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Seawall Repair with Polyurethane Foams | Plural Component vs Single Component Foam

Seawall Repair with Polyurethane Foams
Plural Component vs Single Component Foam

This article contains an excerpt from the “SealBoss Concrete Solution Network Podcast – Seawall Repair | Bulkhead Repair | Erosion Control | Permeation Grouting”, featuring Jerald Sargent of Slabjack Geotechnical. Jerald has over 30 years of experience in the slabjacking and geo-technical industry. If you’d like to listen to the complete conversation, an audio version of the podcast is posted at the bottom of the article.

In this podcast we talk about the use of single and plural component foams for seawall repairs.

Both foam types have their place in seawall repair but the contractor needs to have a good understanding of their respective characteristics and area of application.

Single component (accelerator activated) foams offer outstanding crack sealing and good soil penetrating, permeation and soil aggregate stabilizing properties.

Plural component foams are excellent void fillers, support and lifter foams, predominantly used for slabjacking and slab lifting.

Single Component Foams are Preferred for Soil Permeation and Soil Consolidation — Plural Component Foams are Good for Filling Voids in Certain Applications

In the following Jerald discusses the use and limitations of Plural Component Foam.

Jerald Sargent: …Sometimes plural components make a lot of sense… where there’s obvious gaps behind the wall or maybe in a you know in a big boulder type of Bulkhead where they just use big rock rather than poured concrete. So plural components are good for filling voids in there and helping to lock [larger] aggregate together…

In most poured concrete walls we stay away from plural component simply because of the risks associated with it.

Going right along with that, one of the things that plural component is not appropriate for is injecting underneath the walls…

There’s virtually no permeation [into the soil] involved with plural component polyurethanes. It’ll [the soil] take up, it’ll absorb a little bit push through a little bit of that but it will not do it to the point where you have a solid structure built below the wall itself.

And I think that it is really important to understand the real limitation of the plural component polyurethane. And we use hundreds of thousands of pounds of a year in our slapjack in operation.

But it really isn’t appropriate in most cases to do a poured concrete wall [soil] stabilization.

To learn more about seawall repair and single and plural component foams you may want to listen to the podcast below.

Or just call us directly at 714-662-4445.

Seawall Repair with Polyurethane Foam

Technical Podcast for the Infrastructure Repair Industry

A Concrete Solutions Network / Sealboss ® Production Podcast ©

A Conversation Between Two Industry Professionals
Episode 3

How To Podcast:
Seawall Repair | Bulkhead Repair | Erosion Control | Permeation Grouting

Podcast Details Here

SealBoss Polyurethane Grouts

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Seawall

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Polymer Soil Stabilization

A Modern Solution to Age-Old Challenges

The world of civil engineering is no stranger to the trials posed by unstable soils. From erosion and improper compaction to the effects of freeze-thaw cycles and the decomposition of organic materials, these factors can seriously compromise the structural integrity of any project. The result? Soils that shift and refuse to stay anchored, posing significant risks to structures and their foundations. For geotechnical engineers, the challenge has always been to find innovative solutions that not only reinforce the ground but also restore its ability to bear loads effectively.

Polymer soil stabilization, a cutting-edge soil injection system turn the tables on unstable terrains. Soils that were loose and unmanageable are transformed into cohesive, fortified masses. How it works: Polymeric resins, with their unique properties, seep into porous soils, filling gaps and compacting even the most stubborn terrains. This not only halts the processes of subsidence and erosion but also prevents the migration of fine particles. SealBoss offers polymer soil stabilization solutions that meet the highest industry standards.

Polymer Soil Stabilization

A Modern Solution to Age-Old Challenges

Polymer soil stabilization, a cutting-edge soil injection system turn the tables on unstable terrains. Soils that were once loose and unmanageable are transformed into cohesive, fortified masses. How it works: Polymeric resins, with their unique properties, seep into porous soils, filling gaps and compacting even the most stubborn terrains. This not only halts the processes of subsidence and erosion but also prevents the migration of fine particles. SealBoss offers polymer soil stabilization solutions that meet the highest industry standards.

The Mechanics Behind Polymer Foam Stabilization:

Permeation and Matrix Formation: The polymers permeate through loose sediments, soils, and sands, binding them together into a cohesive matrix forming a solid structure.
Erosion Control and Water Displacement: By displacing water from areas affected by erosion, they prevent further deterioration of the soil.
Void Filling and Void Management: Polymers effectively fill spaces left by decomposed organic matter or resulting from inadequate soil compaction.
Strengthening and Adhesion: Their unique ability to adhere to soil particles ensures the creation of a fortified substrate.

Performance Highlights of Polymer Soil Stabilization:

Polymer soil and sand stabilization efficiently treats unstable soils and sands in-situ, eliminating the need for excavation. These polymers compact treat loose or unstable soils, enhancing their structural strength and offering long-term stabilization. By permeating loose sediments, displacing water from eroded areas, and filling voids, they create a fortified soil matrix that resists erosion and subsidence. Additionally, NSF/ANSI/CAN 61 certification of the specific polymer foam resins ensures safety for potable water contact, emphasizing both their efficacy and environmental commitment. Geotechnical Engineers, kindly reach out to our technical team for detailed specification guidance and assistance.

Related Links:

Grout Injection Lances

Stainless Steel Grout Injection Needles

Stainless Steel Injection Needles

SealBoss Injection Needle for specialty grouting applications and product delivery into soil substrate, through small holes, Oakum Soakum Injection Technique and more. Suitable for PU, EP, Polyacrylate, and Silicate grouts.

