ACI 224.1R, ASTM C881, ASTM C882, ICRI Technical Guidelines 310.2R, ACI 318

• Map all cracks by location, orientation, width (feeler gauge), and pattern; photograph all locations.
• Classify each crack: structural (>0.010") vs.
• non-structural (moving, cosmetic).
• Assess root cause: differential settlement, overload, shrinkage, thermal movement, or rebar corrosion.
• Submit written crack survey report before beginning injection work.

• Blow out crack with oil-free compressed air; plug any voids or spalls adjacent to crack face.
• Seal crack face between injection ports with epoxy paste cap; allow cap to cure before injecting.
• For active water cracks: inject hydrophilic PU foam first to stop water, then epoxy after.

• Install surface-mounted ports at 6"–12" o.c.
• along crack; closer spacing for narrow deep cracks.
• Inject starting from lowest port (bottom-up); continue until epoxy emerges from adjacent port.
• Cap injected ports; allow full cure (24–48 hours minimum) before loading injected element.

• Hydrophilic PU foam: for cracks with active water infiltration; expands 20–30× on water contact.
• Hydrophobic PU: for permanently dry environment where elasticity is needed.
• Do not use PU for structural load-transfer — epoxy required for structural applications.

Post-injection core (at EOR request): drill through crack to verify fill continuity. Maintain injection log: port locations, materials, pressures, and volumes injected per crack.