Method Statement for Repair of Cracks in PQC

1. General The methodology of repair pertains to the process of repair of various types of cracks development in PQC panels. The process of repair has been formulated keeping in view a practical and feasible approach. This is as per the relevant standards of repair and also in conjunction with the recommended guidelines provided. 2. Materail The material used for primer coat and injection grouting is two components low viscosity epoxy resin having high strength and good bonding properties with the concrete resistance to moisture penetration. The mixing ratio of resin shall be in the ratio as per manufactures specifications. No other material like thinner or solvent is mixed in the adhesive or its components. The material procured shall be the quality product from the establish and reputed manufacturer with the proven track record in the market. 3. TOOLS & EQUIPMENTS The equipment used for injection grouting is portable type compressed air operated low pressure epoxy injection gun or pump. The pump is manually operated fitted with a material receiving tank and capable of discharging mixed epoxy adhesive with a pressure of 1 to 2 kg/m2 The entry ports made for epoxy injection are through a flange type GI nipples (10 mm dia.) fixed and grouted formally in position keeping the orifice over the crack. The nipples are fixed at the desired locations (normally 300mm c/c along the length of crack) extending about 20mm below the surface of slab. For stitching operation, electric hand drill machine shall be used for making such holes. 4. REPAIR OF CRACKS Various methods are used to seal and grout the cracks. Depending upon the type of crack, its cause and location, the appropriate method of repair is chosen. Cracks are classified by their direction, width and depth. For selection of restoration techniques for cracked concrete slabs, all the observed cracks are broadly classified into following categories: (1) Partial depth cracks (Multiple discrete and parallel cracks) (2) Structural full depth cracks 4.1 REPAIR OF PARTIAL DEPTH CRACKS These cracks include those cracks, which are observed in the form of large number of plastic shrinkage cracks, and cracks caused by the plastic deformation to the concrete. 4.1.1 SURFACE COATING OF CRACKS (FINE HAIR LINE CRACKS) 1. In case of a network of fine hairline cracks(less than 0.2 mm in width) no repair is required. 2. For network of fine hairline cracks (0.2mm-0.5mm width) which have propagated up to depth half of thickness of slab, only a surface coating of cracks with epoxy adhesive applied with a brush. These cracks are generally tight and do not endanger the stability of the pavement.

4.1.2 SEALING OF CRACKS (FOR CRACKS OF WIDTH LESS THAN 2 MM) These cracks (0.5 mm- 2.0 mm) are short length and do not structural cracks and extending up to partial depth of the slab. These cracks do not endanger the stability of the pavement and not impairing the serviceability of the road. The repair may be taken up as follows: 1. A V notch (about 10mm wide and 10mm deep) is formed at the top along the length of crack by chiseling/mechanical cutter. The surface adjacent to crack and other areas of application shall be cleaned with air compressed air removing all loose dirt, dust or other foreign matter including any unsound concrete around the crack.
Crack Portion PQC Surface PQC Surface

10 mm

10 mm

V groove 2. Epoxy primer coat shall be applied uniformly over the notched surface of crack with the help of stiff nylon bristle brush. 3. Before the primer coat is fully cured, epoxy mortar (prepared by mixing quartz sand in the desired consistency and in conformity with the manufactures recommendations) shall be applied and surface finished by means of trowels and floats. The interval between the application of primer coat and epoxy mortar shall be approximately 15/30 minutes depending upon the ambient temperature. 4.1.3 GROUTING OF CRACKS (FOR CRACKS WIDTH MORE THAN 2MM) & FULL DEPTH CRACKS 4.1.3.1-BY CROSS -STICHING OF PANELS Cross-stitching of panels prevents the crack from vertical and horizontal movement or widening. The technique mainly for the signal longitudinal or diagonal full depth or partial depth cracks. Their length may be equal to or more than the length of one panel. The purpose of cross-stitching is to maintain aggregate interlock and provide added strength and reinforcement. This technique knits the cracked portion of the slab together and reduces the chances of crack to grow further. It shall be performed in the following steps. 1. The full depth of holes of 22 mm dia. is drilled across the crack at a pitch distance of 300mm at an offset of 150mm from the crank. The holes are drilled at an angle of 30-45 degrees, alternatively from each side of the crack so that one hole passes through the crack from left to right while the next from right to left. The length of drilled hole shall be about 500mm providing a full depth grip across the crack. 2. The holes are flushed with the compressed air to clean out the residual dust. Then epoxy adhesive of low viscosity is poured into the holes. Immediately after epoxy filling deformed steel tie bars of 12mm dia, 450mm long is inserted in each hole. The tie bars holds the crack tightly closed and enhances the aggregate interlock.

