delamination’s are detected by sounding.
4.3 Spalls
Spalls (concrete pieces that are flaking or breaking away from the surface) are detected
during a visual review.
4.4 Corrosion
Detection of rebar corrosion is directed towards two main objectives: detection and
evaluation of intensity of active corrosion, and detection and evaluation of the severity of
existing corrosion.
4.5 Concrete Material Deterioration
Detection of concrete deterioration involves measurement of a change or variability of
material properties regardless of what is the cause of concrete deterioration: corrosion,
alkali-silica reaction (ASR), carbonation, and mechanical or thermal stresses.
4.6 Alkali Silica Reactivity
ASR is a widespread problem, affecting concrete structures in almost every area of the U.S.
It occurs when silica in aggregate and alkali in cement react in the presence of water. This
reaction creates a gel in the hardened concrete. Over time this gel expands causing cracks
and disintegration of the bond between the concrete ingredients.
5.0 Crack type classified as:
 Hairline – barely visible
 Fine – 0.8mm to 1.6mm
 Medium – 1.6mm to 3.2mm
 Wide – Greater than 3.2mm
 Patterns, location, and orientation of cracks (whether stress related or not)
 Scaling, classified as:
 Light – does not expose coarse aggregate
 Medium – involves loss of surface mortar to 1/8 inch to 3/8 inch in depth and
exposure of coarse aggregate.
 Severe – involves loss of surface mortar to 1/8 inch to 3/8 inch in depth with
some loss of mortar surrounding aggregate particles 3/8 inch to 5/8 inch in
depth.
 Very Severe – involves loss of coarse aggregate particles as well as mortar
generally to a depth greater than 5/8 inch.
 Spalling, classified as:
 Small – involves a roughly circular depression not greater than 5/8 inch in depth
and 6 inch in any dimension.
 Large – may be roughly circular or oval or in some cases elongate; more than
5/8 inch in depth and 6 inches in greatest dimension
 Exposed reinforcement
 Other general defects that can be identified by visual observation are:
 Surface distress: Disintegration of the surface, surface honeycombing.
 Water leakage: Surface dampness, efflorescence, seepage or leakage through
joints or cracks.
 Movements: Deflection, heaving, settlement.
 Metal corrosion: Rust staining, exposed post-tension cable strands.
 Miscellaneous: Blistering membranes and coatings, ponding of water,
discoloration.
6.0 Selection of repair procedures
Based on the careful evaluation of the extent and cause of cracking, procedures can be
selected to accomplish one or more of the following objectives:
 Restore or increase strength.
 Restore or increase stiffness.
 Improve functional performance.
 Provide water tightness.
 Improve appearance of the concrete surface.
 Improve durability.
 Prevent development of a corrosive environment at reinforcement.
7.0 Epoxy injection
Cracks as narrow as 0.002 in. (0.05 mm) can be bonded by the injection of epoxy. The
technique generally consists of establishing entry and venting ports at close intervals along
the cracks, sealing the crack on exposed surfaces, and injecting the epoxy under pressure.
Epoxy injection has been successfully used in the repair of cracks in buildings, bridges,
dams, and other types of concrete structures. Unless the cause of the cracking has been
corrected.
However, new cracks will probably form near the original crack. If the cause of the cracks
cannot be removed, then three options are available:
 rout and seal the crack, thus treating it as a joint.
 establish a joint that will accommodate the movement and then inject the crack with
epoxy or other suitable material.
 install additional support or reinforcement at the crack location to minimize
movement.
 Epoxy materials used for structural repairs should conform to ASTM C 881 (Type IV).
 This technique is not applicable if the cracks are actively leaking and cannot be dried out.
 Wet cracks can be injected using moisture-tolerant materials that will cure and bond in
the presence of moisture, but contaminants in the cracks (including silt and water) can
reduce the effectiveness of the epoxy to structurally repair the cracks.
 Epoxy injection requires a high degree of skill for satisfactory execution and use of the
technique may be limited by the ambient temperature.
8.0 Gravity filling
 Low-viscosity monomers and resins can be used to seal cracks with surface widths
of 0.001 to 0.08 in. (0.03 to 2 mm) by gravity filling.
