Description
CONCRESIVE INJECTION RESINS are two component crack injection fluids for sealing cracks, filling cavities and voids in concrete and stopping water ingress. They can be injected into cracks of varying sizes including cracks too fine to be filled with traditional materials.
Types and primary uses
CONCRESIVE INJECTION RESINS are available in three grades each formulated for a specific purpose, applied by two distinct methods of injection.
CONCRESIVE 1315 (Rebond LV)
A two component epoxy resin system based on low-viscosity resins. Ideal for sealing static cracks from widths greater than 100 microns but not more than 9mm. It is highly penetrative and cures to form a permanent seal against ingress of corrosive fluids and gases and is capable of restoring integrity to structural elements. (Use Method 1 or 2).
CONCRESIVE 1320 (Rebond UR)
A two component polyurethane system for the effective sealing of live cracks. Cures to form a flexible and impermeable seal where further limited movement of concrete is anticipated. (Use Method 2).
CONCRESIVE 1335 (Rebond UW)
A two component moisture reactive polyurethane which expands to form a closed cell foam when in contact with water.
Typical applications
Repair and sealing of various types of concrete cracks including static, limited movement cracks (live) and where there is water ingress or leakage. The injection resins can be used to fill and bond static dormant and dynamic cracks in:
- Columns
- Bridge decks
- Floors
- Piers
- Abutments
- Tunnels
- Basements
- Beams
- Underpasses
Advantages
Low viscosity
- Will penetrate deeply into cracks and cavities.
- For horizontal cracks with widths of 1mm and greater, CONCRESIVE 1320 can be simply poured in.
Excellent adhesion
- CONCRESIVE INJECTION RESINS have superior adhesion to dry and damp surfaces.
Versatile - CONCRESIVE 1315 will enable a structural repair to be effected whilst CONCRESIVE 1320 will offer a flexible seal to enable limited structural movement. CONCRESIVE 1335 will block the passage of water until such time as a more permanent seal can be made.
Impervious - CONCRESIVE 1315 and 1335 will resist hydrostatic pressure and block penetration of deleterious substances.
Chemical resistance - CONCRESIVE INJECTION RESINS will resist commonly encountered solutions such as sewage, sea water, alkalis, dilute acids, ammonia, formaldehyde, mineral and vegetable oils, animal fats and corrosive gases.
Pre-packed and easy to use - Materials are pre-weighed and require only on site mixing. (Bulk packaging available)
Solvent free - Can generally be used in confined spaces without ventilation.
Physical and technical properties*
|
CONCRESIVE 1315 |
CONCRESIVE 1320 |
CONCRESIVE 1335 |
Composition |
2 part solvent free epoxy resin |
2 part liquid polyurethane |
2 part liquid polyurethane |
Specific gravity of mixed material |
1.05 |
1.06 |
1.05 |
Pot life (1 ltr) |
53 mins 25°C 30 mins 40°C |
45 mins 25°C 20 mins 35°C |
6 hrs 35°C No contact with water or humidity |
Tack free time |
6½ hrs 25°C 3 hrs 40°C |
|
n/a |
Final cure |
10 days (35°C) |
7 days (35°C) |
Will cure in contact with water |
Service temp. range |
-20°C to +60°C |
-20°C to +80°C |
-20°C to +80°C |
Bond strength (mean shear slant) ASTM C-881 |
2 days : 21N/mm² 14 days :>46N/mm² |
n/a |
n/a |
Compressive strength |
68N/mm² at 24 hrs 70N/mm² at 3 days 71N/mm² at 7 days |
n/a |
n/a |
Tensile strength (ASTM D 638) |
21N/mm² at 3 days 22N/mm² at 7 days |
2 N/mm² |
n/a |
Flexural strength |
54N/mm² at 24 hrs 70N/mm² at 3 days 85N/mm² at 7 days |
n/a |
n/a |
Volatile content % |
1.5% |
n/a |
n/a |
Absorption 24 hours |
0.2% |
n/a |
n/a |
Shrinkage (ASTM C881) |
Passes |
n/a |
n/a |
Permeability (cured resin) |
Impermeable |
Impermeable |
Impermeable |
Elongation at break ASTM D638 |
n/a |
60-80% |
n/a |
Modulus of elasticity (DIN 53457) |
n/a |
4.2-4.6N/mm² |
n/a |
Shore "A" hardness DIN 53505 |
n/a |
60-80 |
n/a |
Chemical resistance
CONCRESIVE INJECTION RESINS have excellent resistance to most aqueous substances and liquids. These include:
- Sea water
- Brackish water
- Effluent and raw sewage
- Acids of low concentration
- Alkalis
- Oils (mineral and organic)
Application methods
Method 1
Areas where cracks occur but which are not substantially affecting the integrity of the concrete or structure i.e. sealing to prevent further deterioration through the ingress of harmful substances.
Method 2
Where cracks have developed and require absolute restoration of structural integrity i.e. pressure sealing to ensure total bond between interfaces or where injection of CONCRESIVE 1335 is required to stop the ingress of water.
It is strongly recommended that the services of an injection specialist are used for this method.
In each method of injection, all cracks to be treated should be flushed out with clean, dry, oil free compressed air or inert gas (nitrogen). This should be done after drilling of injection holes or fixing nipples.
Where loose mortar or aggregate exists these should be neatly routed out into a small U groove and the dust blown out.
Method 1
Figure 1 : Sequence of operations
Untreated crack in face of wall. Crack cleaned and injection nipples bonded on. Crack sealed with CONCRESIVE 2200 or 1418 and ready for injection. CONCRESIVE injection grout system injected, nipples removed, and surface sealed. Concrete wall. Crack. Injection nipples. Adhesive securing nipple. Vertical application
Pre-drill holes into the crack to a minimum depth of 15-25mm. The centres of these drilled holes should be set apart approximately 1 -1.5 times the depth of the crack. (approx. 150-300mm)
Note:
If cracks are very fine, drilling should be avoided as the dust produced may block the fissures and interfere with the injection process.