Polymer Soil Stabilization

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Polymer

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Concrete Leveling Polyurethane Foam

Introduction to Concrete Leveling Polyurethane Foam

Concrete leveling polyurethane foam offers an innovative solution for maintaining the integrity of concrete slabs. This versatile material addresses various underlying issues that can cause slabs to become uneven or unstable.

Erosion

Erosion is a primary cause of concrete slab instability. It occurs when water washes away the soil beneath the slab. This can happen due to several factors:

Improper Property Slope: Water directed towards the slab due to a slope can erode the soil
Gutter Runoff: Inadequate drainage systems can cause water to seep into the soil
Sewer Line Breakages: Wastewater from broken sewer lines can contribute to soil erosion

Substandard Soil Compaction

The foundation of a concrete slab depends heavily on the compaction of the underlying soil. Proper soil compaction reduces the space between soil particles, creating a solid base for the slab. If this process is skipped or done incorrectly, the slab is prone to sinking over time.

Expansive Soil

Expansive soils, which swell when they absorb water and shrink as they dry, pose a significant challenge to concrete slabs. This cycle of swelling and shrinking can cause the slab to lift, sink, and eventually crack, compromising its stability and appearance.

Tree Roots

Large trees near concrete slabs can also affect their stability. Tree roots can absorb water from the soil under the slab, causing the soil to shrink. Additionally, as these roots decay after the tree’s death, voids can form beneath the slab, leading to further instability.

Understanding the Causes

Understanding the factors that lead to concrete slab issues highlights the importance of using concrete leveling polyurethane foam. This solution not only addresses the root causes of slab instability but also provides a long-lasting fix, ensuring the durability and safety of concrete structures.

The Repair Process Overview

Concrete leveling foam, a two-component, high-strength polyurethane material, is pumped beneath sinking concrete slabs, sidewalks, driveways, or patios. It provides a strong foundation by filling the void and elevating the sunken concrete while expanding. The process is also known by various terms like polyjacking, concrete lifting, slab jacking, foam jacking, foam lifting, all achieving the same goal.

The Process in Detail

Leveling and Lifting: Utilizing the concrete slab itself to deliver polyurethane foam, our method raises the concrete, fills voids, and stabilizes soils. A small hole is drilled into the slab, into which a tapered delivery port is inserted. The injection gun, connected to the port, pumps the polyurethane material through the port and slab, with the foam expanding within seconds, compacting loose soil and lifting the concrete.

This highly accurate and simple process is executed via incremental injections. The lifting foam fully expands within a brief period, allowing for monitored elevation and prevention of over-raising the concrete slab.

Applications of Concrete Leveling Foam

Void Filling: Polyurethane foam is not limited to addressing concrete settling. It can also fill voids under slabs resulting from excessive settling or washouts. It imposes 15-25 times less weight than traditional mudjacking or cementitious grout mix, easing the pressure on a failed subgrade.

Joint/Slab Stabilization: Slab stabilization is critical when slabs lack support and are susceptible to cracking under heavy loads. This specialized foam, designed for joint/slab stabilization, fills voids to provide support and eliminate movement. Its slow reaction time and minimal expansion strength allow for thorough coverage under the slab or along a joint.

Concrete Leveling Polyurethane Foam Injection vs. Mudjacking

Concrete leveling foam offers several advantages over mudjacking, a method developed approximately one hundred years ago. Mudjacking is typicall messier and requires substantial machinery to transport and pump the heavy slurry under the slab. Any spillage can result in a significant mess. Mudjacking slurry, a mixture of sand, cement, and other natural materials, weighs approximately 100 pounds per cubic foot, compared to concrete leveling foam’s weight of 2.5 to 4 pounds per cubic foot. Moreover, the much larger 2-inch holes required for mudjacking can crack the concrete slab and provide an avenue for roots to penetrate.

Unlike mudjacking slurry, concrete leveling polyurethane foam is hydrophobic, inert, and waterproof, ensuring its structural integrity remains uncompromised when in contact with water. Conversely, mudjacking slurry can wash away upon contact with water, leading to further slab sinking.

Finally, concrete leveling foam operates with rapid effectiveness and exhibits prolonged durability. Upon being injected beneath the slab, it solidifies within mere minutes. On the other hand, mudjacking demands an extended application duration and frequently yields a shorter effective lifespan, which, dependent upon environmental factors and particular conditions, may only persist between 2 to 5 years before the slab descends again. This stands in sharp contrast to the notably extended typical longevity offered by concrete leveling foam.

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SealBoss Slab Lifting Systems

Slab Lifting
Soil Compaction & Consolidation

Introduction:

Ensuring concrete structure stability often depends on addressing the underlying soil conditions. Techniques such as slab lifting, soil compaction, permeation, and consolidation injection systems provide the necessary support.

Using methods like polyurethane foam injection and permeation grouting, we can achieve efficient, non-invasive, and durable solutions for various soil and slab issues.

Slab Lifting, Soil Compaction, Permeation, and Consolidation Injection Systems

Effective void filling and slab lifting procedures can provide for stable subsoil to adequately support the structure above. If there are concerns about the subsoil’s stability, soil permeation grouting should be considered, provided the soil composition is suitable.

Slab Lifting and Void Filling

Slab lifting and void filling involve injecting structural polyurethane foam into voids beneath settling or uneven concrete slabs. This proven method stabilizes slabs without the need for excavation and adds minimal weight. Known as slab jacking, foam jacking, polyurethane concrete raising, poly jacking, or poly leveling, this technique offers several advantages over traditional mud jacking methods.

Advantages of Polyurethane Foam Injection

Non-Invasive: No need for excavation, preserving the surrounding landscape and structures
Lightweight: Adds minimal weight compared to other materials, reducing the risk of further sinking
Quick Setting: Polyurethane foam sets rapidly, allowing for quicker project completion
Durability: Provides long-lasting stability and support.

