Repair of Cracks in Concrete Structures

Abstract
Cracks in the concrete structures are early signs of distress which have to be diagnosed properly otherwise the repair of same
crack takes place again and again causing loss of time and money. The structural cracks need more attention than non structural
cracks. The repair materials and methodology are different depending upon types of cracks, their locations such as joints, structural
members etc. and conditions such as dry or moist. The present paper focuses the various types of cementious and polymeric
materials that are being used for repair of cracks.

Introduction
Concrete inherits certain type of cracks in pre-hardening stage and also develops some other types of cracks in post hardening
stage in due course of time due to various reasons, despite our utmost care in prevention of cracks. While concrete becomes older,
these cracks become sources, of leakages and seepages and give easy access to the moisture, oxygen, chloride, carbon dioxide,
and other aggressive chemicals and gases into the concrete leading to serious degradation of the structure and causing corrosion
of steel and damage in the concrete in the form of spalling etc. and subsequently causing structural failure of the member. Cracking
is the initial sign of distress of the structure baring other forms of distress and deterioration like deformation, surface deposits and
construction defects etc. causing damage to structural strength, durability and serviceability.

Causes
The deterioration levels of concrete on the basis of percentage of occurrence in descending order can be categorized as cracking,
spalling, staining, honeycombing, reinforcement corrosion, efflorescence, pop outs (alkali silica), scaling, and delaminations.

During pre-hardening stage the majority of cracks are due to plastic shrinkage and drying shrinkage which occurs in the process of
setting of concrete [1]. The factors which led to formation of plastic shrinkage cracks are higher water/cement ratio, absence of
moist curing after post setting of concrete in green stage and excessive water absorption by aggregates from the mix. The factors
which led to formation of drying shrinkage cracks are higher temperature and high wind during casting of concrete which helps for
rapid drying of concrete, relative humidity and difference in ambient temperature. The other types of pre-hardening cracks are
settlement cracks which occur due to improper compaction which may lead to honey-combing and voids formation in the concrete
and specially the congested reinforcement at junctions of column and beam, movement of formworks, settlement of sub grades [1].
The construction defect related cracks during this stage are due to absence of required cover, gaps in formworks, excessive
vibration, segregation of mix, lack of joints, ineffective joint treatment for expansion and contraction joints, cold joints, construction
joints and absence of curing for specified period and prolonged curing up to 28days. Post-hardening cracks are due to bad quality
of materials, long term drying shrinkage cracks, thermal shrinkage cracks, chemical and electro chemical corrosion related cracks
[1].

The cracks can be classified as structural cracks and non-structural cracks. Non-structural cracks appear due to internally induced
stresses in building materials, environmental effects and restraints to these effects and do not endanger the safety of the structure.
These inevitable nonstructural or intrinsic cracks are quite harmless to the extent of acceptable limits of cracks as given in the code
of practices of IS456:2000 [2] (Table: 1).Again the cracks are classified as active and dormant cracks depending on the movement
of cracks in terms of length, depth and width. Dormant cracks can be repaired easily but active cracks are difficult to be repaired
and have to be observed for longer period and at least for 6 months before doing any repair to such cracks.

Table: 1.

Width of
Exposure conditions
Cracking
Members where cracking is not harmful and does not have any serious adverse effects on
0.3 mm
reinforcement & durability
Members where cracking in tensile zone is harmful, exposed to moisture/contact with soil or
0.2 mm
ground water
Severe exposure conditions 0.1 mm

Evaluation
Before repair of any type of crack the causes and nature of the crack should be diagnosed properly. The visual observation can be
made for surface appearance of the crack which indicates the basic cause of the cracking. Location and pattern of cracking like
diagonal, longitudinal, transverse, vertical and horizontal are also to be noted. Some non-destructive tests should also to be carried
out to find out the root cause of cracks in the concrete. Ultra-sonic pulse velocity is being used to find out the voids, identifying the
cracks and measuring the crack depth. Crack microscope can be used to locate and find out the width of the crack and a digital
crack measuring gauge can also be used for the same purpose. For active crack a crack monitor should be used which is used to
monitor the changes in the crack by taking observation for a longer period. Concrete endoscope and fiberscope are also being
used to find out the cracks inside the concrete. Cracks due to fire damage can be evaluated by petrography. To detect the
leakages, voids inside the concrete thermal imaging camera can be used. The Table 2 shows how to identify the pattern of cracks,
their possible causes and further tests required.

Table: 2.

