Prof S K Singh - Repair of Cracks

5/8/2015
Repair of Cracks in Concrete Structures- A Proper

Understanding of Materials and Methodologies
S. K. Singh
Principal Scientist & Associate Professor
CSIR-Central Building Research Institute
Roorkee-247 667 Uttarakhand
sksingh_cbri@yahoo.co.in; sksingh@cbri.res.in
Training Programme on
NDT Analysis and Repair of Concrete Structures
NITTTR Chandigarh , May 07 - 08, 2015
Outline
General introduction
Classifications of cracks
Case studies
Discussions
Conclusion
SK Singh, CSIR-CBRI, Roorkee
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Introduction
Cracks develop when the applied

stress exceeds tensile strength
Types:
(i) Nonstructural cracks
(ii) Structural Cracks
Non-structural cracks
Caused due to internally induced

stresses
Usually do not endanger the safety of a
building
Look unsightly-Give impression of:
(i) Faulty work
(ii) Poor workmanship
(iii) Instability of building/components
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Principal Causes of Non-structural cracks
Moisture Movement: reversible (movement

of water from pores) and non reversible
movements (expansion of burnt clay
bricks on removal from kilns)
Thermal Variations: Restrained movements

due to rise or fall of temperature
(foundation may offer restrain to
superstructure)
Elastic deformation: Excessive deflection

or rotation of structural components
Principal Causes of Non-structural cracks

Creep: Time-dependent long-term deflections
in concrete and brickwork.
Chemical Reaction: AAR/ASR
Sulphate attack: (Soluble sulphates +ground water
+ C3A + Lime + Water = Expansive Products)
Carbonation: (CO2 + Moisture = Carbonic Acid +
CaOH2= CaCO3)
Results in shrinkage cracks
Lowers alkalinity of concrete increasing
susceptibility of rebars to corrosion
Usually confined to surface layers
Vegitations
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Vertical Cracks in the Side Walls

The cracks are due to thermal
expansion aggravated by
moisture of brickwork,
noticed in hot weather.
The cracks start from the DPC

level and travel upward, are
straight and pass through
masonry joints and there is a
difference in the level on the
two sides of the cracks. Such
cracks occur in buildings
constructed in cold weather. VERTICAL CRACKS AT COPRNERS IN THE SIDE WALLS
OF A LONG BUILDING DUE TO THERMAL MOVEMENT
vertical cracks near the quoins in the front elevation of a

long building having short return walls
the cracks are due to thermal expansion and occur when

adequate provision for movement joint has not been made
in the buildings. these cracks start upward from DPC
level.
X C
A X
ELEVATION THIS END OF WALL A HAS DUE TO

EXPANSION OVERSAILED AT DPC LEVEL
AND CAUSED ROTATION OF RETURN
WALL B. RESULTING IN CRACKS AT X
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VERTICAL CRACKS BELOW OPENINGS IN LINE WITH

WINDOW JAMBS
These cracks are due to vertical shear caused by differential strain

in the lightly loaded masonry below the opening and heavily
loaded portion of wall having no openings.
FIG. : FLEXURAL TENSION CRACK IN WALL MASONRY
VERTICAL CRACKS AROUND STAIRCASE OPENING

AND BALCONIES
These cracks are caused by drying shrinkage and

thermal movement in a building and occur around
staircase openings because of weakening in the wall
and floor at the staircase portion of the building. These
cracks are generally not very conspicuous.
VERTICAL CRACKS IN THE EXTERNAL WALL AROUND STAIRCASE OPENINGS OF A BUILDING
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HORIZONTAL CRACKS IN THE TOP MOST STOREYS

BELOW SLAB LEVEL
These cracks are due to deflection of slab and lifting up of
edge of slab, combined with horizontal movement in the
slab due to shrinkage. The cracks appear a few months
after construction and are more prominent if the
span is large. These cracks are mainly on the top
most storeys because of light vertical load on the wall due
to, which end of slab lifts up without encountering much
restraint.
FIG. : CRACKING IN TOP MOST STOREY LOAD

