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Midwest Joint Fill Training | SealBoss 6500 Polyurea & JointMaster Pump

Midwest Joint Fill Training
SealBoss 6500 Polyurea & JointMaster Pump

Another

On the Job Training

Joint Fill & Repair

Heartland Warehouse Renovation

Introduction:

This article explores the real-world training and application of the SealBoss® 6500 QuickFix Polyurea Joint Filler and the JointMaster® Pro2 Pump during a recent aerospace facility renovation project. The focus is on the critical importance of proper industrial floor joint repair in high-performance environments, particularly in sectors with heavy equipment use and stringent facility requirements.

The case study is based in St. Louis, Missouri, where a local contractor—new to joint filling work—was selected to complete repairs on 6,000 linear feet of floor joints. Understanding the complexity and performance standards expected by the aerospace client, the contractor partnered with SealBoss for professional training. A SealBoss Technical Representative provided on-site, hands-on instruction to ensure proper use of both the material and the pump system.

This project showcases the effectiveness of direct technical support and the role of quality equipment in enabling successful outcomes, even for contractors without prior experience in joint filling. It also highlights how tailored renovation work helps prepare industrial floors for the heavy-duty usage expected in aerospace and manufacturing environments.

As the construction of tilt-up concrete buildings and warehouse facilities continues to rise nationwide, many existing structures are not immediately suitable for new tenants and require modification before operations can begin. Floor joint restoration using reliable products like SealBoss 6500 Polyurea and the JointMaster Pro2 Pump can be an essential part of that process—ensuring durability, performance, and long-term facility integrity.

SealBoss Expertise Elevates Industrial Floor Joint Repair at Aerospace Facility

On-Site Training Brings Professional Results in St. Louis, Missouri

In the thriving industrial hub of St. Louis, Missouri, SealBoss was called upon to provide specialized, on-site training in the use of SealBoss professional-grade Floor Repair Systems.

A SealBoss Technical Representative visited a local contracting team to deliver targeted instruction in joint filling techniques using the SealBoss® 6500 QuickFix Polyurea Joint Filler and the JointMaster® Pro2 Dispensing Pump.

This hands-on training session was designed not only to introduce the contractor to SealBoss technologies but also to prepare them for an urgent renovation at a warehouse soon to be occupied by a major aerospace company. The goal: enable a successful, high-performance floor joint fill that would meet the strict operational standards of a high-profile tenant.

Meeting Aerospace Industry Demands with Advanced Joint Filler Technology

The aerospace industry places exceptional demands on facility infrastructure. In this case, the client required a durable floor surface capable of handling continuous heavy forklift traffic and the movement of substantial aerospace components.

To meet these challenges, the project team selected SealBoss 6500 QuickFix Polyurea, a fast-cure, heavy-duty joint filler with A 80 Shore hardness and 200% elongation. This advanced material is engineered for industrial environments where impact, stress, and movement are constant. Its flexibility and toughness ensure long-lasting performance—especially crucial in environments that cannot afford downtime.

Equipping the Team: The JointMaster® Pro2 Joint Fill Pump

The project marked the first time the contractor used the JointMaster® Pro2 Pump, a battery-powered, dual-component pump designed specifically for dispensing fast-setting polyurea joint fillers. Recognizing the importance of proper equipment use, the SealBoss Technical Representative provided detailed instruction on pump operation, material mixing, flow control, and cleaning procedures.

Thanks to its intuitive design, the pump quickly became a natural extension of the crew’s workflow, allowing for precise, efficient filling throughout the day.

Scope of Work: 6,000 Linear Feet in One Day

The scope of the project was significant: fill and finish 6,000 linear feet of floor joints within a single day. While ambitious, this target was achievable through careful planning, expert training, and the efficiency of the SealBoss system.

Day-Before Surface Preparation

Preparation began the day before joint filling, with the contractor removing all failed or deteriorating joint material. Adhesion and delamination issues were resolved, and the joints were cleaned thoroughly. Backer rod was inserted to the proper depth across all areas to ensure optimal material flow and control during the next day’s application.

Streamlined Team Configuration for Maximum Efficiency

To complete the project in the shortest possible time while ensuring seamless execution and maximum efficiency, a three-man crew configuration was implemented:

Pump Operator – Managed flow and refill, maintaining steady output from the JointMaster Pro2 Pump.
Joint Filler Applicator – Guided the dispensing nozzle and ensured joints were filled evenly.
Floater / Finisher – Performed critical joint shaving within 8–15 minutes of fill, maintained supply of materials, and ensured the entire process stayed on track.

This streamlined crew layout proved highly efficient for fast-paced, high-volume joint filling.