Permeation Grouting and Soil Stabilization

Permeation grouting and soil stabilization are performed by injecting a single-component, low-viscosity polyurethane hydro-active foam, catalyzed with an accelerator to specification, into the soil. This is done through injection packers, lances, or grout injection needles to consolidate and compact the substrate, increasing stability by binding soil particles together.

Procedure and Considerations

Soil Analysis: Before any permeation grouting procedure, the soil composition must be analyzed to predict the effectiveness of the treatment
Injection Process: The foam is injected into the soil to fill voids, stabilize loose soil, and enhance the load-bearing capacity of the ground
Equipment Used: Injection packers, lances, and grout injection needles are utilized to deliver the foam precisely where needed

Conclusion

Slab lifting, void filling, and permeation grouting are essential techniques for maintaining and restoring the stability of concrete structures. By using advanced polyurethane foam injections, these methods provide efficient, non-invasive, and durable solutions for various soil and slab issues. Proper soil analysis and the right application of these techniques ensure the long-term stability and safety of the structures.

Filling / Lifting / Permeation
Grouting

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Floor Joint Filler Pumps

SB JointMaster

Crafted from 30+ Years of Experience and Trusted Customer Insights

Are You in the Market for a New Floor Joint Repair Pump?

Floor joint repair pumps go by many names; Floor Joint Pump, Polyurea Joint Fill Pump, Floor Epoxy Pump, Polyurethane Floor Joint Filling Pump, etc.

Even though companies market these machines with similar vernacular, it is important to know these machines are not all the same. It is important to know exactly what material your pump is designed for in order to get the best results and not damage your machine.

Before you purchase a machine for your intended application, it always important to factor in the different attributes of your pump, before you make your final decision.

Key Factors to Consider Before Your Purchase

Function: Can it reliably pump the materials you need?

Always refer to data sheets and SDS.
Consult a technician for precise advice.

Design: Appearance matters.

A professional, sleek design boosts confidence.
Ensure there aren’t any nuts, bolts, or awkward seams protruding.

Quality: Daily use can take a toll.

Opt for machines with robust frames and superior workmanship.
High-pressure gear pumps are a must to prevent costly leaks.
Only settle for top-quality, CE-rated motors.

Versatility: Does it cater to your unique needs?

Look for options like extended battery operation, heater bands for cold environments, and additional purge valves.

Safety: Never compromise.

Ensure all moving parts are fully enclosed.
Avoid machines where the full voltage runs through the applicator wand.

Price: Seek value, not just cost.

A system’s longevity and ease of maintenance are paramount.

Introducing: The Sealboss JointMaster Pro 2

Consider the industry gold-standard, the JointMaster stands out as a third-generation professional machine.

Built on valuable customer feedback and real-world experience.
Boasts an innovative low-voltage control line, ensuring no high voltage at the applicator wand – a unique Pro2 standard.
Trusted and sold worldwide.
The SealBoss JointMaster Pro 2

Partner with SealBoss

Let us elevate your business with superior products and expertise. Maximize your investments with our high-quality range and exceptional know-how.

Questions? Need a Quote?
Connect with us at 714-662-4445. We’re here to help.

Links to JointMaster Floor Repair and Joint Filling Applications

SealBoss JointMaster

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JointMaster

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Showroom Floor Detailing – Joint Filler

Off-Road Vehicle Dealership

Showroom Floor Detailing
Joint Filler Application

SealBoss Polyurea Joint Filling System

Showroom Floor Detailing: Insights into Joint Filler Application

In the realm of construction and interior detailing, achieving the desired finish is crucial. A recent project, the construction of an Off-Road Vehicle Dealership, offers insights into this process. This article explores the initial steps taken to prepare for a polished “Showroom Finish” for the dealership’s floor, with a focus on the SealBoss Polyurea Joint Filling System.

The Vision

As the construction of the new Off-Road Vehicle Dealership neared its completion, the owner had a clear vision in mind. They desired the joints in both the showroom and the maintenance shop to be filled with a joint fill that not only exuded quality but also promised durability and flexibility. The ultimate goal? A polished floor that mirrors the high standards of the vehicles on display.

The Product of Choice

Enter the SealBoss 6500 Polyurea QuickFix Joint Filler. Recognized for its superior quality, this product was chosen to be applied using the SealBoss JointMaster Pro2, a professional joint filling machine. This machine, known for its efficiency and precision, ensured that the joint filler was applied seamlessly.

The Process

The application process was streamlined and efficient, thanks to the SealBoss JointMaster Pro2. With this machine at their disposal, a three-man crew managed to fill approximately 1,400 lineal feet of joints, each with a depth of 1 ½ inches, in a mere two hours. The crew was strategically divided, with two members operating the pump and one dedicated to joint preparation and shaving.

The Art of Joint Preparation

Joint preparation is a meticulous task that demands attention to detail. It begins with chasing and vacuuming out the joints to ensure they are free from debris. Once cleaned, a unique technique is employed. Ivory soap is used to create a bond break between the floor surface and the SealBoss 6500 Polyurea Joint Filler. This not only facilitates an easy and clean shaving procedure but also eliminates any potential “shadowing” effect, which can sometimes be observed when installing joint fillers.

Conclusion

The construction of the Off-Road Vehicle Dealership showcases the importance of precision and quality in floor detailing. With the right products and techniques, achieving a “Showroom Finish” appearance is not just a possibility but a reality. The SealBoss Polyurea Joint Filling System stands as a testament to the advancements in the field of construction and interior detailing, promising a future where aesthetics and durability go hand in hand.