BEARING BUILDING
horizontal cracks in the top most storey above the slab

level when seen from outside and inside
These cracks are caused due to thermal expansion of slab
accompanied by bowing up which occurs due to thermal gradient
in the slab.
FIG. : HORIZONTAL CRACKS IN TOP MOST STOREY SLAB FIG. : HORIZONTAL CRACKS IN TOP MOST STOREY
DUE TO SHRINKAGE AND DEFLECTION OF SLAB SLAB DUE TO ARCHING & EXPANSION OF SLAB
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Foundation Movement & Settlement
CRACKS AT THE CORNER OF A BUILDING

DUE TO FOUNDATION SETTLEMENT
Cracks Due to Foundation Movement & Settlement of Soil
Cracks due to Vegetation Growth
CRACKING OF A COMPOUND
WALL DUE TO GROWING OF
TREE ROOTS UNDER THE
FOUNDATION
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Corrosion of Reinforcing Bars
Heavily corroded reinforcing bar
Spalling of Cover Concrete

Foundation Movement
Shear Crack due to local settlement
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Honeycombing in Concrete
Typical voids in concrete

Plastic Shrinkage Cracks

Occur in1 to 8 hours after
placing of concrete
Due to loss of water by
evaporation from surface of
concrete
Due to suction by dry concrete
below
Controlling Measures/ limiting loss of moisture
Covering fresh concrete with polyethylene sheets
Using curing compound immediately after concreting
Using wind breakers to reduce wind velocity
Concreting in low temperature environment
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Crazing in Concrete
It consists of fine random cracks on concrete surface

It takes place when surface layer of concrete has a
higher moisture content than the interior concrete
Higher surface moisture content may be due to over
vibration causing paste migrating to the top of surface
Cracks due to Alkali Silica Reaction
Sufficient Sufficient
Alkali moisture
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Curling of Concrete Pavement
Typical corner
of a pavement
Corner
cracking
Widely observed crack pattern in pavement

Caused due to differential shrinkage between the top
and interior regions of the slab
Differential shrinkage causes lifting of corners
Corners crack when loaded
Cracks in Building
Diagonal cracks emanating from the
corner of electrical boxes needs only
patch repair.
Sinking of Ground floor this give rise to

crack or a gap between the skirting and
flooring. These cracks and gaps shall be
thoroughly cleaned repaired using
cement + sand + Acrylic emulsion.
Treatment of roof terraces: Clean to

avoid stagnation of water leading to
A B
B
seepage through roofs. DIAGONAL CRACKS IN CROSS WALLS OF
MULTI-STOREYED LOAD BEARING STRUCTURE
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Structure: The structure as a whole has excellent

aesthetic appearance. Structurally, the cause of cracks
are due to differential settlement and hence a and suitable
treatment is needed.
Separation of walls at left of entrance at the roof Inside crack at left of the junction of
level.(Outside front view). Further separation can be entrance and the front wall at the roof level
arrested by bonding the junction. Restoration can be (front view). Its remedy is plastering after
made by grouting bolts running through both the walls ensuring the proper bond at the junction
INSIDE CORNER CRACK AT ROOF LEVEL AT THE JUNCTION CRACK AT THE JUNCTION OF THE SOUTHERN
OF SOUTHERN PROJECTED PORTION (ZOOM VIEW) WALL AND THE ROOF
CRACK AT THE JUNCTION OF THE SOUTHERN SEPARATION OF RIGHT OF ENTRANCE AT THE ROOF LEVEL
WALL AND THE ROOF (ZOOM VIEW) (OUTSIDE FRONT VIEW)CRACK AT THE JUNCTION OF TWO WALLS
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CRACK PROPAGATED TO ABOUT 25-35 MM SINCE 2ND OCTOBER

1996. A SIGN OF THE SOUTHERN FOUNDATION SETTLEMENT
TELL-TALE PLACED AT THE WALL IN SOUTH
DIRECTION IN SOUTHERN PROJECTED
CRACKS IN THE BRICK PILLAR OF THE WEST FACING

SOUTHERN PORTION CRACKS ARE WIDE AT THE TOP
CRACKS IN THE FLOOR OF THE SOUTHERN GALLERY,
AND NARROW AT THE BOTTOM A SIGN OF THE
A SIGN OF THE SOUTHERN FOUNDATION SETTLEMENT
SOUTHERN FOUNDATION SETTLEMENT
THE PROBLEMS OF LEAKAGE, VEGETATION GROWTH,