Attach nipples with flange attachments over these centres and bond with either CONCRESIVE 1418 or CONCRESIVE 2200.
If concrete members are cracked on both sides those nipples set in the rear should be sited midway relative to those at the front (in instances where the thickness of the member and width of the crack will possibly inhibit the penetration of grout, Method 2 should be considered). Once all nipples have been bonded the cracks are then sealed at the surface with either CONCRESIVE 1418 (which will cure sufficiently in 2-3 hours) or CONCRESIVE 2200 (which should be allowed to cure overnight). It is obviously imperative that cracks be sealed on both sides.
Injection
Thoroughly blend and mix the 2 components (Part A & B) ensuring a uniform colour is achieved. Pour the mixed material into the INJECTION GUN and insert into the lowest point. Inject material until it seeps out of the nipple above. Blank the first nipple and continue the injection process in the nipple above.
Repeat the process until the whole length of the crack has been injected. Ensure that injection is effected at a steady rate. Allow to cure overnight and remove nipples. Repair any blemishes with either CONCRESIVE 1418 or CONCRESIVE 2200.
Figure 2: Injection sequence
Injection gun Plastic tube Crack BASF-ME sealing compound CONCRESIVE 2200 or CONCRESIVE 1418 Flanged injection nipple CONCRESIVE injection grout Horizontal application
For simple applications such as horizontal slabs, wider cracks can be filled simply by pouring in CONCRESIVE 1315 or 1320. It may be necessary to make a small surface reservoir with mastic or a similar product by applying around the crack perimeter. This will avoid spillage and wastage of CONCRESIVE 1315 or 1320.
Method 2
Using a percussion drill with a 10mm bit, drill access holes on either sides of the crack at 45° angles to the centre of the plane of the crack. The drill is to pass through the centre of the crack plane at a depth of half the slab thickness (A-B) = ½CD. Holes are drilled at regular intervals on both sides of the crack. (See Figure 3).
Using an angle grinder, cut a groove 3-5mm deep over the crack. Clean the groove and fill with CONCRESIVE 2200. Build the CONCRESIVE 2200 2-3mm thick over the crack, extending 15-20mm either side of the crack.
Figure 3 : Concrete section illustrating angles of entry and depths of drilling
Corresponding holes on opposite sides of crack shall be midway relative to each other and the distance from crack to access hole should be half the thickness of the concrete member. (Refer to Figure 3).
Figure 4 : Concrete member in plan illustrating positioning of access holes
Distance between crack and access holes(A-B) (B-C) to be approximately half the thickness of the section. Distance between access hole (A-A) & (C-C) to be approximately the thickness of the section. The back side of the member is sealed where possible using either CONCRESIVE 1418 or CONCRESIVE 2200 and allowed to cure. The proprietary injection needle is inserted and the fastening nut is tightened. The supply line from the injection pump is connected to the fastened needle and pumping commences (from the bottom upwards in vertical members). Depending on the depth and width of the crack a pressure ranging from 50-150 bar is suitable.
The injection resin is forced out at the interfaces of the crack ensuring total contact between interfaces. Additionally all voids, subsidiary cracks and other vacant spaces are filled and sealed.
Pumping of the resin continues until resin exudes from the crack on either side of the access hole. The injection needle is removed and the access hole temporarily plugged. The process is then repeated in an adjacent access hole.
After initial cure of the CONCRESIVE resin the temporary corks are removed and the access holes are permanently plugged to their full depth using CONCRESIVE 2200 or similar.
Injection to stop water ingress:
CONCRESIVE 1335 will stop the flow of water as it foams and cures. When the water ingress stops, start injection with CONCRESIVE 1320. Sufficient CONCRESIVE 1320 should be pumped through and out of the crack to ensure all water and dust is removed.
Allow 48 hours for the concrete to dry if CONCRESIVE 1315 is to be used as the secondary resin. Blowing out with nitrogen may assist.
Watchpoint
It is strongly recommended that the services of an injection specialist are used for Method 2.
Before sealing or injecting any materials, it is important to ascertain why and how the cracks originated, this will significantly affect the selection process of repair materials. All cracks should be thoroughly cleaned to ensure a strong bond develops between interfaces. Equipment should be cleaned immediately following use with cleaning solvent. Estimation
1 litre will fill 1m² at 1mm thickness.
Packaging
CONCRESIVE INJECTION RESINS are all packed in pre - weighed 1 Iitre units. Larger packs are available upon request.
Specification clause
All cracks and voids, where indicated shall be injected with CONCRESIVE INJECTION RESINS (specify) as manufactured by BASF-ME, or similar approved. The appropriate material shall be mixed and placed in accordance with the manufacturer's recommendations.
An BASF-ME technical representative or approved applicator should be consulted to assist with on-site recommendations etc.
Storage
Store under cover out of direct sunlight and protect from extremes of temperature. In tropical climates the product must be stored in an air conditioned environment.
Safety precautions
As with all chemical products, care should be taken during use and storage to avoid contact with eyes mouth, skin and foodstuffs (which can also be tainted with vapour until product fully cured or dried). Treat splashes to eyes and skin immediately. If accidentally ingested, seek immediate medical attention. Keep away from children and animals. Reseal containers after use.
Note
Field service, where provided, does not constitute supervisory responsibility. For additional information contact your local BASF representative.
BASF reserves the right to have the true cause of any difficulty determined by accepted test methods.