From Training to Performance: Results That Speak for Themselves

After a concise yet thorough training that included a product overview, equipment setup, and a 20-minute hands-on session, the contractor’s team quickly demonstrated their ability to handle the task. With a dispensing rate exceeding half a gallon per minute, the crew successfully filled and shaved the entire 6,000 feet of joints in a single day.

This successful outcome underscores the transformative value of SealBoss support—empowering even less-experienced contractors to deliver professional results under demanding conditions.

Conclusion: High-Caliber Products Paired with Expert Support

This project in St. Louis exemplifies the SealBoss commitment to excellence—combining premium products with in-person technical training to deliver top-tier industrial solutions. As the demand for tilt-up warehouse renovations grows across the United States, projects like this one illustrate the value of selecting a partner who goes beyond product sales and invests in contractor success.

With SealBoss 6500 QuickFix Polyurea Joint Filler and the JointMaster Pro2 Pump, facilities can be prepared to meet the rigorous demands of aerospace, logistics, and other heavy-duty industries—quickly, efficiently, and professionally.

Interested in training, product demos, or partnership opportunities? Contact SealBoss today.

“We Provide Field Service When You Need It!

We have been offering experienced and responsive technical support since 1988. While providing on-site support and training, we create a positive learning environment focusing on building applicator confidence allowing for successful repairs to be continued after the training. From training new companies and their employees, SealBoss has continued to provide support to our clients for over 36 years.

On-site training consists of an overview of products, the pump and it’s features. This is followed by hands on training with actual dispensing of material on the job site until the applicator has gotten confident with the application techniques and nuances of the material used. Finally we focus on the correct cleaning procedure of the equipment.

We don’t leave a job site until I’m confident that everyone is fully comfortable with the systems and capable of teaching the next person in line.

With a knowledgeable technical support team, we are here to help with any questions you may have.”

SealBoss ® Technical Support and Sales Team

SealBoss Floor Joint Filler

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Aluminum Injection Packers – Aluminium Injection Packers

Aluminum Injection Packers by SealBoss

Aluminium Packer Advantages

Aluminum | Aluminium Packers for Our Customers Worldwide
Quality Aluminum Construction for Secure Fit During Injection
Very Affordable Injection Packer
The Most Economical Way to Perform Crack Injection
Anti Return Valve in Zerk
A SealBoss Prime Economic Packer – The Aluminum Evolution Packer

SealBoss® Aluminum Injection Packers – The Smart, Economical Choice for Concrete Crack Injection

When it comes to concrete crack injection, professionals demand reliability, efficiency, and affordability. For most everyday injection scenarios, SealBoss® Aluminum Injection Packers offer the ideal balance between performance and cost—delivering professional results without overburdening your project budget.

Whether you’re waterproofing a foundation, stabilizing a slab, or filling cold joints, SealBoss provides a full line of AL-Type aluminum mechanical injection packers that are lightweight, easy to use, and built to SealBoss quality standards.

What Are Aluminum Injection Packers?

Aluminum injection packers are mechanical fittings used as injection ports for delivering resins—such as polyurethane (PU) injection foams, gels, and resins, as well as acrylate gels, and to a lesser extend epoxy resins (EP) — into cracks, voids, and construction joints in concrete structures. Once installed into pre-drilled holes, they serve as access points for high-pressure injection of leak-sealing or structural repair materials.

Key Benefits of SealBoss® Aluminum Injection Packers

Constructed from high-quality aluminum – Lightweight yet durable
Designed for secure fit – Compression rubber sleeve expands inside drilled hole
Economical – The most cost-effective choice among metal injection packers
Anti-return valve in Zerk fitting – Prevents backflow; removable for port-to-port travel
Compatible with multiple resins – PU, epoxy, silicates, polyacrylate gels
Available in multiple sizes – Including the popular 13-100AL (13 mm x 100 mm or 1/2” x 4”)

Why Choose SealBoss® AL-Type Aluminum Packers?

The SealBoss Evolution Aluminum Packer is modeled after the proven S-Type Steel Packer Line, offering a reliable, tested format at a lower price point. For most standard injection jobs—such as leak repair, void filling, or general water stop concrete crack injection — this aluminum option is more than adequate.

Affordable to buy in bulk
Lighter to transport and install on job sites
Faster and easier setup during time-sensitive projects
Ideal for contractors handling large-scale or repetitive injection work

“SealBoss aluminum injection packers are the economic alternative for most standard injection scenarios. They’re much lighter to carry, cheaper to ship, and easy to handle on-site.”

⚙️ Installation and Use

Drill a hole at a 45° angle into the crack or cold joint.
Insert the packer and tighten the bolt or nut, expanding the rubber sleeve to secure it in place.
Connect your injection pump to the Zerk fitting or grease nipple.
Inject your chosen resin (PU, Acrylate Gel, etc.) under pressure.
Remove the packer after curing, or leave it embedded depending on specifications.