More information here:

Floor Detailing | Joint Fill

Joint Filling System Products Used

Cleaning Materials: Xylene, R70 Pump Flush, rags, bucket
Additional Tools: Class 27 Deep Cycle battery, Crack Chaser, Ivory Soap bars, 6” Scraper, Access 110v Power, Vacuum

Reach Out to Your SealBoss® Expert for Showroom Floor Joint Solutions

Should you have inquiries about concrete floor joint repairs, joint filling, floor crack remedies, or any associated applications, our dedicated team of SealBoss floor repair specialists is here to assist. Schedule an on-site consultation and comprehensive system training with us. Dial 714-662-4445 to connect.

More information here:

SealBoss Joint Filling Systems

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Joint Fill

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Bridge Crack Repair

Structural Epoxy Injection with Professional Equipment

Structural Epoxy Injection & Equipment for Bridge Crack Repair

Bridges, crucial for transport and commerce, often face damage from harsh environments and heavy traffic, leading to cracks and structural issues.

A cost-effective solution is crucial for maintaining bridge safety, and structural epoxy injection has become a popular method to repair cracks and restore integrity without expensive replacements.

Structural Epoxy Injection & Equipment for Bridge Crack Repair

Bridges, crucial for transport and commerce, often face damage from harsh environments and heavy traffic, leading to cracks and structural issues.

A cost-effective solution is crucial for maintaining bridge safety, and structural epoxy injection has become a popular method to repair cracks and restore integrity without expensive replacements.

Structural Epoxy Injection:
A Reliable and Cost-Effective Solution for Bridge Crack Repair

One of the most effective ways to reinstate a concrete structure’s integrity and provide a long-lasting solution is through crack injection with structural strength epoxy resin. This method involves the use of specially formulated epoxy resins to fill and bond the cracks, improving the overall strength and stability of the structure.

Structural epoxy injection offers several benefits, including:

Cost-effectiveness: Epoxy injection eliminates the need to spend unnecessary dollars on removing old structures and installing new ones, reducing overall project costs
Time savings: Structural epoxy injection offers a quick and efficient repair process, ensuring minimal downtime and disruption to traffic
Versatility: This method is suitable for various bridge types, including concrete, steel, and masonry structures
Improved structural performance: Epoxy injection not only repairs the existing cracks but also improves the overall performance of the structure by positively effecting load-bearing capacity and resistance to environmental factors
Professional Equipment for Bridge Crack Repair: The SealBoss PA3000 Epoxy Injection Pump and SealBoss Injection Ports

To ensure the success of bridge crack repair using structural epoxy injection, it is crucial to employ professional and proven equipment that guarantees precision, efficiency, and ease of use.

The SB PA3000 epoxy injection pump is a pneumatic unit designed to handle many linear feet of structural epoxy injection per day, catering to the needs of contractors and engineers. The pump features a large stainless steel reservoir size, allowing for continuous epoxy delivery with minimal refilling.

The SealBoss PA3000 epoxy injection pump offers several advantages, including:

Ease of operation: The user-friendly design ensures that contractors and engineers can operate the pump with minimal training and supervision
High performance: The pump is capable of delivering epoxy consistently throughout the day, ensuring a seamless and efficient repair process
Versatility: The SB PA3000 can be used for various applications, including crack repair, bonding, and sealing in bridges, tunnels, dams, and other civil engineering structures
Durability: The robust construction of the pump, and it’s modular design and easy maintenance, ensure long-lasting performance, even under harsh conditions

Montana Department of Transportation
Bridge Repair Project

The Montana Department of Transportation (DOT) has recently released an extensive work plan covering multiple bridge restoration initiatives, which involve the use of structural strength epoxy resin systems for crack injections.

A renowned construction company has been entrusted with the responsibility of executing these repairs. The project entails the injection of structural epoxy resin into specified cracks utilizing the SealBoss Epoxy Injection System. Key components of this system include SealBoss 4040 low viscosity structural epoxy resin, SealBoss 4500F crack seal and port setting paste, SealBoss Injection ports, and the SealBoss PA3000 epoxy injection pump.

Regional manager Chris Conderre conducted a comprehensive training session on the jobsite in Montana, focusing on proper operation, cleaning, and injection techniques for the SealBoss PA3000 epoxy injection pump.

The training also included demonstrations of the use of accessories such as static mixers, Tri-Base Plastic Epoxy Injection Surface Mount Ports, and all connecting equipment required to establish a union between the applicator and the substrate.

Conclusion

Bridge crack repair using structural epoxy injection is a reliable, cost-effective, and efficient method that caters to the needs of contractors and engineers.

The use of innovative equipment like the SealBoss PA3000 epoxy injection pump, along with high-quality materials such as the SealBoss 4040 low viscosity structural epoxy resin and the SealBoss 4500F crack seal and port setting paste, ensures a seamless and successful repair process. Furthermore, proper training and education on the usage of these advanced tools and techniques are critical in achieving the desired outcomes.

As the demand for reliable and cost-effective bridge crack repair solutions continues to grow, it is essential for contractors and engineers to stay updated with the latest advancements in technology and materials. By adopting innovative methods like structural epoxy injection and utilizing state-of-the-art equipment, industry professionals can ensure the longevity and safety of bridges and other vital infrastructure components.

In summary, bridge crack repair using structural epoxy injection and advanced equipment like the SealBoss PA3000 epoxy injection pump offers numerous benefits. By adopting solid injection techniques and professional equipment, contractors and engineers can ensure the safety, reliability, and longevity of bridges and other critical infrastructure components, ultimately benefiting the communities they serve.

