METHODOLOGIES & STANDARDS
At EG CORE, we apply precision-engineered injection methodologies to restore structural integrity and provide permanent waterproofing solutions. Our techniques are designed for maximum penetration and long-term durability.
Cracks in structural components, whether dry or moderately damp, can be effectively filled from the surface to restore load-bearing capacity. To facilitate a successful injection process, rigorous preparation is required. We utilize high-grade injection packers which are bonded into place at precise intervals corresponding to the depth of the crack, up to a maximum of 60 cm.
Crucially, the cracked surface must be sealed to withstand injection pressure. If the crack is accessible from both sides, sealing is performed on both faces to ensure full penetration. For cracks deeper than 60 cm, we deploy specialized adhesion packers to optimize the filling process. On horizontal or slightly inclined surfaces, we utilize gravity-fed systems, often making a precision cut along the crack’s line to introduce the injection compound and maintain a continuous, void-free flow.
To fill damp, moist, and water-bearing cracks and cavities in components, channels are drilled at a specific angle intersecting the crack or cavity. The spacing between these drilled channels should be half the depth of the crack, up to a maximum of 60 cm. This ensures that the injection compound—typically an expanding polyurethane or structural resin—reaches the furthest points of the void, displacing water and creating a permanent, high-strength seal. This method is the industry standard for deep structural repair where moisture is a persistent factor.
To fill water-bearing construction joints or expansion joints, there are two methods: using drilled channels or injection hoses. When injecting via drilled channels, holes are made at a specific inclined angle crossing the joint or at a 90° angle through the rear material. In the case of construction joints, the intervals between the holes should correspond to half the thickness of the component, up to a maximum of 60 cm.
However, for expansion joint injection work, significantly larger packer intervals are possible, depending on the flow path configuration. For more detailed instructions and guidance, it is recommended to refer to the application instructions specific to the injection material being used.
To address dampness in components, two methods can be used for sealing: curtain injection from the outside or the provision of a barrier membrane (both horizontal and vertical). In the curtain injection approach, injection holes are drilled through the component to introduce the necessary materials for sealing. Alternatively, relevant joints can be crossed with injection holes to implement the barrier membrane. Both methods aim to effectively seal and protect the components from dampness and water infiltration where external excavation is impossible.
ENGINEERING RESOURCE
Surface injection is limited to visible, dry cracks. Drilled channels allow us to intercept cracks inside the concrete core. This is critical for water-bearing cracks, as the angle of the drill ensures the resin meets the water source directly, displacing it and reacting with it to create a pressurized, watertight seal.
By drilling through the component into the soil-side interface, we inject low-viscosity Acrylic Gels. These materials permeate the soil immediately adjacent to the concrete, solidifying into an elastic, impermeable "curtain." This creates a secondary barrier membrane that prevents hydrostatic pressure from ever reaching the concrete surface.
Construction joints are static; they require a high-strength seal. Expansion joints are dynamic and move with thermal changes. For expansion joints, we use highly elastic polyurethanes with high elongation properties, ensuring the seal remains intact even as the structure expands and contracts.
For deep-section concrete, we employ staged injection using high-pressure adhesion packers. We monitor the flow from adjacent packers; once resin emerges from the next packer in the sequence, it confirms that the void has been fully saturated. This sequential travel verification guarantees zero internal voids.
We analyze Moisture Level, Temperature, and Chemical Exposure. For instance, in sewerage structures, we utilize resins with high chemical resistance to prevent degradation by hydrogen sulfide or other aggressive agents present in the environment.
When the methodology is matched correctly, it is a permanent structural restoration. Epoxy injections have a higher tensile strength than the original concrete, "welding" the crack. Waterproofing PU resins are non-biodegradable and designed to last for the remaining service life of the structure.
Absolutely. For floor slabs, we often use gravity-assisted resin feeding. By cutting a small 'V' groove along the crack, we create a reservoir that allows the material to seep deep into the slab. We supplement this with pressure injection for heavy-duty industrial floors.
Depending on the material, initial set can happen in as little as minutes (for fast-foaming PU) to a few hours (for structural epoxies). Most structures are fully operational within 24 hours. We can stop active water flow instantly using ultra-fast reacting catalysts.