Limitations to Consider

While SealBoss aluminum injection packers are excellent for most day-to-day applications, they may not be suited for every scenario. Their strength is slightly lower than SealBoss S-Type steel or SealBoss B-Type brass packers, and they may not be the ultimate choice for:

Steel Packers Specified Jobs
Extremely high-pressure injection
Severely deteriorated concrete
Extremely tight or hairline cracks
Structural injections requiring maximal anchoring strength

💬 Pro tip: Always keep a variety of packer types and sizes on hand. Testing different types side-by-side on-site is the best way to determine what works best for your current conditions.

Aluminum or Aluminium – One Packer, Many Names

Whether you say aluminum (US) or aluminium (UK/Europe), the SealBoss AL-Type mechanical packer is a globally trusted product used by professionals in over 50 countries. The design may be lightweight, but its performance is heavy-duty where it counts.

SealBoss Injection Systems – Full Support and Training

SealBoss doesn’t just sell products—we deliver complete system solutions, including on-site support and training in multiple U.S. states.

Our technical sales team is available to:

Help you choose the right packers and resins
Offer field training for your injection team
Guide you through difficult project conditions
📞 Contact us today at +1 714-662-4445

Example Product: SealBoss® 13-100AL Aluminum Packer

Size: 13 mm x 100 mm (1/2” x 4”)
Material: Aluminum body with expanding rubber sleeve
Pressure Capacity: Up to 6,000+ psi (depending on substrate and grout)
Best Use: Polyurethane injection, epoxy crack repair, curtain grouting

Conclusion: Save Time and Money with SealBoss® Aluminum Injection Packers

When you’re looking for a cost-effective, efficient, and field-proven solution for concrete crack injection, SealBoss® Aluminum Injection Packers deliver. From day-to-day waterproofing tasks to general crack repair, these packers help professionals do the job right—without breaking the bank.

Reliable
Economical
Backed by SealBoss expertise

📄 Browse All Injection Packers on SealBoss.com
🌐 Request a Quote or Technical Data

SealBoss ® Injection Packers

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PACKERS

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Watertight Pipe Penetration Sealing

Guidelines for Pipe Penetration Waterproofing

Introduction

Waterproofing pipe penetrations is a critical task in maintaining the integrity of a structure housing utility systems. Ensuring that pipes and conduits passing through walls or floors do not allow water ingress is essential for preventing damage and maintaining safety, especially in environments with high moisture or any water exposure. This guide provides a comprehensive overview of the steps and techniques necessary for effective pipe penetration waterproofing and sealing.

It covers the basics of installing new or replacing failed water stops around existing pipe penetrations, utilizing a range of products and techniques to seal these areas effectively. Whether you are dealing with active leaks, dormant leaks, or the unwanted migration of pollutants or gases such as exhaust fumes, unsealed pipe penetrations and conduits require an understanding of the best sealing procedures for your specific situation, this guide, along with the expert assistance of SealBoss technicians, offers the knowledge and solutions needed to address these challenges confidently.

How to Replace failed Water Stop around existing Pipe Penetrations

Step 1: Clean the area – Begin by eliminating any old grout or deteriorated concrete from around the pipe penetrations. Ideally, remove material to a depth of at least 1″ and a width of 1/2″ all around the pipe’s circumference. In this demonstration, an air chisel was utilized adhering to the safety protocols outlined by the natural gas plant.

Step 2: Clear the debris – After the removal of old grout or concrete, it’s essential to thoroughly clean the area. Employ a brush, air blower, or vacuum cleaner to eliminate any remaining dust or loose particles.

Step 3: Initiate the repair process – Once the area is clean, you’re ready to proceed with the installation of the repair products. Your pipeline is now prepped for the restoration process to commence.

Utilizing Multiple Products and Techniques for Pipe Penetration Sealing

Using SealBoss Seal Oakum for pipe penetration waterproofing by following the “Oakum Soakum” technique with SealBoss Water Stop Foam 1510 / 1570 and Oakum.

Oakum Saturation with Foam Grout

Oakum Soakum Installation

The process starts by unwinding and snipping an adequate length of Oakum rope to encircle the part of the pipe where it breaches the wall. The installer will initially manipulate and expand the Oakum, augmenting its surface area for better adherence with the catalyzed resin.

Next, using a zip-top bag or a bucket, dispense a sufficient quantity of SealBoss 1510/1570 resin to comprehensively saturate the Oakum strand. Following this, add the desired 15x catalyst concentration of 5% – 20%, contingent on the intensity of the leak.

The catalyst ratio dictates the reaction time and expansion rate. For dormant leaks, we recommend a catalyst percentage of 5% to 10%, and for active leaks, a proportion of 10% to 20% is suggested. Our technical representatives are available for any queries related to catalyst ratios.

