REPAIR WORK – Concrete Damage Solutions

Concrete structures often develop weak zones due to improper construction practices, environmental wear, or structural stress. These defects, if not addressed, can lead to severe leakages and compromise structural integrity. Aquaseal offers tailored repair solutions based on the nature of the defect and intensity of water ingress.

Common Types of Concrete Defects:

  1. Cold Joints
    Formed when there’s a delay between concrete pours, preventing proper bonding. These become potential weak points in the structure.

  2. Construction Joints
    Occur where one concrete pour ends and another begins (e.g., between slabs or beams). Load transfer is managed using keys or dowels, but they require sealing to prevent leakage.

  3. Honeycombs / Voids
    Caused by insufficient compaction, leaving hollow spaces that allow water to pass.

  4. Cracks
    Result from improper mix design or inadequate curing, which leads to shrinkage and water ingress.

  5. Tie Rod Holes
    Formed during shuttering; these are common leak spots and must be filled correctly.

  6. Pinholes
    Small surface imperfections due to air bubbles or poor de-shuttering technique.

Moisture Entry Classification:

  1. Dampness
    Slight moisture visible on the surface — can be arrested using cementitious plugs.
  2. Seepage
    Intermittent dripping of water — requires cementitious or epoxy grouting for effective sealing.
  3. Leakage
    Continuous, high-pressure water flow — best treated using PU injection grouting for rapid sealing.

Recommended Repair Solutions

1. Cementitious Repair Mortars

Used for repairing weak zones in dry or SSD (Saturated Surface Dry) conditions.

Types:

a) Polymer Modified Mortar

  • Components: Cement, sand, SBR latex, water

  • Mix Ratio: 1C : 3S : 0.15 SBR : 0.2W

  • Primer (Bond Coat): 1 Part SBR + 1 Part Cement

  • Pin Hole Filler: 5 Parts Cement + 500 ml Latex + 500 ml Water

b) Crystalline Mortar

  • Reacts with unhydrated cement and water to form waterproof crystals

  • Mix Ratio: 4-4.5 Powder : 1 Water

  • Coverage: 1–1.5 kg/RMT (25x25mm repair)

  • Primer Coat: 3 Powder : 1 Water

c) Epoxy Mortar

    • Solvent-free, 3-component repair mortar

    • Mix Ratio: 1:1:1

    • Coverage: 2 kg/mm/sqm

      2. Cementitious Repair Plugs

      a) Crystalline Plug (e.g., Penetron-Peneplug)

      • Used during active leaks

      • Mix: 1 kg Powder + 250 ml Water

      • Permanent waterproofing

      b) Polymer Plug (e.g., Fosroc Renderoc Plug)

      • Temporary fix for dampness

      • Mix: 3 Part Plug + 1 Part Water

        3. Cementitious Grouting

        Fills internal voids using pressure pumping of cement slurry + admixtures.

        Admixtures:

        • PRAH (for Hydrostatic Conditions)
          E.g., Penetron Admix
          Mix: 1 kg Cement + 500 ml Water + 10g PRAH

        • PRAN (for Non-Hydrostatic Conditions)
          E.g., Fosroc Cebex 100
          Mix: 1 kg Cement + 500 ml Water + 4.5g PRAN

          4. Resin Injection Grouting

          a) PU Injection Grouting

          • Used for active leaks

          • Reacts instantly with water

          • 1K System: Con Repair CYH-500

          • 2K System: Sika-201 CE

          • Mix: As per manufacturer (usually 1:1)

          b) Epoxy Injection Grouting

          • Slower setting, used for structural strength

          • Rigid, with excellent bond strength

          • Not ideal for flexible applications

Key Notes Before Application:

  • All repair areas should be in SSD condition.

  • Primer coat is essential before applying repair mortars.

  • Proper surface preparation ensures effective bonding and long-lasting repairs.

Repair work
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