Cracked masonry is more than a cosmetic defect — it is often a symptom of underlying movement, thermal expansion, moisture ingress, or structural stress. Left untreated, cracks can lead to loss of structural stability, increased water penetration, and accelerated deterioration of the façade.

Our crack stitching process is a non-invasive structural reinforcement method designed to restore the tensile strength of the masonry without dismantling the wall. This makes it an ideal solution for live buildings where minimising disruption and preserving the original appearance is a priority.

Step-by-step approach:

1. Cause Identification:
2. We begin with a structural assessment to determine the cause of the cracking — whether it’s settlement, thermal movement, lintel failure, corrosion of embedded steel, or inadequate support.
3. Precision Slot Cutting:
4. Horizontal slots are cut into the mortar bed along the line of the crack using dust-controlled tools to protect occupants and maintain a clean work area.
5. Stainless Steel Helical Bar Installation:
6. High-tensile stainless steel reinforcement bars are inserted into the slots. These bars are engineered to flex with building movement, preventing the crack from reopening.
7. Grout Bonding:
8. A thixotropic cementitious or resin-based grout is injected to encapsulate the reinforcement and bond it to the surrounding masonry.
9. Mortar Repointing:
10. Slots are finished with colour-matched mortar to ensure the repair blends seamlessly into the existing façade.

Applications include:

• Stabilising cracked brick and block walls.
• Repairing failed archways and window lintels.
• Strengthening retaining walls and parapets.
• Localised façade repairs without full reconstruction.

We use marine-grade stainless steel to guarantee long-term corrosion resistance, even in coastal environments. Where appropriate, we integrate the repair with other façade works such as repointing, waterproofing, or concrete patching, ensuring a complete and lasting remediation.

The result is a structurally sound wall that maintains its original character and withstands future building movement — without the cost and disruption of full rebuilds.

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If you’re ready to get started, we're ready to help.

Take the next step and let’s build something that lasts.

📞 Call Us: 0410 515 509

✉️ Email Us: hello@atomicprojects.com.au

— Ben Tran, General Manager, Atomic Projects

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