After thoroughly soaking the Oakum, swiftly wrap it around the pipe, manipulating the fibers to fill as much of the pipe penetration annulus as possible. This forms a gasket-like sleeve around the pipe. Spray the soaked Oakum with water to facilitate the foam’s catalyzation. Within moments, you’ll observe the foam starting to form and expand.

Upon the foam’s complete curing, consider the repair concluded successfully.

In areas of constant hydrostatic pressures it is often recommended to inject the circumferential void throughout the thickness of the wall using SealBoss 1510 or 1570 Water Stop Foam.
With the use of a SealBoss Grout Injection Needle and a low cost HP1500 Ultra Light Hand Gun or a HP 100 Hand Pump, the foam grout can be conveniently placed and injected into the void. Depending on the conditions at the jobsite, the injection can be performed following the ‘Oakum Soakum Procedure’, by penetrating the initial repair with the injection needle and inject SealBoss Water Stop Foam behind it.
For small jobs and pipe diameters, and for low cost applications where hand pump and injection needles are not feasible, SealBoss Can-Seal Foam can be used as a lower grade alternative.

Upon completion of the leak-sealing application, carefully remove any surplus cured foam protruding from the annulus to ensure a clean working area for the subsequent application of grout or mortar around the pipe penetration.

SealBoss SwellCaulk is a premium, single-component hydroactive sealant, specifically designed to expand upon contact with water, thereby creating a secure, watertight seal. This product is especially effective for repairing pipe and cable penetrations. For optimal results with SwellCaulk, apply a bead of an appropriate size around the pipe, extending it beyond the chipped area and up to two inches deep into the circumferential void. Upon exposure to moisture, this hydrophilic material initiates its expansion process, thereby effectively forming a watertight seal around the pipe.

Pipe Penetration Sealing Products

Which Pipe Sealing Procedure is Right for You?
Call Your SealBoss Technician

Should you have any inquiries regarding pipe penetration sealing, crack injection water stop methodologies, or any other injection-related procedures, do not hesitate to reach out to our team of proficient SealBoss representatives. We are more than happy to assist you.

In order to assist you in understanding our systems more effectively, we provide on-site visits along with practical, hands-on training sessions involving our injection systems.

Call us at 714-662-4445.

SealBoss Leak Sealing

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Leak-sealing

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SealBoss Swell Caulk Joint Sealer

Swell Caulk Joint Sealer

Introduction

SealBoss SwellCaulk™: The Ultimate Solution for Reliable, Watertight Joint Sealing

When durability, flexibility, and watertight joint performance are non-negotiable, SealBoss SwellCaulk delivers. Specially engineered for construction joints, pipe penetrations, and sheet pile interlocks, this high-performance, single-component hydrophilic waterstop caulk expands upon contact with water—creating a hydro-active compression seal that reliably prevents water infiltration.

Ideal for both new construction and retrofit applications, SealBoss SwellCaulk combines ease of use with powerful expansion properties. It adheres to a variety of substrates, including concrete, PVC, HDPE, and metals, and remains effective even under continuous wet-dry cycling. Whether you’re sealing below-grade concrete, precast joints, or pile systems, this caulk is a go-to choice for engineers, contractors, and waterproofing specialists seeking long-lasting results in demanding environments.

With a proven performance history in tough field conditions, SealBoss SwellCaulk is the trusted solution for ensuring structural integrity and watertight protection in a wide range of civil and commercial applications.

Concrete Joint Sealing and Sheet Piling Caulk Applications with SealBoss Swell Caulk Joint Sealer

SealBoss® Swell Caulk Joint Sealer is a high-performance, single-component, hydrophilic, gun-grade waterstop caulk engineered to deliver a dependable, hydro-active compression seal across a wide spectrum of demanding construction environments. Its advanced formulation activates upon contact with water, creating an expanding, watertight barrier that enhances the integrity and durability of concrete structures.

Expanded Applications of SealBoss® Swell Caulk Joint Sealer

The versatility of SealBoss® Swell Caulk Joint Sealer makes it ideal for a broad range of below-grade and water-exposed construction details, including but not limited to:

Construction joints
Pipe and conduit penetrations
Manhole and catch basin connections
Precast concrete segments
Cold joints and expansion joints
Tunnel segment interfaces
Sheet pile interlocks
Poured concrete wall structures
Basement walls and retaining structures
Water tanks and wastewater treatment structures
Utility vaults and cable duct entries

Whether you’re working with smooth or rough substrates, this caulk adapts effectively, delivering consistent performance. When exposed to moisture, it swells intelligently to create a high-pressure, watertight seal, without exerting excessive force on adjacent concrete or structures. Its optimized swelling capacity makes it suitable even for green (fresh) concrete applications, preventing cracking or displacement.