Structural Epoxy Injection System Products Used

Related Links

SealBoss Surface Mount Epoxy Port Selection

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Epoxy versus Polyurethane Crack Injection

Epoxy vs Polyurethane Injection

Crack Injection Superheroes

Epoxy Resins versus Polyurethane Resins
A Concrete Crack Injection Comparison

Epoxy versus Polyurethane Crack Injection

Epoxy and Polyurethane Resin Based Crack Repair Systems are the Superheroes of Concrete Crack Repair

When you need to repair a crack in a concrete structure — such as a foundation or wall — from the inside (negative side) of the structure, there are typically two injection techniques and corresponding product technologies that you need to consider — epoxy resin injection and polyurethane chemical grout injection.

Epoxy Versus Polyurethane Injection – How to Differentiate the two Injection Methods and Techniques

Epoxy injection is typically performed on dry substrates versus polyurethane injection that works very well on wet and actively leaking substrates.

Fully cured high quality epoxy offers outstanding compressive and tensile strength properties, making epoxy injection the preferred method where structural crack repair is desired.

Polyurethane injection is performed to seal active leaks, prevent moisture migration and to protect structures from corrosion and water related decay. Polyurethanes are designed to interact and expand in contact with moisture, making polyurethane injection technology superior in wet and actively leaking environments.

There is an injection solution to most concrete crack related problems. But, there is no one-size-fits-all solution.

Let us compare some of the main characteristics of each type of crack injection, outlining their strengths and their recommended range of applications.

Injection Repair Conditions and Objectives

Does your crack impact the structure?
Do you need to restore structural strength to the structure?
Does the crack carry water?
Is the crack actively leaking?
Do you need to protect the structure from water ingress and water damages?

Comparison of the Characteristics of Epoxy and Polyurethane Polymers and Elastomers

Epoxies and polyurethane polymers are chemical resins with different reaction profiles and physical properties.

Epoxy is a strong adhesive or glue that does essentially not expand. While curing epoxy creates a strong bond with the concrete substrate and ultimately provides a repair of high compressive and tensile strength properties.

Epoxy is a two component system, one component is the epoxy resin and the second is the hardener. The components are blended in the static mixer of the injection pump applicator immediately before crack injection. Injection epoxies cure chemically within a specified time and harden further over days and weeks.

Polyurethane injection foam is primarily a water activated sealant or leak-seal grout with expanding properties during reaction. The cured product creates a compression seal of varying flexibility.

Polyurethane foam resin often utilizes an activator or accelerator. Resin and activator are mixed before they are injected. Polyurethane resins are also available in two component chemical cure variants. No moisture needed.

Polyurethanes are extremely versatile. Their chemical and physical properties vary to suit the needs of specific applications and jobsite conditions.

Polyurethane resins vary from rigid and strong to flexible, rubbery and soft elastomer compositions. The initial cure time for crack injection polyurethanes is generally 1 – 10 minutes and is influenced by accelerator usage, temperature and moisture availability.

Differences in The Epoxy and Polyurethane Crack Injection Processes

Epoxy crack injections are typically performed at lower injection pressures (20-200 psi) and with surface mounted ports.

Polyurethane crack injection is often performed at higher pressures to move the expanding foam through the cracks with special injection pumps and packers installed into drilled holes. The injected polyurethane is supposed to fill the crack through the entire thickness of the structure thereby preventing water from entering the crack.

Epoxy Crack Injection

Structural Repair – The tensile strength and compression strength of cured epoxy is typically much greater than the strength of concrete making epoxy a good choice for foundation wall structural crack repair. When tension is applied to a crack due to thermal cycling or other forces, the cured epoxy crack repair will not typically yield. Epoxy is typically rigid and not flexible.
Extended curing time allows the epoxy to penetrate the crack and fine fissures. SealBoss epoxies can be obtained in various viscosities to suit fine to wide cracks.
Dry Substrate Recommended – Epoxy typically has reduced adhesion to wet and saturated surfaces. A dry environment is desired for best results. Actively Leaking Cracks – Epoxy cannot be used for actively leaking cracks. Epoxy resin needs to be contained in a crack until cured sufficiently to achieve full strength.
Epoxy injection is performed through surface mounted ports. Moisture adversely affects the adhesive qualities of the anchoring epoxy used to glue the injection ports onto the crack. Without sufficient bond strength, the anchoring epoxy will not withstand the pressure of the injection.
SealBoss provides mechanical packers and special plastic packers to permit epoxy injection in adverse environments.

Polyurethane Crack Injection

Wet and Dry Applications – Polyurethane injection foams and resins can be used in adverse environments regardless of the condition of the crack and the weather. The crack can be fine or wide, actively leaking, full of mud and/or mineral deposits. (Whenever possible it is advised to flush and clean out a crack prior to injection)
Water Stop and Structure Preservation – The rapid curing of polyurethane is beneficial when stopping a gushing leak. The chemical expansion of the polyurethane foam (typically 2-40 times its original volume) makes polyurethane very effective at filling voids within the concrete. Polyurethane resins and foams play an important role in preserving concrete and rebar.
Not a Structural Repair – Polyurethanes do not provide structural repairs in concrete cracks.
High injection pressures are often required to move PU foam into fine cracks and fissures.
Mechanical packers require drill holes. No matter if the crack is actively leaking, under water or the concrete is deteriorated, mechanical packers are designed to work in adverse environments.