 High molecular weight methacrylates, urethanes, and some low viscosity can be
used.
 The lower the viscosity, the finer the cracks that can be filled.
 The typical procedure is to clean the surface by air blasting, water blasting, or both.
 Wet surfaces should be permitted to dry for several days to obtain the best crack
filling.
 The monomer or resin can be poured onto the surface and spread with brooms,
rollers, or squeegees.
 The material should be worked back and forth over the cracks to obtain maximum
filling because the monomer or resin recedes slowly into the cracks.
 The use of this method on elevated slabs will require sealing of the cracks on the
bottom of the slab to contain material from leaking through the crack.
 Excess material should be broomed off the surface to prevent slick, shining areas
after curing.
 If surface friction is important, sand should be broadcast over the surface before the
monomer or resin cures.
 If the cracks contain significant amounts of silt, moisture, or other contaminants, the
sealant cannot fill them.
 Water blasting followed by a drying time may be effective in cleaning and preparing
these cracks.
 Cores may be taken to verify crack filling and the depth of penetration measured.
Caution should be employed to avoid cutting existing reinforcement during the coring
process.
 Cores can be tested to give an indication of the effectiveness of the repair method.
9.0 Epoxy Injection Vs Gravity Feed Resin
EPOXY INEJECTION
Causes for concrete cracking drying shrinkage, thermal
contraction or expansion, settlement, lack of appropriate
control joints, overload conditions that produce flexure,
tensile, shear cracks in concrete, restraint movement.
Objective is to restore the structural integrity and the
resistance to moisture penetration of the concrete element
Used horizontal, vertical and overhead cracks
Epoxy resins are hazardous materials
Surface mounted and socket mounted are two types of
entry ports for injection process
Capseals used to ensure containment of injected epoxy
resin
Epoxy injection strength check can be done using
destructive and non destructive tests
Can be injected from one or both sides of a concrete
member
Crack width ranging 0.010 in. (0.3 mm) to 0.002 in. (0.05
mm) in width and greater. Repair can be done using epoxy
injection for 0.010 in. (0.3 mm) or smaller, use a
low-viscosity epoxy (500 cps or less)
Cracks caused by corrosion of reinforced steel bars should
not be repaired by epoxy injection
Surface preparation by wire brushing, high-pressure water,
“oil-free” compressed air, or power vacuums.
Equipment used for epoxy injection:
• Air guns;
• Hand-actuated delivery systems;
• Spring-actuated capsules; and
• Balloon-actuated capsules.
Epoxy materials are viscosity based depending on crack
size, thickness of the concrete section, and injection
access. If injection access is limited to one side, a medium
to gel viscosity material may be more suitable
GRAVITY FEED RESIN
Causes for concrete cracking steel corrosion freezing,
thawing, sulphate attack, alkali aggregate reaction, poor
construction practices, shrinkage or settlement, improper
joint spacing and load imbalances.
Provides temporary solution to reduce possible future
deterioration caused by freeze-thaw cycles, steel
corrosion, and chemical attack of the concrete.
Used only to horizontal concrete elements such as bridge
and parking decks, floor slabs, plaza decks.
Epoxies and HMWMs are hazardous materials.
Pouring the gravity feed resin mixed material over the top
of the cracks and allow it to penetrate by gravity alone.
No need capseal for gravity feed repair.
Gravity feed resin strength check can be performed by
destructive and non destructive tests
Penetrating by gravity alone, the resin fills the crack and
forms a polymer plug that seals out water, salts, and other
aggressive elements.
Concrete crack width less than 0.006 in. (0.15 mm) wide
shall be used.
Gravity feed of resin should not be viewed as a long-term
solution to cracking caused by corrosion, sulfate attack, or
AAR
Surface preparation is achieved by treating individual
cracks, with wire brushes and wheels, followed by high
pressure, oil-free compressed air to remove dust from the
surface of the crack.
Equipment used for epoxy injection: • Mixing buckets,
drills, mixing paddles;
• Flat rubber squeegees, brooms, or rollers;
• Small cans or squeeze bottles for pouring into individual
cracks; and
• Grinder and air compressor.
Gravity feed resign materials are epoxies and high
molecular weight
methacrylates (HMWM)used as gravity feed crack repairs.