Sheet Pile Interlock Sealing

In sheet pile applications, where watertight integrity is crucial, SealBoss® Swell Caulk Joint Sealer is specifically formulated to be gunned directly into the female interlock (knuckle) of the sheet pile before driving. This technique ensures the formation of a continuous, watertight barrier between interlocked sections—effectively sealing against groundwater intrusion and enhancing the overall performance of retaining walls, cofferdams, and flood protection systems.

The product’s robust adhesion and swelling action fill the micro-voids and potential leak paths in the interlock zone, dramatically increasing resistance against hydraulic pressure.

Adhesive for SealBoss® Swell Tape Integration

Another key application is its role as a recommended adhesive for the SealBoss® Swell Tape system, a popular waterstop solution used in combination with bentonite and polyurethane-based swelling tapes. This hybrid solution harnesses the strengths of both products — Swell Caulk and Swell Tape — providing an integrated waterstop system ideal for high-performance sealing of complex concrete structures, including joints with variable geometries.

Using SealBoss® Swell Caulk as an adhesive improves tape placement accuracy, enhances tape adherence to uneven surfaces, and creates a dual-layer swelling seal when moisture is present.

Application Guidelines

To maximize effectiveness, SealBoss® Swell Caulk Joint Sealer should be applied using a standard caulk gun directly into the joint or void area to be sealed. It is ideal for:

Construction joints in foundation walls and slabs
Pipe and steel penetrations through floor slabs and walls
Tunnel and segment joints in underground infrastructure
Precast structure connections and segmental retaining walls
Cold joints in cast-in-place concrete elements
Utility duct entries and around embedded elements

Allow the material to cure appropriately before concrete placement or water exposure, following SealBoss® product guidelines for optimum results.

Key Benefits of SealBoss® Swell Caulk Joint Sealer

SealBoss® Swell Caulk offers a host of technical and practical advantages over conventional joint sealing solutions:

Single-component formulation: Easy to apply with minimal preparation and equipment.
Time and labor savings: Faster application compared to multi-part systems, reducing on-site costs.
Water-reactive expansion: Hydrophilic polymer swells upon contact with water, forming a pressure-tight seal.
Safe for fresh concrete: The controlled expansion does not damage surrounding concrete during curing.
Excellent substrate adhesion: Bonds to a wide variety of construction materials, including concrete, metal, PVC, and more.
Durable and flexible: Withstands cyclic wet and dry conditions without losing performance.
Eco-conscious formulation: Low VOC and environmentally friendly, contributing to sustainable construction goals.
Cost-effective: Combines ease of use with performance, reducing material waste and installation errors.

A Reliable Solution for Demanding Construction Environments

SealBoss® Swell Caulk Joint Sealer is more than just a caulk—it’s a proactive water management solution that strengthens structural reliability across a wide array of projects. From infrastructure and utilities to commercial buildings and environmental containment, its hydrophilic technology ensures consistent, long-term waterproofing performance.

Whether you’re building new structures or reinforcing existing ones, incorporating SealBoss® Swell Caulk Joint Sealer into your project ensures protection against water intrusion, minimizing maintenance and extending service life.

Conclusion

SealBoss® Swell Caulk Joint Sealer represents a significant advancement in waterstop technology. Engineered for reliability, ease of use, and adaptability, it provides a proven solution for challenging sealing applications—particularly in wet or moisture-prone environments.

By integrating this high-performance product into your construction or remediation strategy, you ensure not just a temporary fix, but a long-lasting, hydro-active defense system for your concrete structures.

For optimal results, pair SealBoss® Swell Caulk Joint Sealer with other compatible SealBoss® products, and always follow the manufacturer’s installation guidelines.

Trusted by engineers, contractors, and builders worldwide, SealBoss® helps you build with confidence — below grade and beyond.

SealBoss Swell Caulk

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Swell Caulk

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SwellCaulk Construction Joint Sealant – Hydrophilic Swelling Waterstop Cartridges | Sausages

SwellCaulk Construction Joint Sealant
Hydrophilic Swelling Waterstop Cartridges & Sausages

SealBoss® Swell Caulk Joint Sealer – Smart Waterproofing in Action

SealBoss® Swell Caulk is a high-performance, hydrophilic caulk that expands on contact with water to create a long-lasting, watertight seal. Designed for use in construction joints, pipe penetrations, precast segments, and sheet pile interlocks, it forms a reliable barrier against water infiltration. Easy to apply with a sausage gun for SwellCaulk Sausages, or standard caulking gun for SwellCaulk Cartridges, it is the smart solution for concrete joint waterproofing and protection.

