METHOD STATEMENT

Sika® Crack Injection, structural

30.04.2021 /VERSION 5 / SIKA UK / STEPHEN ARMFIELD

WATERPROOFING
TABLE OF CONTENTS
1 Scope 3
2 Description 3
2.1 Limitations 3
3 References 3
4 Products 3
4.1 Material Storage 3
5 Equipment 4
5.1 Injection equipment 4
6 Health and safety 6
6.1 Personal protection 6
6.2 First aid 6
7 Environment 7
7.1 Cleaning Tools / Equipment 7
7.2 Waste disposal 7
8 Substrate preparation 7
9 Installation of Packers 8
9.1 Injection Via Drill Hole Packers 8
9.2 Injection Via Surface Packers 9
10 Mixing 9
11 Injection 10
11.1 Structural repair of dry, damp, wet (without hydrostatic pressure) and even oily cracks 10
11.2 Application Limits 11
12 Inspection, Quality Control 12
13 Disclaimer and adress of Sika Company 12
14 Key Words 12

Method Statement
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1 SCOPE
This method statement describes the step by step procedure for structural crack repair by injection.

2 DESCRIPTION
This method statement describes the structural (= force transmitting) crack repair of dry, wet and even oily cracks
by means of epoxy resin injection via packers and injection pumps.

2.1 LIMITATIONS
◼ Products shall only be applied in accordance with their intended use.
◼ Local product differences may result in performance variations. The most recent and relevant local Product
Data Sheets (PDS) and Material Safety Data Sheets (MSDS) shall apply.
◼ All work shall be carried out as directed by a supervising officer or a qualified specialist.
◼ Not all products are available in local countries.
◼ Crack filling by gravity – pouring – can also be done with Sika® Injection-400 Series and Sikadur®-52. As a
simple application procedure this is not handled in this Method Statement.

3 REFERENCES
To ensure correct application of all components of Sika® Injection and Sikadur®, please refer to
PDS (Product Data Sheet) and MSDS (Material Safety Data Sheet) of each product component.

4 PRODUCTS

Sika Products Description key words

Sikadur®-52 Epoxy-based, compact, high strength

®
Sika Injection-458 injection resins with low viscosity for durable
structural crack repair.
Sika® Injection-456
(example picture)

Epoxy-based, compact, high strength

®
Sikadur -31 CF putty for durable crack patching.
(example picture)

4.1 MATERIAL STORAGE

Materials shall be stored properly in undamaged original sealed packaging, in cool, dry conditions.
Refer to specific information contained in the product data sheet regarding minimum and maximum
storage temperatures.

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5 EQUIPMENT

5.1 INJECTION EQUIPMENT

1-Component Injection pump equipped with high pressure hose
and ball valve.

A handgun valve is convenient and safe.

Piston pumps and diaphragm (airless) pumps are recommended.

Nipple-gripper for round-head nipples (4 claws recommended).

Connection between pump and Sika® Injection Packer Type MPS.

The nipple-gripper shall be replaced periodically

as the seal wears through normal usage

Sika Surface Packer, ø= 44mm → Sika® Injection Packer SP 44

Mixing Paddle (plastic, steel, wooden)

Depending on the quantity

Driller:
Diameter: depending on packer (+1mm wider than the packer)
Length : >250mm depending on structure

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 Impact drill (we recommend Hilti)

Tool box with screwdrivers, wrenches, ratchet set

(Diameter 6mm up to 24mm), tongs, etc.

Battery drill (we recommend Hilti)

Clean buckets

Measuring cups

Cleaning towels

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6 HEALTH AND SAFETY

6.1 PERSONAL PROTECTION

Work Safely!

Handling or processing injection products can cause chemical

irritation to the eyes, skin, nose and throat.

Appropriate eye protection should be worn at all times while

handling and mixing products.

Safety shoes, gloves and other appropriate skin protection must

be worn at all times.

Always wash hands with suitable soap after handling products and
before food consumption.

In addition to protective clothing it is also recommended to use a barrier cream on the skin. If any injection resin
gets on clothing, remove the garment at once. The friction of resin-saturated fabric on the skin can cause serious
chemical burns. Wash your exposed skin occasionally during the workday and immediately if any material gets on
it. Avoid using solvents, since they can help material penetrate into the skin and solvents themselves are
aggressive and harmful to the skin. Avoiding skin contact by keeping tools and equipment clean is one of the best
ways to protect oneself. Despite safety precautions, with any instances of skin contact rinse immediately with
clean warm water and use soap to thoroughly clean the skin.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

6.2 FIRST AID

Seek immediate medical attention in the event of excessive inhalation, ingestion or eye
contact causing irritation. Do not induce vomiting unless directed by medical personnel.

Flush eyes with plenty of clean water, occasionally lifting upper and lower eyelids. Remove
contact lenses immediately. Continue to rinse eye for 10 minutes and then seek medical
attention.

