How to Repair Concrete Cracks in Tanks and Structures
Concrete tanks and structures are the backbone of many industrial operations. Over time, environmental stresses, chemical exposure, and heavy use can cause cracks to form, putting your assets, safety, and compliance at risk. Addressing these cracks early with the right repair techniques prevents costly leaks, structural failures, and unplanned downtime.
Why Prompt Concrete Crack Repair Matters
Even small cracks in concrete can escalate into bigger problems if left untreated. Water intrusion, chemical attack, and freeze-thaw cycles can all widen cracks, accelerate deterioration, and compromise the integrity of tanks, secondary containment, or other structures. Fast, effective repair prevents these issues, prolongs asset life, and helps maintain regulatory standards.
Step-by-Step Tips for Concrete Crack Repair
1. Assess the Crack
- Inspect thoroughly: Identify whether the crack is structural (affecting load-bearing capacity) or non-structural (surface-level or cosmetic).
- Measure width and length: Cracks wider than 1/16 inch or that are growing require immediate attention.
- Check for active leaks: If water or chemicals are seeping through, prioritize containment and repair.
2. Clean and Prepare the Area
- Remove debris: Use a wire brush, vacuum, or compressed air to clear out dust, loose concrete, and contaminants.
- Dry the area: For best adhesion, ensure the crack and surrounding surface are dry before applying repair materials.
3. Choose the Right Repair Method
- Epoxy Injection: For structural cracks, low-viscosity epoxy is injected to bond and seal, restoring strength and preventing water ingress.
- Polyurethane Injection: For cracks with active leaks, water-activated polyurethane expands to seal and stop water flow—even under pressure.
- Surface Patching: For non-structural or surface cracks, polymer-modified cementitious materials or advanced patching compounds provide lasting repairs.
- Carbon Fiber Reinforcement: For high-stress areas or recurring cracks, carbon fiber composite wraps add structural strength and chemical resistance without major downtime.
4. Apply the Repair System
- Follow manufacturer specs: Mix and install materials carefully, using injection ports for deep cracks or trowel-applied compounds for surface repair.
- Ensure full penetration: Especially for injection repairs, make sure the product fills the entire crack to prevent hidden voids.
- Cure and inspect: Allow time for the repair to cure fully, then inspect to ensure the crack is completely sealed.
5. Protect and Maintain
- Apply coatings or linings: For tanks and chemical containment, use chemical-resistant coatings or NSF 61-approved linings to further protect from future attack.
- Schedule regular inspections: Monitor repaired areas for new cracks or signs of movement.
RAK’s Approach to Concrete Tank & Structure Repair
RAK Industrial Services specializes in rapid, non-disruptive repairs for concrete tanks, secondary containment, and structural assets. From emergency leak sealing and advanced epoxy injections to carbon fiber reinforcement and protective coatings, our solutions restore integrity, minimize downtime, and keep your operations compliant.
Our 24/7 rapid response and proven materials ensure every repair is built to last—even in the harshest industrial environments.
Conclusion
Concrete cracks in tanks and structures don’t have to lead to major headaches or shutdowns. With proactive inspection, expert repair methods, and advanced materials, your facility can maintain safe, reliable, and long-lasting infrastructure.