SealBoss SwellCaulk Construction Joint Sealer

Solvent free, pliable gungrade mastic
Adheres to concrete, PVC, HDPE, steel, fiberglass
Unconfined expansion 200-350 %
Flexible product for irregular surfaces
Easy application
Adhesive for SealBoss ® SwellTape

SealBoss SwellCaulk Construction Joint Sealer

SwellCaulk mastic is a one-component, grey, polyurethane-based, elastic, hydro-swelling caulk, supplied in cartridges and sausages, for the sealing of expansion and construction joints and around pipe penetrations. SwellCaulk swells in the presence of moisture. Curing time is dependent on temperature and humidity conditions.

Inquire more about the SealBoss Cartridge System when you call us here at SealBoss.

Chris Coderre

National Sales Manager

SealBoss Construction Joint Seal Systems

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swellcaulk

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Shut Down Gushing Leaks – SealBoss 15X Accelerator for Water Stop Foam

Shut Down Gushing Leaks
15X Accelerator for Water Stop Foam

SealBoss 15X Accelerator / Catalyst for Water Stop Foam

SealBoss ® 15X – Wide Range Accelerator

Shut Down Gushing Leaks
Hairline Crack Injection Leak-Seal
Slow Reaction
Fast Reaction
Semi Rigid Foam
Flexible Foam
Low Viscosity Foam

A Powerful Additive for the SealBoss Hydrophobic Injection Foam Line

By adding accelerator at varying ratios you can change reaction time and behavior of each foam to precisely suit your needs. With a little accelerator ‘magic’ you can shut down gushing leaks, seal hairline cracks and perform soil stabilization with the same product.

Shut Down Gushing Leaks: SealBoss 15X Accelerator and 1510 Water Stop Foam in Action

Water infiltration in concrete structures is one of the most persistent and destructive challenges in the construction and infrastructure repair industry. Whether it’s a gushing leak in a basement wall or an active water ingress point in a tunnel or foundation, fast, reliable solutions are crucial to protect structural integrity and reduce costly damage.

One of the most effective and versatile approaches to address these critical issues is the use of SealBoss 15X Accelerator in conjunction with SealBoss 1510 Water Stop Foam.

This combination empowers contractors and engineers to shut down gushing leaks quickly, safely, and permanently—even in high-pressure or wet environments.

The Problem: Gushing Leaks in Concrete

Gushing leaks often appear in concrete structures due to poor waterproofing, failed construction joints, cold joints, or natural aging. These leaks can carry hydrostatic pressure, often increasing during rainfall or seasonal groundwater shifts. Left untreated, they can cause:

Corrosion of steel reinforcement
Deterioration of concrete
Property damage and high repair costs
Mold and mildew growth

Because these leaks occur under pressure and may spread through hairline cracks or porous areas, traditional surface patching techniques often fail.

The Solution: Shut Down Gushing Leaks with Polyurethane Injection

Enter SealBoss’s polyurethane foam injection system, specifically the 1510 Water Stop Foam enhanced with 15X Accelerator. This powerful two-part solution is designed for rapid expansion and water-reactive sealing, forming a flexible, watertight foam barrier inside the structure itself—where the leak originates.

Meet the Products: 1510 Water Stop Foam and 15X Accelerator

SealBoss 1510 Water Stop Foam

This single-component, hydrophobic polyurethane grout is engineered to react quickly with water, expanding to create a semi-rigid, closed-cell foam that effectively fills voids and seals leaks. The foam:

Reacts in seconds when in contact with water
Expands to 30–40 times its original volume
Adheres to wet surfaces
Creates a long-lasting seal in cracks, joints, and porous concrete

Learn more: SealBoss 1510 Water Stop Foam

SealBoss 15X Accelerator

SealBoss 15X is a multi-range catalyst designed to control the reaction speed and expansion behavior of polyurethane foams like the 1510. This accelerator allows contractors to fine-tune foam performance based on environmental conditions and leak severity.

Use as little as 2% or as much as 20% by volume
Adjusts reaction speed from slow to ultra-fast
Works with 1510, 1570, and 1570 LV foam systems
Ideal for gushing leaks, hairline cracks, and soil stabilization

With 15X, users can slow down foam for deep penetration or speed it up to instantly shut down gushing leaks.

Learn more: SealBoss 15X Accelerator

How It Works: The Injection Process

Preparation
Identify the source of the leak. Drill angled holes targeting the crack or joint. Install mechanical injection packers.
Mixing
The SealBoss 1510 foam is catalyzed with a specific percentage of 15X Accelerator based on site conditions. For rapid leak sealing, 10–20% is often used.
Injection
Using a high-pressure pump (like the SealBoss P2002), the catalyzed resin is injected into the structure. When it encounters water, it reacts instantly—expanding and pushing water out while filling every crevice.
Curing
The foam cures rapidly, forming a permanent seal. Once the leak is stopped, packers are removed, and injection ports are patched.