Rinse contaminated skin with plenty of water. Remove contaminated clothing and continue to rinse for 10 minutes
and seek medical attention.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET OF THE CORRESPONDING PRODUCT!

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7 ENVIRONMENT

7.1 CLEANING TOOLS / EQUIPMENT

Tools and equipment used for mixing and applying Sika® Injections can be cleaned according to the PDS Sika®
Injection Cleaning Systems.

Sika Products
Description Key words
Injection Material
Cleaning agent for cleaning injection pumps during
Sika® Injection Cleaner C1
or directly after the injection
Very strong cleaning agent for cured resins. It can
Sika® Injection Cleaner C2 be used to remove cured resins from tools and
pump parts. Not for pump cleaning.
Cares for the valves and seals of a pump if the
Sika® Injection Conservator
pump will not be used for a long time.

7.2 WASTE DISPOSAL

Do not empty surplus material into drains. Dispose responsibly through a licensed waste disposal
contractor in accordance with legislation and local / regional authority requirements. Avoid run-off
into soil or waterways, drains or sewers.

Hardened resins can be disposed of with other combustible waste in a waste incineration plant. Under no
circumstances burn the resin in an open fire, due to the potentially dangerous gases which could be released.
Uncured resin must be disposed of as hazardous waste. It is forbidden to mix it with conventional waste.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

8 SUBSTRATE PREPARATION
Cleaning of the surface helps the technician to identify the exact location and the width of the crack to be injected.
Sometimes the concrete surface is hidden under a surface of mineral deposits left from long-term water leakage.
Items that obscure the crack should be removed, because the crack must be seen clearly in order to lay out the
drilling patterns for the injection holes.
The cracks must be free from loose particles, dust, oil, grease or any other contamination etc.
Moisture, dampness up to non-pressing water and small amounts of oil can be tolerated if special resins are used.

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9 INSTALLATION OF PACKERS

9.1 INJECTION VIA DRILL HOLE PACKERS

In order to inject the resin into a crack that reaches into the middle of the structure, usually mechanical injection
packers are used. In some exceptional cases such as very thin structures, heavily reinforced structures, drilling
prohibited, etc. surface packers are used (see 9.2). The objective of the repair depends on the degree of
penetration (crack width/thickness). For structural repair >75% of the crack`s volume must be filled.
The correct installation is very important to ensure a continuous injection and durable crack repairing results.

Drill packer holes at 45° angle to the concrete

Dimension of the drill-hole depending on the used packer

and thickness of the wall; typically 7-14 mm.

Ø of drill hole = Ø of packer + 1 mm

Drill hole depth:

~d = long enough to reach minimum the middle of the
structure under approx. 45° drilling angle

d: building component thickness

d/2: interval
- from packer to packer
- from packer to crack

Packer placing alternately on both sides of the crack.

After drilling, remove dust e.g. using oil free compressed

air. Otherwise the dust can block the fine crack branches.
Optional crack patching e.g with Sikadur®-31 CF avoids
spilling of resin and ensures the high degree of filled
volume.
Place Sika® Injection Packers in the previously drilled hole,
so that the top of the rubber sleeve is below the concrete
surface. If the packer cannot be pushed into the hole, tap
it in. Tighten the packer with a wrench. Remove the
nipples in order to check the connectivity and flow of
injection resin later on.

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 Crack patching (e.g. with SikaDur-31 CF) is necessary to
avoid spilling of the resin. It allows building up pressure in
the crack and makes sure the crack is fully filled after the
injection process.
Leave a venting hole (in vertical cracks the last packer in
the row at the highest point of the crack) for controlling
the filling progress.
Observe curing times and refer to relevant PDS.

Fix the nipple on the first (starting) packer.

In horizontal cracks the starting packer is the one at
narrowest part of the crack.

In vertical cracks the starting packer is the lowest one.

Injection can be started after patching is cured

9.2 INJECTION VIA SURFACE PACKERS

Fix the surface packer with a nail directly on the crack.
The nail will keep the injection canal open and holds the
packer until the adhesive is cured. Use epoxy adhesive e.g.
SikaDur-31 CF for installation/patching.

If surface packers are used, e.g. thin structure or when

drilling is prohibited, it must be considered that full crack
penetration is mandatory for structural repair.

Fix the nipple on the first (starting) packer.

In horizontal cracks the starting packer is the one at
narrowest part of the crack.

In vertical cracks the starting packer is the lowest one.

Injection can be started after patching is cured.

10 MIXING
Prepare the injection material according to the Product Data Sheet and fill into the pump hopper. Measure
accurately, stir briefly and use within the pot life. Prepare only that amount you are able to apply well within the
pot-life. Epoxy resins may create a lot of heat during reaction.

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11 INJECTION
The applicator should be carefully watching three points of reference:
• The crack/packers Resin flowing out of the work face.
• The pressure line For pump pulsations indicating resin flow.
• The gauge (if available) For actual injection pressure applied.

