Cracks in concrete, brick, stone, wood

Fill holes and cracks, fill joints, stitch across cracks

Property Repair Systems - 01626 331351 - speak to real people about cracks in masonry

 

 

 
     

Crack Filling in Wood and Masonry - structural repair with Epoxy Primer and Epoxy Moldable Putty

How to fill Cracks and Holes - a summary of the crack filling method

1. Grind or cut out the crack to make a clean slot at least 15mm x 15mm in section.

2. Remove all dust by brush or vacuum.

3. Prime with Epoxy Primer and place Moldable Epoxy Putty or, for bigger holes, pour in Structural Epoxy Pouring Resin, which is self beveling.

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How to choose a crack repair method and material

General principle - cut out the cracks with a saw, Router, masonry grinder, or Allsaw, to form square edged slots, and remove all dust and debris. Avoid V shaped slots - the repair will be much weaker.

Repair Thickness - the more material that we can put in to the repair, in terms of width and depth, the better it will be able to accommodate natural movements caused by changing temperatures and therefore the better it will last.

Caution - Always consult a Structural Engineer and the building's Insurers before proceeding.

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Fine to medium cracks - hairline to 15mm wide.

Cut out to - 15mm to 25mm in width

Apply Epoxy Primer liquid by brush and whilst tacky lay in the putty-like repair mortar, Moldable Epoxy Putty.

Epoxy Primer - available in 500cc and 1 litre, two pot, liquids.

Moldable Epoxy Putty - available in 500cc and 1 litre, two pot, putties.

Cut out cracks to a clean slotMixing Mouldable Epoxy Putty - natural colour

Slot correctly cut out, square shouldered, dust blown out, ready to Prime and Fill.

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Larger holes and cracks - over 15mm wide

Cut out to - 20mm plus in width - can fill holes of any size.

Pour or inject Structural Epoxy Pouring Resin.

Structural Pouring Resin - available in 1 litre, 2.5 litre and 7.5 litre packs, containing two liquids and a powder.

Pouring Structural Epoxy Resin - paddle mix with an electric drillJoist end repair - pouring epoxy resin

Shutter Box and dug out timber. Pouring Structural Pouring Resin. Small Joist Repair.

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For cosmetic matching of colour or texture - you can add your own Site dust or chippings to the surface, (or ask for our Mortar Colour

Powder), which you can mix into Moldable Epoxy Putty, used as a surfacing finish.

Apply Epoxy Primer liquid by brush and whilst tacky lay in the putty-like repair mortar, Moldable Epoxy Putty.

Epoxy Primer - available in 500cc and 1 litre, two pot, liquids.

Moldable Epoxy Putty - available in 500cc and 1 litre, two pot, putties..

Mouldable Epoxy Ptty - mixed in the gloved hand - shown in its natural colourMouldable Epoxy Putty coloured Red using our Colouring Powder - only a pinch is required

Mixing Moldable Epoxy Putty in the gloved hand. Coloured Red with Colouring Powder.

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Brickwork Stitching - masonry stitching with epoxy rods and epoxy resin

Brickwork Stitching - epoxy resin injection method

Cut out every third mortar course 250mm each side of the vertical crack with an angle grinder, to 2/3rds of the brick/block or stone depth. Remove all debris and dust. Injection a bead of Thixotropic Epoxy Resin or Thixo Rapid One Pack Resin and insert the epoxy/glass rod into the resin. Push the rod inwards using a screwdriver or a spare length of rod. Apply another bead to cover. Re-point in a matching material. Always consult a Structural Engineer and the building's Insurers before proceeding.

Putting a stitch of Epoxy Glass Bar into a brick mortar joint

Inserting an Epoxy-Glass Rod Stitch into Thixotropic Epoxy Resin

Fill the vertical crack with flexible Thixotropic Epoxy Injection Resin - this is available in 400cc packs with cartridge kits, for easy use in a standard skeleton gun.

Thixotropic Epoxy Injection Resin - available in 400cc, two pot, with cartridge kit.

Thixo Rapid Injection Resin - available in 280cc, single tube, fits standard skeleton guns.

Epoxy-Glass Rod - available in 6, 8, 10, 12, 16mm diameters x 1 metre lengths.