Applications: Where to Use the SealBoss System

Below-grade foundation walls
Elevator pits
Parking garages
Tunnels and subways
Cold joints and construction joints
Dams, reservoirs, and tanks
Culverts and stormwater systems

Whether facing a slow leak or a gushing torrent of water, the SealBoss system provides a proven method to regain control and restore watertightness.

Real-World Performance

Contractors worldwide rely on the SealBoss 1510 and 15X system to manage demanding jobs. One of the key advantages is its flexibility. In colder climates or low-temperature substrates, a higher percentage of accelerator ensures the foam sets quickly. In situations where deeper penetration is needed, less accelerator allows the foam to travel before expanding.

With no need for excavation or external sealing, this internal injection method minimizes disruption while delivering powerful results.

Why Choose SealBoss?

SealBoss is ISO-Certified: Quality and consistency in every batch
Fast Support: Regional sales and technical teams available for on-site guidance
Versatility: Solutions for leak seal, soil stabilization, and crack repair
Training: On-demand training and technical support for contractors and engineers

Shut Down Gushing Leaks—The Right Way

Time is critical when you’re dealing with gushing leaks in a concrete structure. The longer water flows, the greater the risk of structural and environmental damage. The SealBoss 1510 and 15X Accelerator combo gives professionals the tools they need to act quickly and confidently.

With customizable reaction times, exceptional expansion, and field-proven durability, this system continues to be a go-to solution across a range of industries.

Get Expert Support Today

Need help selecting the right system for your leak repair project? Our team is here to assist. Whether you’re new to injection systems or looking to upgrade your leak sealing arsenal, SealBoss can provide the expertise, products, and equipment you need.

Contact us today: SealBoss Contact Page
View all leak sealing solutions: SealBoss Water Stop Products

Related Articles

15x accelerator spans all three of our base resins the 1510 Water Stop Foam, the 1570 Flexible Leak-Seal Foam and a 1570 LV Low Viscosity Crack Injection Foam. 15X Accelerator can be used in a wide range by volume in a percentage anywhere between 2% and 20%.

15x Accelerator - the little star that does a lot.

Inquire more about 151X Accelerator when you call us here at SealBoss. Your representative will be happy to help you out.

Chris Coderre

National Sales Manager

SealBoss ® 15X ACCELERATOR

Accelerator
Single Component Injection Foams

Accelerator For 1510/1570 PU Injection Foam.

Adjust foam gel-time and foam expansion from low foamer to high foamer depending application.

SealBoss ® 1510

Concrete Leak Sealing

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam Grout

Our #1 Selling Polyurethane Injection Foam
Water Cut-Off Injection Grout
Semi-Flex Foam, Water-Activated chemical injection grout. Our most versatile product. Water activated hydrophobic polyurethane foam, expands up to 30-40 times.

Contact Your SealBoss ® Technician

Cold Joint Injection

Leaking Cold Joints Sealed

Cold Joints in Concrete Structures and the Polyurethane Polymer Solution

Introduction

Concrete is a versatile and strong material that plays a key role in modern construction, but it comes with certain challenges. One common issue is the formation of cold joints — visible lines or separations that occur when new concrete is poured against concrete that has already begun to set. These joints can compromise the structural integrity, creating weak points that are vulnerable to water infiltration, leaks, and long-term damage. Proper identification and repair of cold joints are essential for maintaining the durability and performance of any concrete structure.

Cold Joint Injection: Permanent Solutions for Concrete Leaks and Structural Integrity

Concrete is one of the most widely used building materials in the world due to its strength, versatility, and durability. However, like all materials, concrete has vulnerabilities. One of the most common and potentially damaging issues in concrete construction is the formation of cold joints. These unplanned discontinuities in concrete can significantly impact the long-term integrity of structures, particularly when they become pathways for water infiltration.

Fortunately, cold joint injection using advanced polyurethane polymers offers an effective and lasting solution. This article will explore what cold joints are, why they occur, the risks they pose, and how cold joint injection provides a reliable fix for both residential and commercial construction projects.

What are Cold Joints?

A cold joint forms when freshly poured concrete is placed next to or on top of concrete that has already started to set. Rather than bonding as one cohesive mass, the two layers remain separated by a visible and structural boundary. This boundary lacks proper adhesion and can act as a weak point in the structure.

Cold joints typically occur due to:

Delays in pouring concrete batches
Interruptions in concrete delivery or placement
Temperature variations that cause uneven curing
Scheduling issues or construction mistakes

The result is a distinct line or seam in the concrete that appears harmless at first but can lead to serious problems over time. Cold joints are particularly vulnerable to water infiltration, which can trigger internal corrosion of rebar, cause freeze-thaw damage, and reduce the overall life expectancy of the structure.

