Plan staple quantities before drilling and grouting. Choose units, spacing rules, and waste allowance quickly. Get totals, hole counts, and printable field sheets instantly.
Effective stitched length = Crack length + 2 × End extension. It adds coverage beyond visible crack ends to improve anchorage.
Intervals = ceil(Effective stitched length ÷ Staple spacing). Staples per line = Intervals + 1. This places a staple at both ends and maintains spacing.
Total staples = Staples per line × Number of crack lines. Recommended purchase = ceil(Total staples × (1 + Waste%)). Drilled holes = Recommended purchase × 2.
Begin by mapping the crack path and measuring its centerline length. Note changes in direction, branching, and nearby reinforcement. For long repairs, break the line into segments and confirm access for drilling, cleaning, and grout injection. Record substrate thickness, delamination, and exposure conditions, site conditions to support staple spacing decisions and product selection.
Staple spacing controls load transfer across the crack and limits future opening. Many specifications set a maximum spacing and require additional staples near high‑stress regions such as corners, openings, and joints. End extension adds reinforcement beyond visible crack tips, reducing stress concentration and improving anchorage. Where cracks are active, consider joint movement, temperature cycles, and whether routing and sealing is also required.
The calculator converts your crack length, spacing, and end extension into an effective stitched length. It then counts equal intervals along that length and adds one staple to place reinforcement at both ends. Multiply by the number of crack lines, then apply a waste allowance to cover bends, misdrilled holes, and damaged staples. Use the waste factor to match your fabrication method, site constraints, and crew experience.
Each staple typically uses two legs and a bridge width, so fabrication length affects logistics and cost. The optional steel length and weight estimates help order bar stock and plan cutting. Drilled holes are twice the purchased staple quantity, guiding crew time, bit consumption, and dust control planning. Confirm that embedment clears cover requirements and does not conflict with embedded utilities or post‑tensioning hardware.
Before installation, verify bar diameter, leg embedment, and hole diameter against the repair design. Maintain consistent drilling angles, clean holes thoroughly, and use the specified grout or epoxy system. Document measured crack lengths, installed quantities, and any field adjustments for closeout and warranty records. A simple photo log of each stitched segment can reduce disputes and supports future monitoring of crack activity.
Use the spacing required by your repair detail or engineer. If a range is given, start with the maximum allowed and tighten near corners, openings, or high‑stress zones. Smaller spacing increases reinforcement but also drilling time and material.
Cracks often propagate beyond what is visible. Extending the stitched length past each end reduces stress concentration at the crack tip and provides better anchorage for the staples, improving long‑term performance under load and vibration.
It calculates an effective stitched length, divides by spacing, rounds up to a whole number of intervals, then adds one staple. This places staples at both ends while keeping intermediate spacing at or below your input value.
Typical allowances are 5–15%. Use the low end for shop‑bent staples with controlled drilling, and the high end for tight access, hard concrete, or when field bending and cutting are expected.
No. The weight output is for procurement and logistics only. Structural adequacy depends on the repair design, embedment, grout/epoxy properties, and substrate condition. Always follow the project specification and verify assumptions with the engineer.
Yes. Increase the number of crack lines to match how many separate stitched runs you will install. If cracks vary in length or spacing, run the calculator for each case and sum the recommended purchase quantities.
| Crack length | Spacing | End extension | Lines | Waste | Staples per line | Recommended purchase | Drilled holes |
|---|---|---|---|---|---|---|---|
| 6.0 m | 0.30 m | 0.15 m | 1 | 10% | 22 | 25 | 50 |
| 18.0 ft | 1.0 ft | 0.5 ft | 2 | 8% | 20 | 44 | 88 |
| 12.0 m | 0.40 m | 0.20 m | 1 | 5% | 32 | 34 | 68 |
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.