Crack Pattern (Symptom) Possible Cause (Diagnosis) Further work-up (Tests)

Rust stain on surface.
Crack in cover concrete,
Rebars exposed, concrete
spalls.
Vertical and horizontal
cracks at interval.
Cracks at definite interval.
Map pattern
Diagonal cracks in beams
near the support.
Vertical cracks in beams
near mid span.
Vertical tapering cracks in
masonry near vertical joint.
Horizontal cracks
Cracks between RCC and
masonry.
Water routed through cracks Movement of joint, through crack in RCC
in concrete. member.
Ferrous compounds present in concrete/ Chemical analysis of sample,
mortar, binding wire, nails etc. left, corrosion cover check and carbonation
of rebars. test.
Corrosion of rebars (main and secondary) Cover check, loss of rebars,
caused by chlorides. carbonation and chlorides test.
Cover to secondary rebars
Corrosion of secondary Rebars.
check.
of rebars. Rebars too near the surface,
Cover check.
corrosion
Alkali-Silicate Reaction, early drying out
Chemical analysis of
condition, high cement content, excess
constituents.
compaction, poor curing.
Overload inadequate section of beam, Reverse calculation of shear
inadequate stirrups. strength of beam section
Overload, inadequate section of beam,
-
inadequate longitudinal Rebars.
Foundation / substrate / supporting member
-
movement.
Check the rebar near the crack
Corrosion of embedded Rebars
for corrosion.
Check the bond between RCC
Thermal expansion and contraction.
and masonry.
Check the Rebar detail.

Repair of Cracks
The aim of crack repair has to be established a prior and achieved by proper selection of repair material and methodology. As
described in ACI 224.1R [3] the goal of all crack repairs is to achieve one or more objectives such as: restore and increase the
strength of cracked components; restore and increase the stiffness of cracked components; improve functional performance of the
structural members; prevent liquid penetration; improve the appearance of the concrete surface; improve durability; and prevent
development of a corrosive environment at the reinforcement.
Materials for nonstructural crack repair of dormant nature should be a rigid material. The crack should be three to four times wider
than the largest aggregate particle. Cementitious, polymer modified cementitious grouts of acrylic, styrene-acrylic and styrene-
butadiene should be used for wider cracks. However polyester and epoxy resins should be used for injection of dormant cracks.
For live cracks flexible material of polysulphide or polyurethane should be used [4]. Before repair of any non structural cracks the
factors have to be considered are: whether the crack is dormant or live; the width and depth of the crack; whether or not sealing
against pressure is required, and, if so, from which side of the crack will the pressure be exerted and whether or not appearance is
a factor.

Repair of Dormant cracks

Dormant cracks may range in width from 0.05 mm or less (crazing) to 6 mm or more. The width of the crack has a considerable
influence on the materials and methods to be chosen for its repair.The fine cracks are repaired by low viscous epoxy resin and
other synthetic resin by injecting. Wide cracks on a vertical surface are also repaired by injection methods. Cracks on horizontal
surface can be repaired by injection or by crack filling by gravity.
Dormant cracks, where the repair does not have to perform a structural role, can be repaired by enlarging the crack along the
external face and filling and sealing it with a suitable joint sealer. This method is commonly used to prevent water penetration to
cracked areas. The method is suitable for sealing both fine pattern cracks and larger isolated defects. Various materials are used,
including epoxies, urethanes, silicones, polysulphides, asphaltic materials and polymer mortars [5]. Polymer mortars are used for
wider cracks. The crack is routed out, cleaned and flushed out before the sealant is placed. It should be ensured that the crack is
filled completely. Where ever a cementitious material is being used, dry or moist crack edges must be wetted thoroughly.

Cementitious Grouts
It is used for repair of cracks that are 6 mm and greater in width. It is a mixture of cementitious material and water, with or without
aggregate that is proportioned to produce a pourable consistency without segregation of constituents.

Cement-based grouts are available in a wide range of consistencies; therefore, the methods of application are diverse. These
materials are the most economical of the choices available for repair. They do not require unusual skill or special equipment to
apply, and are reasonably safe to handle. These materials tend to have similar properties to the parent concrete, and have the
ability to undergo autogeneous healing due to subsequent hydration of cementitious materials at fracture surfaces. Shrinkage is a
concern in such type of grouts. These are not suitable for structural repairs of active cracks.

For application of cementious grouts generally, some form of routing and surface preparation, such as removal of loose debris are
needed. Pre-wetting should be done to achieve a Saturated- Surface-Dry (SSD) condition. Grouts are generally to be mixed to a
pourable consistency by using a drill and paddle mixer, and the consistency may be adjusted thereafter. Application should be done
by hand troweling or dry packing into vertical and overhead cracks to fill all pores and voids .Finally, a suitable coating to be applied
on the repaired surfaces.

One of the potentially effective repair procedures is to inject epoxy under pressure into the cracks. The injection procedure will vary,
subject to the application and location of the crack(s), with horizontal, vertical, and overhead cracks requiring somewhat different
approaches. The approach used must also consider accessibility to the cracked surface and the size of the crack. Cracks can be
injected from one or both sides of a concrete member. If access is limited to only one side, installation procedures may include
variations in epoxy viscosities, injection equipment, injection pressure, and port spacing to ensure full penetration of epoxy into the
crack. Depending on the specific requirements of the job, crack repair by epoxy injection can restore structural integrity and reduce
moisture penetration through concrete cracks 0.002 in. (0.05 mm) in width and greater. However, before any concrete repair is
carried out, the cause of the damage must be assessed and corrected and the objective of the repair understood. If the crack is
subject to subsequent movement, an epoxy repair may not be applicable.