Product Characteristics

EPOXY (EP)

Rigid, very strong adhesive for structural repairs
Mainly for dry or damp environments, potentially reduced adhesion on wet substrates
Excellent to regain structural strength in torn structures: earthquake damage, extended stress damage, shrinkage cracks, corrosion
Not a water-stop material and does not tolerate extended movement – cracks can form next to repair
Two component formulation – Quick reaction time and cure
Viscosities from very low liquid to paste
Very resistant, long term solution
Available in bulk and cartridges
Recommended Products:
Resins: 4040, 4050
Paste/Putty: 4500 Epoxy Quick Seal
Cartridge System: 4000 Epoxy Cartridge System
SealBoss Surface Mounted Ports / Injection Packers

POLYURETHANE (PU)

Flexible to semi-flexible sealants with less structural strength compared to EP
Typically Hydro-Active – reacts with water forming foams (water-stop & leak-seal), gels and solid (non cellular) flexible or semi flexible sealants
Two Component PU Resins can be dry reactive. No water needed
Classified as hydrophobic (foams/resins) for crack injection, joints voids or hydrophilic (foams/gels) for curtain, bladder injection behind structures. Both groups are water activated for use in wet environments
Superior water-stop capabilities
Single or two component, accelerators common. Viscosities low to medium. Very resistant, long term solution
Recommended Products:
Foams: 1510, 1570, 1570 LV
Flexible resin: 1403, 1503 LV-Resin Line
Gel/Foam: Flexgel2
Cartridge System Available

Epoxy versus Polyurethane – Conclusion

In non structural water related repairs PU is generally the material of choice. This is true for most below grade repairs including basements, tunnels, parking garages and manholes. PU is a good void filler and is also used to stabilize dirt and lift structures.

EP is an excellent adhesive for structural repairs of stressed concrete substrates and deteriorated concrete structures.

TIP

When initiating concrete crack injection, it’s advisable to commence with an exploratory grouting or mock-up injection stage. This entails identifying a deep, distinctly defined, and potentially actively leaking crack for the initial injection. This preliminary step facilitates the estimation of required material quantity and necessary injection pressures.

The consumption of material should be closely monitored and measured, and the injection pressures should be accurately assessed.

This process helps us understand the conditions of the project and plan the remaining injection process effectively.

Accessories

EPOXY (EP)

Surface port injection at lower injection pressures 30 – 100 psi — Reason: Injection is typically done in dry environments and surface ports can be attached easily with epoxy adhesive.
Holes do not have to be drilled – there are exceptions
The crack surface between the ports has to be surface sealed to prevent leakage during injection
The viscosity of the epoxy resin stays low during the injection process, resulting in lower injection pressures
Recommended Products:
Surface ports, specialty ports

POLYURETHANE (PU)

Mechanical packer injection at higher pressures 50 – 3000 psi — Reason: PU injection is often performed in a wet environment where adhesives for surface ports cannot be used.
Mechanical packers are installed by drilling a hole into the structure which the packer fits snugly. The packer is tightened mechanically for high pressure injection
PU Foam immediately reacts with moisture in the crack increasing resistance of product flow, resulting in higher injection pressures
Recommended Products:
Complete line of packers: S-Type, R-Type, custom sizes, Hammer-in packers, specialty packers

Conclusion:

PU generally needs higher pressures and therefor the more sophisticated connectors / packers. There are many exceptions. For example curtain injection with PU gel into the space between structure and soil needs lower injection pressures but higher rates of material flow. The filling of larger voids and joint injection also uses lower pressures. PU injection through surface ports is not common, but high pressure epoxy injection through packers is seen more frequently. Reasons could be very thick concrete to be penetrated or damp / wet surface conditions.

Pumps

EPOXY (EP)

Two component equipment for most epoxy resins for ease of use and precise mixing
Epoxy is a very strong adhesive and may render equipment unusable if not cleaned thoroughly
EP is not very moisture sensitive and not moisture reactive. Epoxy does not expand during reaction – which results in lower injection pressures
Pneumatic or manual guns for cartridge systems / smaller jobs
Two component injection pumps achieve high injection pressures for large volume commercial injection projects. Pumps are pneumatic or electric
SealBoss Corp. supplies EP resins and paste also in cartridges
Recommended Products:
Hand held guns, electric pump P3003, pneumatic pump PA3000, 4000 Cartridge System

POLYURETHANE (PU)

Single component equipment for most water activated hydrophobic PU foams, accelerator to be added prior to pumping
Either single or two component equipment for true two component PU resins such as 1400 LV-Resin Line
Either single component or multi-ratio two component equipment for hydrophilic PU Gels based on the application and product.
Single component pumps include inexpensive hand held devices, hand pumps and electric pumps
Multi ratio devices can be manual, electric and pneumatic. SealBoss Corp. supplies PU in bulk and in containers as small as 1 gal units and in cartridges
Recommended Products:
Hand held guns, manual pumps, electric pumps, Signature Line Pumps

Choose Your Pump:

No matter if you are faced with a minor basement leak or a major tunnel gusher of large hydrostatic pressure , we have you covered. You need to have the right tools at hand to achieve the results. SealBoss infrastructure repair pumps provide you with tried and true concrete solutions.

Final Thoughts:

Over the years, injection technology has evolved, becoming both sophisticated and intricate. At SealBoss, we pride ourselves on offering a diverse range of products, pumps, and accessories tailored to meet the ever-growing needs of injection applications.

Our commitment extends beyond just providing products; we offer comprehensive technical support to ensure you find the perfect product-equipment synergy for your project’s success. We invite you to leverage our expertise and training resources. Remember, we are only a phone call away, eager to assist and guide you.

SealBoss ® EPOXY

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SealBoss ® POLYURETHANE

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Epoxy Crack Injection Concrete Repair

Epoxy Crack Injection
Concrete Repair

Epoxy Concrete Crack Injection Systems

Epoxy Crack Injection Resin can mitigate problems of cracked concrete with larger and fine cracks. ACI specifies cracks widths that are acceptable in structures under defined conditions. ACI 224R-012 provides a guideline for crack widths for reinforced concrete under service loads for new construction. Crack widths deemed acceptable may range from 0.004 in. (0.1 mm) to 0.016 in. (0.41 mm), and even smaller widths for concrete in wet or aggressive environments. These crack dimensions would be considered fine and hairline cracks.

