Concrete Crack Repair Sydney

Polyurethane & epoxy injection by trained technicians — stop water at the source.

Two Methods, One Right Answer

Not every crack calls for the same fix. Polyurethane injection stops water in active, wet, or moving cracks — the expanding foam seals on contact with moisture. Epoxy injection restores tensile strength in dormant cracks where the concrete needs to act as one monolithic element again.

Applying the wrong product makes things worse: rigid epoxy in a moving crack creates new fractures beside the repair line. Every Econyc job starts with a free crack assessment before any drilling begins.

Matching Method to Condition

Polyurethane Injection

Hydrophilic PU resin for active, wet, or moving cracks. Reacts on contact with water and remains flexible after cure — ideal for basement walls and slab joints.

Epoxy Injection

Rigid, high-strength epoxy for dormant structural cracks in dry substrates. Cures to compressive strength exceeding parent concrete.

Diagnosis First

Every job starts with a free site assessment — crack width, moisture, movement, and structural significance evaluated before any injection begins.

Why Concrete Cracks — and Why It Matters

Concrete is strong in compression and weak in tension. Every structure experiences tension through thermal movement, shrinkage, loading, and settlement. A hairline crack in a basement wall can transmit thousands of litres of groundwater per year. An untreated crack in a parking deck widens under traffic, admits chloride-bearing water, and initiates reinforcement corrosion — costing 10–50× more to repair at the spalled stage than at first detection.

Crack Assessment Before Any Repair

Active or dormant? An active crack continues to move. Filling it with rigid epoxy transfers stress to adjacent concrete, creating new cracks. A dormant crack has stopped moving and can be filled rigidly. Wet or dry? Wet cracks need hydrophilic polyurethane; dry structural cracks need epoxy. Structural? Cracks in load-bearing elements need an engineer’s assessment before repair.

Polyurethane Injection — Step by Step

  1. Ports (surface packers) fitted at 150–300 mm centres along the crack.
  2. Crack surface sealed between ports with epoxy paste.
  3. PU resin injected at the lowest port first, continuing until resin appears at the next port up.
  4. Ports progressively capped; process repeated to the top of the crack.
  5. After cure (30–60 min), ports removed and face dressed.

Epoxy Injection — Step by Step

  1. Crack cleaned with compressed air to remove dust, moisture, and contamination.
  2. Surface ports adhered at regular intervals; crack surface sealed between ports.
  3. Low-viscosity epoxy injected at very low pressure (0.2–0.5 MPa) to allow complete penetration.
  4. Epoxy cured for 24–72 hours before structural loading.

Comparison: Polyurethane vs Epoxy

FactorPolyurethaneEpoxy
Primary purposeWater sealingStructural restoration
Crack conditionWet or dry, active or dormantDry and dormant only
After-cure flexibilityFlexible / elasticRigid
Structural strength addedNegligibleSignificant
Sydney cost guide$150–$300 per lin. metre$200–$500 per lin. metre

Compliance & Documentation

Structural crack repairs should conform to AS 3600 and the repair material manufacturer’s specifications. Econyc provides full documentation — material data sheets, injection pressures, volumes injected, and a signed waterproofing certificate for your records and certifier.

Crack Letting Water In? We'll Stop It.

Free site assessment · Fixed-price quote · 5-year injection warranty