Crack injection

As crack injection shall be understood the filling of cracks in reinforced concrete buildings or brickwork by means of grouting with mineral based materials or resins.

Cracks in concrete can be caused by several different reasons, like setting or shrinking of the concrete or mistakes in design or in construction process.

Especially water bearing cracks are the reason for corrosion on the reinforcement and jeopardize the safety of a concrete building. TPH offers secure and long term solutions for the crack injection in reinforced concrete.
All products, systems and solutions, which will be presented in the following chapters, are approved for many years on the sites and are in possession of a General Appraisal Certificate.

Sealing crack injection

Solid structure crack injection

Recommended systems – Sealing crack injection

Acrylate gel

  • Viscosity is comparable with the one of water. Thus hair cracks can be grouted successfully
  • Adjustable reaction time
  • No risk of corrosion on the reinforcement
  • High mechanical strength

RUBBERTITE®

Rubber-elastic, 3 C acrylate gel, multi purpose applicable

  • Very low viscous acrylate gel with high flexibility
  • Very good penetration, even in water filled cracks
  • Long term stable. Proven stability of at least 16 years

VARIOTITE

Adjustable, rapid-reacting 3 C acrylate gel

  • Very good elongation properties
  • for renovation of dilatation joints

Polyurethane resin

  • Penetrates even into haircracks
  • Flexible hence good movement assimilation

PUR-O-CRACK

2-component injection resin based on polyurethane

  • Officially approved system
  • Proven against water pressure of 7 bars
  • Approved for use in CHF and LMSS plants

PUR-O-RIP

2-component high flexible injection resin based on polyurethane

  • Universal and economical
  • highly flexible < -50°C

PUR-O-RIP LV

Low-viscous, 2-component injection resin based on polyurethane

  • Very low viscous
  • for hairline cracks

PUR-O-RIP PLUS

2-component resin based on Polyurethane, which foams up in contact with water

  • Slightly foamy

Recommended systems – Solid structure crack injection

Polyurethane resin

  • structural

PUR-O-STOP FS-L

2K Polyurethane resin, which foams up in contact with water. Slowly curing, from ridged to tough elastic

  • Hybrid system for sealing and solidification
  • Fully cured after 50 minutes

Epoxy resin

  • structural

HYDROPOX EP1

Low-viscous 2-component injection resin based on epoxy

  • for friction-fit filling of cracks in reinforced concrete structures
  • use also possible on moist substrates

HYDROPOX EP1 LV

Very low viscous EP resin

  • For imbuing, filling and injection of cracks

HYDROPOX EP1 HV

High viscous EP resin

  • For slender buildings
  • High viscosity adjustment avoid uncontrolled flow

Injection cement

  • For subsequent injection in non-full face mortared bed joints
  • Mixing by means of drilling machine
  • Processed without press-in tools or admixtures

F8000

Single-component injection material based on extra-fine cement

  • Very high compressive-strength
  • For injection in cracks above 0.2 mm

F9100

Minerally, single component injection glue based on trass chalk according to DIN 1060

  • For injection in dry and wet cracks >0,2 mm in brickstone and natural stone
  • No ettringite formation

F9200

Ready to use dry mixture, non shrinking.

  • Grain size 0-0,125 mm
  • For injection in cracks above 0.375 mm
  • Non shrinking

Uses

Acrylate gel for flexible crack injection

RUBBERTITE in combination with POLINIT is employed for the injection into cracks in reinforced concrete buildings. POLINIT is a flexibilisation medium on a polyacrylic basis, which is used for the blending of the B component instead of water. POLINIT increases the flexibility as well as the adhesive power of the acrylate gels to silicate surfaces.
Even capillary cracks can be compressed reliably due to the extremely low blending viscosity of RUBBERTITE/POLINIT. A fissure that has been injected with RUBBERTITE/POLINIT is able to resist a water pressure of 4 bar at the simultaneous fissure expansion of 68% in comparison to the original width of the fissure. This was proven in the course of an application technological test.

Polyurethane resin for flexible crack injection

PUR-O-CRACK, PUR-O-RIP and PUR-O-RIP LV are employed for the injection filling of cracks in reinforced concrete buildings. To achieve this purpose the fissures are initially diagonally spot drilled and high pressure packers are inserted into in the drill holes. A plugging of the crack, e.g. using the assembly cement F300 is usually necessary.

Prior to the injection procedure the single components are weighed or gauged in the prescribed mixing ratio and then blended in a special vessel or in the feed hopper of the injection pump. It is essential to ensure a homogenous (free from reams) blending. After this the injection is carried out via the high pressure packers within the processing time for the respective product with the aid of single-component injection pumps. We recommended that the injection pump CONTRACTOR 1 U and ME 1K ELEKTRISCH are employed for the processing of the Polyurethane resins PUR-O-CRACK, PUR-O-RIP and PUR-O-RIP LV.

Rectification of defective expansion and butt joints

VARIOTITE in combination with POLINIT is employed for the renovation of expansion joints. Initially the joint to be renovated is evacuated as profoundly as possible, i.e. the old joint sealant as well as the polystyrene joint filling is removed. Then the PROOFMATE E compression seal is pressed into the joint and the sealant applied with FIX-O-FLEX H. A PE back fill profile should be installed prior to the sealing process to prevent a three-flank adhesion of the joint sealant material.
When the FIX-O-FLEX H has completely hardened, the filled acrylate gel VARIOTITE / POLINIT is pressure injected into the remaining joint space. The acrylate gel can be inserted into the joint via injection packers or via a previously installed injection hose, for example, VPRESS® or ECOPRESS.
An expansion joint that has been renovated in this manner has been proven to resist a water pressure of 2 bar at a joint expansion of 48% in comparison with the original width of the joint.

Epoxy resin for solid structure crack injection

Epoxy resins are composed of polymers. By addition of appropriate hardeners the mixture results in a synthetic material, which is being used in almost all part of craft work and industry. They have the distinction of a high resistance to chemicals, long life span, low weight, high adhesion ability and low shrinkage.
Epoxy resins are used for many years as injection material for the use of water proofing. Generally they are applied into reinforced concrete structures where solidification of the structure is required.

HYDROPOX EP1 is a two component, low viscous injection resin based on Epoxy with special chemical and physical properties. Due to its low viscosity EP1 can be used successfully in reinforced structures and even penetrate hair cracks. The special formulation allows processing of EP1 even on moist surfaces.

Before injecting HYDROPOX EP1 cracks have to be pinpointed in detail and backfilled, if necessary. Afterwards, cracks gets center drilled angular and the high pressure packers get placed. For processing of HYDROPOX EP1 the components have to be mixed according to the mixing ratio and get scrambled homogenously. By means of a one component pump, e.g. CONTRACTOR 1 U or ME 1K ELEKTRISCH cracks can be grouted.

Upgrate of expansion joints with acrylate gel

Upgrate of expansion joints with joint profile and acrylate gel