Pushing the Envelope – SealBoss Epoxy Systems
– Resins, Pastes, Injection Ports and Pumps –

Epoxy Crack Injection

Cracking does not always affect structural performance, but it can adversely affect the durability of structures.

Common causes of concrete cracking are post cure and drying shrinkage, thermal stress, chemical reaction caused by alkali-reactive silica & sulfates, freezing and thaw cycles due to water expansion, corrosion of steel rebar, settlement, load stresses, construction short comings such as design and construction errors.

The incorporation of steel reinforcement within structural concrete allows these elements to function under both compression and tension, frequently resulting in tension-induced fracturing of the concrete in certain regions.

Water is a major contributor to concrete corrosion in parking garages, bridges, industrial facilities and more. Water, chloride and carbon dioxide can migrate deep into the structure initiating corrosion of the reinforcement structure.

Water ingress, facilitated by fissures or compromised joints, often carries corrosive substances and chlorides that contribute to the degradation of concrete and the corrosion of steel reinforcements and rebar. Fortunately, epoxy concrete crack injection can address many of these concerns in structures exhibiting signs of such issues. Employing a proficient concrete repair team can frequently circumvent the need for a complete teardown.

SealBoss Epoxy Resins

SealBoss Epoxy Crack Injection resins for structural crack repairs conform to ASTM C881 specifications, with appropriate viscosities for the crack widths. The bond strength of epoxy to clean concrete is greater than the tensile strength of concrete itself.

Wider cracks may require a higher viscosity epoxy, small cracks a lower viscosity injection resin. Depending on the requirements, viscosities may range from approximately 150 to 600 cps at room temperature.

SealBoss Epoxy Crack Injection concrete repair can be performed with SealBoss Epoxy Cartridge Systems or SealBoss epoxy bulk resins using air guns, hand-actuated delivery systems, or dual-component injection electric or air-driven pumps.

Prior to repair, the structure must be carefully examined to establish that epoxy crack injection is indeed the correct method to regain the desired structural integrity. The cause of cracking must be determined. Cracks must be identified and the allowable crack width needs to be established. The width of cracks can be measured by using crack gauge cards. In some instances it may be recommended to measure the expansion and contraction cycles of a crack. To determine the depth and cause of cracking, core samples can be taken and examined by petrographic and chemical testing. In addition, nondestructive testing (NDT) ultrasonic pulse velocity can be used to measure the depth of cracks.

Once it has been established that epoxy concrete crack injection is the chosen method of repair, the SealBoss Epoxy Injection System can be utilized to restore the structural integrity of the concrete.

SealBoss ® Surface Mount Injection Ports

Surface-mounted injection ports are typically adequate for injecting most cracks. However, badly deteriorated concrete or higher injection pressures may require the use of drill-in or hammer-in plastic ports or even mechanical packers. Surface ports, aka plastic tubing ports, are glued on the surface over the open cracks using SealBoss epoxy paste adhesive. The injection ports are typically installed at a spacing that is equal to or slightly narrower than the depth of the crack. Hairline cracks require closer spacing than wider cracks.

Wire brushing and vacuuming the crack surface along the crack is often sufficient for surface preparation. In areas of badly deteriorated concrete, pressure washing, grinding, and V-grooving may be specified.

After the surface has been cleaned, surface ports are installed. Sealboss 4500 crack-sealer epoxy paste will be used as surface port adhesive and be applied on the face of the crack between and around the ports.

Once the injection ports are installed, Sealboss 4500 crack-sealer epoxy paste is applied on the face of the crack between and around the ports. To contain the epoxy resin in the crack until it hardens, it is a good practice to seal cracks on all sides of the substrate if possible.

Begin the Epoxy Crack Injection at the Point of the Structure

As soon as the epoxy appears at the next higher port, the current port is capped and the injection is continued from the next port. Multi port injection may be used in most epoxy injection environments. Typical injection pressures are between 50 to 100 psi (3 to 6 bars), with very fine cracks requiring pressures of over 200 psi (12 bars).

Epoxy resins are temperature sensitive. At higher temperatures resin viscosity decreases, but reaction time increases. For best performance during application, it is advised to keep the resin at room temperature or slightly above during injection.

After the injection resin has cured, the epoxy paste adhesive is removed from the surface of the concrete.

Quality assurance and control measures include visual observation of the injection process and product consumption, testing the injection equipment for mix ratio, taking core samples and testing repaired cracks using nondestructive testing methods.

Epoxy Crack Injection System – Epoxy Resins, Ports, Pumps

SealBoss epoxy injection system solution.
Ranging from epoxy resins and structural epoxy gels to injection ports and two component epoxy pumps.

SealBoss ® 4040 LV

SealBoss Highest Quality Epoxy Standard

Injection Epoxy Resin
Multi-Use Epoxy Resin

4040 low viscosity, 100% solids, hi-mod, 2-component, moisture-tolerant, low-viscosity, high strength, multi purpose, epoxy injection resin adhesive

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4050 SLV

Super Low Viscosity Epoxy Resin

4050 super low viscosity, 100% solids, hi-mod,
2-component, moisture-tolerant, low-viscosity, high strength, epoxy injection resin adhesive

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4500 F

SealBoss Highest Quality Epoxy Standard

Fast Cure Epoxy Paste

Epoxy paste products for surface repairs, to prepare cracks for resin injection, and to bond SealBoss surface ports. 4500 NSF Drinking Water Approved Formula available.