3. A V notch (about 10mm wide and 10mm deep) is formed at the top along the length of crack by chiseling. The surface adjacent to cracks and other areas of application shall be cleaned with compressed air removing all loose dirt, dust or other foreign matter including any unsound concrete around the crack. 4. The nipples 10 mm dia. in 12mm dia. hole are fixed flushed to the concrete surface using epoxy mortar at the desired locations keeping the orifice over the crack. Spacing of nipples shall be at 300 mm c/c depth 150 mm. In case of fine cracks, drilling of holes for fixing nipples should be avoided since the loose dust produced may block the crack and interfere with the injection process. 5. Surface seal material shall be applied at the top surface of crack over the remaining length between the entry ports and allowing it to gain adequate strength before injection to sustain injection pressure. 6. Epoxy Injection: The two components of the selected adhesive are mixed in the specified ratio and uniform and consistent mix is obtained by through mixing and stirring in a separate container. The mix is immediately transferred into the material receiving tank of the epoxy injection gun/pump. The epoxy is then pressure injected continuously into the cracks through the entry ports. 7. Injection is done first at the lowest entry port until the grout material is observed to be stopped going in further which is felt with a back pressure or epoxy travel is indicated by appearance at the surface outside or overflow through the adjacent nipple. The entry port shall then be sealed. Thereafter, the epoxy injection shall be transferred to next port. The injection process shall be performed continuously until the full length of crack is completely filled. 8. After the epoxy is set, the nipples are removed and surface leveled. 4.1.3.2- GROUTING OF CRACKS The discrete multiple cracks (>2.0 mm & full depth) in all directions, which are shallow and varying depths are to be treated with this technique. 1. A V notch (about 10mm wide and 10mm deep) is formed at the top along the length of crack by chiseling. The surface adjacent to cracks and other areas of application shall be cleaned with compressed air removing all loose dirt, dust or other foreign matter including any unsound concrete around the crack. 2. The nipples 10 mm dia. in 12 mm dia hole are fixed flushed to the concrete surface using epoxy mortar at the desired locations keeping the orifice over the crack. Spacing of nipples to be kept at 300 mm c/c depth 150 mm. In case of fine cracks, drilling of holes for fixing nipples should be avoided since the loose dust produced may block the crack and interfere with the injection process. 3. Surface seal material shall be applied at the top surface of crack over the remaining length between the entry ports and allowing it to gain adequate strength before injection to sustain injection pressure. 4. Epoxy Injection: The two components of the selected adhesive are mixed in the specified ratio and uniform and consistent mix is obtained by through mixing and stirring in a separate container. The mix is immediately transferred into the material receiving tank of the epoxy injection gun/pump. The epoxy is then pressure injected continuously into the cracks through the entry ports.

5. Injection is done first at the lowest entry port until the grout material is observed to be stopped going in further which is felt with a back pressure or epoxy travel is indicated by appearance at the surface outside or overflow through the adjacent nipple. The entry port shall then be sealed. Thereafter, the epoxy injection shall be transferred to next port. The injection process shall be performed continuously until the full length of crack is completely filled. 6. After the system is fully cured, the nipples are removed and surface leveled. .