Begin the injection at the point of highest resistance to ensure good penetration and minimal loss of chemicals.
This is usually the lowest point on a vertical crack and the narrowest on a horizontal surface.

Material:
Crack filling materials for structural repair must have excellent bond to crack edges and achieve equal or even
higher mechanical values than the ambient structure.
If new cracks appear – these will show up in untreated areas beside the previously repaired crack.
Epoxy based injection resins: Sika® Injection-400 Series or Sikadur®-52 can be used (always refer to PDS).

11.1 STRUCTURAL REPAIR OF DRY, DAMP, WET (WITHOUT HYDROSTATIC PRESSURE) AND EVEN OILY CRACKS

Products: Sika® Injection-400 Series or Sikadur®-52

Start pumping Once the connection is made, start the pump and begin injecting through the
starting Sika® Injection Packer.

Injection process Injection material is now filling the packer then the drill hole (mechanical
packers) and finally the crack.

Injection can be successfully performed at the lowest possible injection

pressures. The pump should be set to the lowest level. This allows to penetrate
well into all gaps and even finest hairline fissures down to approx. 0.15 mm
(depending on the material used and application temperature).

Slow, low-pressure injections are more effective than rapid, high-pressure

injections. A successful injection will be indicated by the pump’s refusal of
injection resin (quit pumping) or by the sight of resin seeping out of any of the

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 open packers. When this happens, install a nipple at the next packer in the row
and continue the injection in this way until resin is visible at the last packer.

Within the pot-life of the resin a secondary injection should be done, ensuring
the crack is completely filled (optional).
In that case injection is started at the first packer again. All nipples except the
last one stay installed. Usually resin will immediately be visible from the
venting hole/ last packer. If not – injection has to be continued and again
controlled by a secondary injection.
Finally the last packer can also be closed and some few strokes of resin injected
at lowest pressure into it.

Attention: High injection pressure can damage the structure and can occur an
additional damage of the structure (a zip effect). For maximum injection
pressure see section 11.2.

Injection progress can be checked by monitoring injection material coming out

of the next packer.

Stop pumping After the injection is finished, close the ball valve on the pump assembly and
turn the pressure down. Disconnect the pump hose from the Sika® Injection
Packer. Stop the pump and release pressure from the hose.

Cleaning Clean pump and tools according to the PDS of Sika® Injection Cleaning System.
Uncured resins can easily be flushed out with Sika® Injection Cleaner C1.
Then fresh cleaner should be circled through the pump for at least 2 minutes.

Finish The crack is repaired after material is fully cured.

Preparing the After curing, packers can be removed

surface (e.g. knocked off). Fill drill holes with
suitable mortar/patching material.
Clean the crack surface if required.
Remove patching mechanically by
grinding and/or with hot-air-gun.

11.2 APPLICATION LIMITS

◼ Always check the material’s pot life and adjust for climate conditions. Do a hand test before injection.
◼ Best results can be achieved when the crack is widest open – e.g. cold season, early morning.

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◼ Cracks filled with water or oil must be flushed with Sika® Injection-456 prior to final crack filling. Resin mixed
with these substances has to be flushed out before fresh resin will do the job.
◼ Very high quantities of oil should be reduced by flushing with warm water/soap water before injecting starts.
◼ The maximum injection pressure can be calculated through:

Pmax. = (concrete strength x 10) / 3

Best injection results are achieved by holding a low pressure for as long as possible in order to fill all cracks,
gaps, branches and hairline fissures.

12 INSPECTION, QUALITY CONTROL

As part of “Good Practice” the contractor shall apply an inspection procedure to check the quality of the applied
repair system. This includes a hand test cup sample of the material as well as a visual inspection of the finished job.

13 DISCLAIMER AND ADRESS OF SIKA COMPANY

The information contained herein and any other advice are given in good faith based on Sika's current knowledge
and experience of the products when properly stored, handled and applied under normal conditions in
accordance with Sika's recommendations. The information only applies to the application(s) and product(s)
expressly referred to herein and is based on laboratory tests which do not replace practical tests. In case of
changes in the parameters of the application, such as changes in substrates etc., or in case of a different
application, consult Sika's Technical Service prior to using Sika products. The information contained herein does
not relieve the user of the products from testing them for the intended application and purpose. All orders are
accepted subject to our current terms of sale and delivery. Users must always refer to the most recent issue of
the local Product Data Sheet for the product concerned, copies of which will be supplied on request.

14 KEY WORDS
Sika® Injection, Cracks, Crack, Injection, Injections, Sika® Injection-458, Sika® Injection-456, Sikadur®-52, Resin,
Sikadur®-31, Epoxy, Structural, Force transmitting, Crack Repair, Refurbishment, Waterproofing.

Sika Limited Version given by

Watchmead Stephen Armfield
Welwyn Garden City Phone: +44 (0) 1707 394444
Hetfordshire Email :
AL7 1BQ [email protected]
United Kingdom
www.sika.co.uk

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