Purpose: To investigate the structural cracks seen on the columns, beams and slabs of a

Tourist Hotel Building in Paharganj and suggest material solutions for restoring the integrity
of the structure.
Method Statement for repair of structural members
i.

ii.

iii.

iv.

v.

Surface Preparation:
Concrete should be a minimum of 3-4 week's old. Surfaces should be sound, clean
and free of oils, grease or other contaminants. Laitance should be removed from
concrete by mechanical means.
Crack treatment upto 15mm wide
Such cracks need to be treated by cutting out a groove 30mm (wide) x 5mm (deep)
and filling them with our Epoxy repair mortar, DURAXY RM 100. This will take
approximately 4-6 hours for initial curing.Incase, the crack is through a wall or slab,
cracks at both thesides must be sealed in similar fashion.
Treatment of spalled cracks greater than 5mm (both in case where
reinforcement is exposed and not exposed)
Remove the unsound material in cracks upto sound surface of concrete member. The
rust, laitance, dust should be removed and scarified properly. This is followed by
applying one coat of Duraxybond (epoxy bonding agent). While the surface is still
tacky, apply DURAMICROKRIT NS (Non sag high strength micro-concrete) to fill
the patch and flush it along the member face. This should be followed by water curing
to allow strengthening of cementitious materials. This may take around 2-3 days.
Injection of corrosion inhibitor
Drill holes into the crack of diameter higher than the grouting nipples upto a depth of
atleast 1/3rd ofstructural member. Insert injection nipples / nozzles in to the drill holes
at a 400mm C/C interval along the length of the member. Pump the corrosion
inhibitor, DURACOROBIT at an injection pressure around 1 kg/cm2 until refusal.
Injection of low viscosity Epoxy grout
a) Mixing: Mix all the hardener (slightly ambered coloured Pack B) into slight
yellow coloured base (Pack A) and mix well. Mix so as not to entrap air into
the product. Mix for 2-3 minutes, using drill and paddle (max. 500 RMP) until
smooth consistency and homogeneous mixture of uniform colour is achieved.
Mix only sufficient material for immediate requirement, leave the thoroughly
mixed material to stand for 2 or 3 minutes to enable entrapped air to escape
from the mix and then use as quickly as possible.
b) Hole Drilling:Drill holes into the crack of diameter higher than the grouting
nipples upto a depth of at lease 1/3rd of structural member. Insert injection
nipples / nozzles in to the drill holes at the intervals along the length of
member.The distance between each nipple shall be kept at 400 mm C/C

toensure that the resin penetrates along the cracks till the next point of
injection.
c) Epoxy injection:Thereafter,Epoxy injection grout Duraxygrout LV may be
injected with steady pressure 2 kg/cm2 until refusal or material starts flowing
from adjacent port. As soon as the system has cured, the nipples can either be
removed or cut. It usually takes around 3 days to develop 70-80% of ultimate
28 day mechanical properties.
d) Nipple Alignment-One end of the injection hose shall be attached to the
lowest nipple on vertical cracks or to either endof the horizontal cracks. Hence
DURACOROBIT and DURAXYGROUT LV shall be injected in alternative
ports until refusal.

DURACOROBIT
200mm
DURAXYGROUT LV
400mm

200mm
DURACOROBIT
200mm
DURAXYGROUT LV

Fig: Injection pattern

NOTE FOR TERRACE ONLY: After injection grouting of terrace, apply 2 coats of
DURAGARD (Polymer modified breathable cementitious waterproof coat) @ 2.5
kg/m2reinforced with glass fiber mesh on the mother slab. This should be followed by 12mm
protective plaster admixed with integral waterproofing compound (DURATITE) @ 200 ml
per bag of cement.