DISPLACEMENT OF PROJECTIONS, AGEING OF MATERIALS,
CORROSION OF IRON COMPONENTS
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Repair of Cracks in Masonry

Removal of cracked portions of masonry walls etc.
piers and rebuilding them in richer mortar
preferably in non-shrinking mortar.
Addition of reinforcing wire mesh on both faces of
the cracked walled, holding it to the wall through
spikes or bolts and then covering it, suitably, with
cement mortar or micro-concrete.
Injecting modified cement or epoxy grout into
cracks in walls.
The cracked reinforced cement elements may be
repaired by epoxy grouting and could be
strengthened by epoxy or polymer mortar
application like shot-crating, jacketing, etc.
After filling the cracks, the exposed surfaces were

chipped and cleaned
A layer of cement slurry/ bond coat

Cage for ferrocement/Application of mortar
Accidental gap filled with viscous mortar
Mortar Mix
Cement : sand - 1 : 2.5/3.5
w/c ration - ~ 0.45
MSA of FA - ~ 3.35 mm
Wire Mesh
Galvanized square woven high strength wiremesh
Dia - 0.79 mm
Opening - 10/12.5 mm
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Non-structural and/ architectural components get easily

affected / dislocated. These repairs involve one or more
of the following:
Patching up of defects such as cracks and fall of plaster;
Repairing doors, windows, replacement of glass panes;
Cracking and repairing electric conduits / wiring;
Checking and repairing gas pipes, water pipes and
plumbing
Re-building non-structural walls, smoke chimneys,
parapet walls, etc;
Re-plastering of walls as required;
Rearranging disturbed roofing tiles;
Relaying cracked flooring at ground level; and
Redecoration white washing, painting, etc.
These architectural repairs do not restore the original

structural strength of structural components.
Structural Cracks
Structural Cracks occur due to:

(i) Incorrect design
(ii) Incorrect detailing of reinforcement
(iii) Faulty Construction
(iv) Overloading of structural system
(v) Disaster- Natural & Manmade
These cracks will endanger the safety of

the building directly
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Characteristics of Cracks
Most building materials are weak in

tension and shear (Tensile strength
typically 1/10 of compressive strength)
Even small magnitude forces causing

tension or shear in a component can cause
cracking
Classifications of Structural Cracks
Based on width:
(i) Thin-less than 1 mm in width
(ii) Medium-1 to 2 mm in width
(iii) Wide-More than 2 mm in width
(iv) Gaping cracks-5 mm or more in width
Hair-line cracks visible to human eye are

usually 0.01 mm in width
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Classifications of Structural Cracks
Based on nature:
(i) Behaviour: Active or dormant
(ii) Depending on width: uniform width,
narrower at ends, narrow at one end and
widening at other
(iii) Geometry: straight, toothed, stepped, map
pattern or random
(iv) Orientation: horizontal, vertical, diagonal
Allowable Cracks as IS 456:2000
Maximum allowable crack width

0.3 mm (protected internal members
under normal exposure condition);
0.2 mm (unprotected external members)
(Limit State of Serviceability)
Maximum allowable crack width

Aggressive Environment: 0.1 mm
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Concrete Pavements
Well designed and constructed concrete

pavements -larger maintenance free life
Fast construction-Advancement in paving

technologies/
Concrete shrinkage and temperature changes-

two major mechanisms leading to initial crack
formation and joint opening
Pavements have a much larger surface area

compared to other structural members such as
beams and columns
Design Aspects of Pavements

Design Parameters Specs. of NH Roads
Compressive strength (MPa) 40

Flexural Strength (MPa) 4.0-4.5
Spacing of Transverse Joints (m) 4.5-5.5
Spacing of Longitudinal Joints (m) 4.0-5.0
Thickness (mm) 250-350
Dowel Bar (Load transfer)-Transverse 25 & 450 mm long
Joint spacing 200-250
Tie bars (Longitudinal Joints) 16 HYSD
L=450 &200-250 c/c
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Concrete Pavements
Changes in weather, wind speed, delayed grove
cuttings, improper curing compounds may cause
early age cracking in concrete.
Even after assuring all quality control measures,

cracks have been found in PQC construction
Potholes have appeared in few roads probably

because of lumps of soil left in aggregates
Improper compaction of sub-base leads to

differential settlement
Concrete Pavements- Construction
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Texturing
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Plastic Shrinkage Cracks (Green Concrete)