 

Epoxy glass rods are available in a wide range of sizes

Thixotropic Injection Resin, Epoxy-Glass Bars, 400cc Skeleton Gun

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Joint Filling - floor to wall joint repair with primer and cementitious filler

Floor to wall Joint Filling

Cut out the floor to wall joint, in the floor itself, with a masonry grinder or disc cutter, to form a square edged slot and remove all dust and debris. Wet out the slot with fresh water and prime with BondAcryl.

Cut out to - 20mm plus in width - can fill a slot of any size.

Insert a waterproof pointing mix of either Fillet Seal (supplied as a powder) or BondAcryl mixed with sand and cement (no water).

Fillet Seal Powder - available in 25kg packs, or use Bondacryl with your own washed sand and cement - supplied in 2.5, 5.0 and 25 litre bottles.

 

Concrete floor meets brick wall - open damp jointQuarry tile floor meets brick wall - needs 'tanking' below the damp proof course

Typical floor to wall joint problems - cut out the floor edge and fill. May require 'tanking' as well.

 

Mix up a mortar of 4:1 sharp, washed sand with fresh Portland Cement, using BondAcryl instead of water. Apply the mix to the primed slot and finish flush.

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Wall Reinforcement - masonry 'stitching' with stainless rods and cementitious mortar

Wall Reinforcement Stitching - cement based grouting method

Cut out the cracks with a masonry grinder to form square edged slots and remove all dust and debris. Wet out the slot with fresh water and inject the shrink compensated repair mortar, W60, using the Grout Master plastic applicator. Insert a length of stainless steel helical reinforcement bar, as per our Method Statement (available free, on request). Apply further W60 Grout to fill the crack. Finish using the Finger Trowel. Always consult a Structural Engineer and the building's Insurers before proceeding.

Helical stainless Steel Bar in a brick joint

Helical Bar used in Stitching

How to stitch a brick joint, step by step

Repair Steps

Supplied complete as a Crack Filling Kit - Grout Master Applicator, Finger Pointing Trowel, W60 Grout, Mixing Paddle, or the materials and tools can be purchased individually.

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Crack Injection - crack stabilisation using injected epoxy resins - injecting hollow patches

Crack Injection

To treat delamination or hollowness, drill a 5mm - 10mm diameter hole into the crack every 100mm to the depth of the separation between layers. (hollow area). Inject Epoxy Primer or Thixotropic Injection Resin until it exudes from the next hole. Test for hollowness with a plastic hammer until the delaminated areas cease to sound hollow.

Injecting hollow render over tanking using syringes and Epoxy Consolidator

Injecting cracks in masonry using a syringe. Syringes - in 10cc, 20cc and 50cc sizes.

Epoxy Primer Consolidator - available in 500cc and 1 litre, two pot, liquids.

Thixotropic Epoxy Injection Resin - available in 400cc, two pot, gels, with cartridge kit.

Thixotropic Epoxy Injection GelInjecting a wall with Thixotropic Injection resin

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Crack Restraint - wall stabilisation using lateral ties

Lateral Wall Ties

The best treatment for external masonry, brick, and stone, that has bulged due to inadequate support. Always consult a Structural Engineer and the building's Insurers before proceeding.

Steps:

  1. Check the location of the joists by lifting a floor board
  2. Drill a test hole to check alignment is central to the joists
  3. Drill a hole every 500mm along the wall
  4. Drill through the masonry hole to create a pilot hole in the joists
  5. Screw the Lateral wall Ties into the joists until below the outer wall
  6. Inject resin to bond the Ties into the outer wall leaf
  7. Re-point the holes

Lateral ties fitted to bulging walls, to restrain brickwork

Installing lateral ties to restrain bulging, cracked walls

Available in various lengths to suit different wall thicknesses

Always consult a Structural Engineer and the building's Insurers before proceeding.

Wall crack repair requires an assessment of the building to determine the reason for the cracking. Wall repair using our Crack Repair Kit or other crack repair products is easy, provided that we have eliminated the underlying cause. To repair brickwork, repair wall masonry or to stabilise a cracked wall ring for free technical advice.


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Site written by: David Moore

David Moore, B.A. (Hons.), C.T.I.S., C.R.D.S. Technical Author

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