– Commercial Bulk Packaging
– Cartridge System

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

SURFACE PORT

Epoxy Injection Port – Industry Standard Bestseller

Durable plastic design surface mounted port suitable for epoxy injections. Tri-Base design with perforation holes for best possible adhesion with SealBoss 4500 Epoxy Paste Adhesive. Caps included. For EP grouts.

Bestseller – a SealBoss Standard

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

1/2" EPOXY DRILL HOLE / HAMMER-IN PORT

‘BELOW’ SURFACE PORT

Epoxy Injection Drill Hole Mount Port

Durable plastic port designed to fit 1/2″ drill hole for higher injection pressures than regular surface ports. Suitable for epoxy injections. Caps included. For EP grouts.

1/2" EPOXY DRILL HOLE / HAMMER-IN PORT

PA3000 The Epoxy Pump Standard

High & Low Pressure
Epoxy Injection & Polyurethane Injection

Top of the Line – Professional Use
Pumps Epoxy & PU resin
Pneumatic
850 psi
2 Comp.
Ratio: 2:1 Standard, 1:1 custom

P3003-2C PUR & Epoxy Pump

High & Low Pressure
Epoxy & Polyurethane Injection Piston System

Versatile,
Pumps Epoxy & PU Resin
Electric Drill Operated
Dual Piston System
5000 psi
2 Comp.
Ratio: 2:1 standard, 1:1 custom

SealBoss ® Epoxy

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epoxy

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Concrete Crack Repair

Using Polymer Grout Injection

Introduction:

Concrete structures are widely favored in construction for their durability and strength, but even the most resilient concrete can develop cracks over time. Addressing these cracks promptly is essential to maintain the structural integrity and aesthetics of the building. One of the most effective methods for concrete crack repair is polymer grout injection, which includes the use of polyurethane resins and foams, acrylates, and epoxy resins. This article delves into the specifics of these polymer-based injection techniques, their applications, and the step-by-step processes involved.

Concrete Crack Repair with Injection Grouting

Injection grouting is a versatile and widely used method for concrete crack repair. It involves injecting a liquid grout into the cracks of a concrete structure under pressure.

The grout then hardens, filling the cracks and while either sealing the cracks with a flexible sealant or by regaining the structural integrity of the concrete with a high strength bonding agent.

For this discussion, we will focus on polymer grouts, specifically polyurethane resins and foams, acrylates, and epoxy resins.

Polyurethane Resin and Foam Injection

Polyurethane resins and foams are highly effective for waterproofing and sealing cracks in concrete structures. They are known for their flexibility, which allows them to accommodate slight movements in the concrete without cracking. Polyurethane injections are particularly useful for concrete crack repair in foundations, basements, and retaining walls where water ingress is a concern.

Polyurethane resins are ideal for waterproofing as they form a watertight seal, preventing water ingress in basements and other below-grade structures. These resins also add structural integrity to the concrete by filling the cracks and preventing further deterioration.

The injection process begins with drilling holes along the length of the crack at regular intervals. The spacing of the holes depends on the size and extent of the crack. The cracks and drilled holes are then thoroughly cleaned to remove any dust, debris, or contaminants, ensuring proper adhesion of the polyurethane resin.

Injection ports, also known as packers, are installed into the drilled holes to prevent leakage during the injection process. The polyurethane resin is injected starting from the lowest point if the crack is vertical or from one end if it is horizontal, continuing until the resin appears at the next port or from the surface.

After the resin has cured, the injection ports are removed and the surface is cleaned. If necessary, the area is ground or sanded to match the surrounding concrete.

Acrylate Injection

Acrylates are another type of polymer grout used for concrete crack repair and curtain injection. They are known for their super low viscosity and rapid setting times, making them suitable for fine cracks and quick repairs.

Due to their low viscosity, acrylates can migrate through very fine cracks that other grouts cannot, making them ideal for situations where other resins cannot penetrate.

The injection process for acrylates begins with drilling holes along the crack at intervals suitable for the size of the crack. The cracks and holes are then thoroughly cleaned to remove any contaminants.

Injection ports are installed into the drilled holes and securely placed to prevent leakage. The acrylate is injected starting from the lowest point or one end of the crack, continuing until the acrylate appears at the next port or the surface. Once the acrylate has cured, the injection ports are removed and the surface is cleaned.

Epoxy Injection

Epoxy injection is a highly effective method for structural concrete crack repair due to its high strength and outstanding bonding properties.

Epoxy resins can restore the original strength of the concrete and are suitable for both fine and wide cracks.

Epoxy resins provide high tensile and compressive strength, making them ideal for restoring the structural integrity of cracked concrete. Available in varying viscosities, epoxy can be used to repair both fine and wider cracks.

The injection process for epoxy begins with placing surface ports over the crack and affixing them using a fast setting epoxy paste. The crack between the packers is sealed using the same fast cure epoxy paste to prevent epoxy leakage.

The epoxy resin is injected starting from the bottom of the crack and working up, continuing until the epoxy appears at the next surface port. After the epoxy has cured, the injection ports are removed. If necessary, the area is ground or sanded to match the surrounding concrete.

Concrete Crack Repair Conclusion

Polymer grout injection, including the use of polyurethane resins and foams, acrylates, and epoxy resins, is a highly effective method for concrete crack repair.

Each type of grout has unique properties that make it suitable for specific applications, from waterproofing to structural repairs. By following the proper procedures and using the right materials, you can preserve and restore the structural integrity and appearance of your concrete.

For any technical support or advice on your concrete crack repair projects, don’t hesitate to contact experts in the field. SealBoss offers comprehensive solutions and assistance to ensure your concrete crack repairs are successful and long-lasting.