Loss of water by evaporation from concrete
surface
ambient temperature,
relative humidity
wind velocity
Plastic shrinkage cracks can be very deep, width
( 0.1 to 3 mm) and can be quite short or as long
as one meter.
To reduce plastic shrinkage - application of
curing compound immediately after paving
RH>50%, Wind Speed< 10 Km/hr, Temp<30 C
Plastic Shrinkage Cracks
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Drying Shrinkage and Cracking
Drying shrinkage- Reduction in volume

caused by loss of water during the period
when initial hardening in concrete takes
place.
Carbonation shrinkage (minor importance)
Autogenous shrinkage
Shrinkage of concrete varies concrete

composition, source of aggregate, ambient
relative humidity
Quality Measures During Construction
OPC-43 grade cement with low heat of

hydration should be used.
Cuing compound-To reduce excessive drying

during initial phases
Moist curing-Covered with polyethylene
sheets- long duration
Reduce in friction between PQC and DLC-A

polythene sheet to be provided
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Repair using Epoxy Injection Grouting
Used to seal cracks as

narrow as 0.05 mm.
Restores the concrete

to its pre-cracked
strength.
Requires use of special

moisture tolerant
epoxies in case of
actively leaking cracks.
Surface
Preparation
Installation of
Entry and
Venting Ports
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Mixing of
Epoxy
Injection of
Epoxy
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Epoxy Injection Grouting
Pouring of Epoxy
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Before Grouting After Grouting


EPOXY GROUTING
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Polymer Modified Cement Grouting
Used for repair of wide

cracks.
Effective method in stopping

water leaks.
Grout material consists of

OPC-43 grade, non shrink
high bonding admixture, latex
or other polymer and water.
Application of Cement Grouting

DRILLING OF
HOLES
CLEANING OF HOLES
AND FIXING OF
NOZZLES
MIXING OF MATERIALS AND

FILLING OF GROUT GUN
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Application of Cement Grouting

GROUTING IS DONE TILL
NOZZLE REFUSES TO
ACCEPT GROUT
CURING OF MATERIAL
FOR 24 HOURS
CUTTING OF NOZZLES
AND SEALING OF
SURFACE
Stitching and Grouting
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Routing and sealing
This method involves enlarging the crack

along its exposed face and filling and sealing it
with a suitable joint sealant
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MEASURES FOR CONTROLLING CRACKS DUE TO SHRINKAGE
Cracking due to shrinkage normally affects mainly the appearance and

finish. Cracking in walls get localized at weak sections, such as doors, window
openings or staircase walls, In external walls of buildings, shrinkage cracks
generally run downward from window sill to plinth level and from window sill
on an upper storey to the lintel of a lower storey.
Shrinkage cracks in masonry could be minimized by avoidable use of rich
cement mortar in masonry and by delaying plaster work till masonry has dried
after proper curing and has undergone most of its initial shrinkage.
Masonry work done with composite cement lime sand mortars (1:1:6,
1:2:9, or 1:3:12).
In all concrete jobs, water cement ratio, grading & quality of aggregates,
use of calcium chloride as accelerator, duration, method & temperature of
curing, presence of excessive fines in aggregates, etc.
To minimize shrinkage cracks in plastering/rendering, composite cement-
lime mortar of 1:1:6 mix or weaker for plaster work is less liable to develop
shrinkage cracks.
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In load-bearing structures, when a roof slab undergoes alternate expansion

and construction due to gain of heat from the sun and loss of heat by radiation
into the open sky, horizontal cracks (i.e. shear cracks) may occur in cross
walls. If movement of slab is restrained on one side of some heavy structure
and insulation or thickness of protective cover on the roof is inadequate,
cracking will be much more severe.
To prevent cracks in such situations, a slab should be provided with
insulation or protective cover on the top, and span of slab should not be very
large.
Slip joint should be introduced between slab and its supporting wall as well
as between slab and cross walls.
Also further either the slab should project for some length from the
supporting wall or the slab should bear only a part width of the wall.
On the inside, wall and ceiling plaster should be made discontinuous by a
groove about 10 mm in width (Fig.)
Instances of very frequent occurrence of thermal cracks combined with
shrinkage in buildings, is the formation of horizontal cracks at the support of
a brick parapet wall.
MEASURES FOR CONTROLLING CRACKS DUE TO

VEGETATION GROWTH
DO NOT LET TREES GROW TOO CLOSE TO
BUILDINGS, COMPOUND WALLS, GARDEN WALLS, IF
SOIL UNDER THE FOUNDATION IS CLAY /
SHRINKABLE SOIL. IF SOME LARGE TREES EXIST
CLOSE TO A BUILDING AND NOT CAUSING ANY
PROBLEM, DO NOT DISTURB THESE TREES.
IF A NEW SITE HAVING A LOT OF VEGETATION
INCLUDING TREES AND THE SOIL IS SHRINKABLE,
REMOVE THE VEGETATION AND DO NOT
COMMENCE THE CONSTRUCTION ACTIVITY ON
THE SOIL UNTIL IT HAS UNDERGONE EXPANSION
AFTER ABSORBING MOISTURE AND HAS
STABILIZED.
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5/8/2015

Repair of Cracks in Concrete Structures- A Proper

SK Singh, CSIR-CBRI, Roorkee

Cracks develop when the applied

SK Singh, CSIR-CBRI, Roorkee

Caused due to internally induced

SK Singh, CSIR-CBRI, Roorkee

Principal Causes of Non-structural cracks

Moisture Movement: reversible (movement

Thermal Variations: Restrained movements

Elastic deformation: Excessive deflection

SK Singh, CSIR-CBRI, Roorkee

Principal Causes of Non-structural cracks

SK Singh, CSIR-CBRI, Roorkee

Vertical Cracks in the Side Walls

The cracks start from the DPC

SK Singh, CSIR-CBRI, Roorkee

vertical cracks near the quoins in the front elevation of a

the cracks are due to thermal expansion and occur when

ELEVATION THIS END OF WALL A HAS DUE TO

SK Singh, CSIR-CBRI, Roorkee

VERTICAL CRACKS BELOW OPENINGS IN LINE WITH

These cracks are due to vertical shear caused by differential strain

FIG. : FLEXURAL TENSION CRACK IN WALL MASONRY

SK Singh, CSIR-CBRI, Roorkee

VERTICAL CRACKS AROUND STAIRCASE OPENING

These cracks are caused by drying shrinkage and

VERTICAL CRACKS IN THE EXTERNAL WALL AROUND STAIRCASE OPENINGS OF A BUILDING

SK Singh, CSIR-CBRI, Roorkee

HORIZONTAL CRACKS IN THE TOP MOST STOREYS

FIG. : CRACKING IN TOP MOST STOREY LOAD

horizontal cracks in the top most storey above the slab

SK Singh, CSIR-CBRI, Roorkee

Foundation Movement & Settlement

CRACKS AT THE CORNER OF A BUILDING

Cracks Due to Foundation Movement & Settlement of Soil

SK Singh, CSIR-CBRI, Roorkee

Cracks due to Vegetation Growth

SK Singh, CSIR-CBRI, Roorkee

Corrosion of Reinforcing Bars

Heavily corroded reinforcing bar

Spalling of Cover Concrete

Shear Crack due to local settlement

SK Singh, CSIR-CBRI, Roorkee

Typical voids in concrete

Plastic Shrinkage Cracks

It consists of fine random cracks on concrete surface

SK Singh, CSIR-CBRI, Roorkee

Cracks due to Alkali Silica Reaction

SK Singh, CSIR-CBRI, Roorkee

Curling of Concrete Pavement

Widely observed crack pattern in pavement

Sinking of Ground floor this give rise to

Treatment of roof terraces: Clean to

SK Singh, CSIR-CBRI, Roorkee

Structure: The structure as a whole has excellent

SK Singh, CSIR-CBRI, Roorkee

SK Singh, CSIR-CBRI, Roorkee

CRACK PROPAGATED TO ABOUT 25-35 MM SINCE 2ND OCTOBER

CRACKS IN THE BRICK PILLAR OF THE WEST FACING

THE PROBLEMS OF LEAKAGE, VEGETATION GROWTH,

SK Singh, CSIR-CBRI, Roorkee

Repair of Cracks in Masonry

After filling the cracks, the exposed surfaces were