Cold Joint Injection: The Polyurethane Polymer Foam Solution

The most effective way to repair and seal cold joints is through a process called cold joint injection, using high-performance polyurethane injection resins. This method restores the integrity of the concrete joint and creates a watertight barrier that prevents future leaks.

Why Use Polyurethane for Cold Joint Injection?

Polyurethane injection resins are hydrophobic or hydrophilic foams that expand upon contact with moisture, filling voids and cracks with precision. When injected into a cold joint, the resin reacts with any water present, forming a flexible yet durable foam that bonds tightly to the surrounding concrete.

Benefits of polyurethane cold joint injection include:

Expands to fill cracks and voids – Ensures complete coverage and sealing
Forms a watertight barrier – Prevents water infiltration and leak recurrence
Flexible and durable – Adapts to slight movements and temperature changes
Non-invasive – No need for major demolition or reconstruction
Fast-curing – Rapid installation and reduced downtime

Step-by-Step Cold Joint Injection Process

The cold joint injection procedure typically involves the following steps:

Inspection and Assessment
The area is assessed to determine the severity of leaks, substrate condition, and appropriate injection points.
Drilling and Packer Installation
Holes are drilled at specific intervals along the cold joint. Mechanical injection packers are inserted to allow precise resin delivery under pressure.
Injection of Polyurethane Resin
Using a high-pressure injection pump, the polyurethane resin is injected into the packers. As it travels into the joint, the resin reacts with moisture, expanding and filling all voids and cracks.
Sealing and Curing
Once the injection is complete, the resin cures quickly, forming a flexible, watertight seal. Packers are then removed and holes patched.
Final Inspection
The site is checked to ensure the leak has been completely sealed and no further moisture intrusion occurs.

Real-World Application: SealBoss Cold Joint Injection in Kansas City

A recent project in Kansas City demonstrated the effectiveness of SealBoss’s cold joint injection system. A structure with both vertical and horizontal cold joints had developed active leaks due to a failed pre-existing waterproofing system.

SealBoss’s Regional Sales Manager provided on-site support and training during the injection process. The contractor drilled injection holes and installed ½” mechanical packers for a secure fit. Based on site conditions, both angled and direct drill placements were used.

The team injected SealBoss 1510 polyurethane resin using the P2002 high-pressure single-component injection pump. Due to the low substrate temperatures, the resin was catalyzed with 15% SealBoss 15X High Foaming Accelerator, which ensured rapid and effective expansion. The result? All active leaks were sealed successfully, and the structure’s cold joints were permanently reinforced.

Advantages of SealBoss Cold Joint Injection Systems

SealBoss offers industry-leading cold joint injection materials and equipment designed for professional contractors and infrastructure repair specialists. Key advantages include:

Complete waterproofing solutions for cold joints, cracks, and voids
High-performance resins that expand even in low temperatures
Specialized pumps and packers for efficient delivery
On-site technical support and training
Trusted by contractors worldwide in demanding applications

Whether repairing parking garages, basements, retaining walls, or tunnels, SealBoss systems deliver reliable, long-term protection against water intrusion and structural decay.

Cold Joint Injection: An Investment in Longevity

Repairing cold joints with polyurethane injection is not just a short-term fix—it is a long-term investment in structural performance. By addressing water infiltration early and effectively, property owners and contractors can prevent costly repairs, ensure code compliance, and extend the service life of critical structures.

For engineers, architects, and maintenance professionals, understanding the value of cold joint injection is key to preserving the quality of concrete infrastructure.

Contact SealBoss for Expert Cold Joint Solutions

SealBoss is a global leader in leak sealing, structural repair, and concrete protection technologies. If your project involves water leaks, cracks, or cold joints, contact our team for expert guidance, high-performance products, and technical support tailored to your needs.

SealBoss delivers on-site training and specialized technical assistance for tackling cold joint leaks, as well as other concrete structure issues.

Considering a Solution for Sealing Cold Joints During Construction?

Look no further! We not only offer systems specifically designed for sealing cold joints but also provide expert advice to prevent moisture issues right from the construction stage.

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Please don’t hesitate to call us at 714-662-4445 with any questions, or request to be contacted here, we look forward to helping you find a solution. On-site support from knowledgeable and experienced technical reps is available upon request.

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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.

In this article we 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.

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Tunnel Water Stop Injection Leak Repair

Tunnel
Water Stop
Injection
Leak Repair

Leak Sealing
Systems

Tunnel Water Stop Injection Leak Repair with Polymer Grout Injection

Introduction:

Tackling Water Leakage in Tunnels: Challenges and Solutions

Water intrusion is a persistent challenge in tunnel infrastructure, affecting safety, durability, and operational efficiency. This article explores the risks associated with water leaks in various tunnel types—utility, vehicle, subway, rail, and pedestrian tunnels—and presents advanced solutions for effective sealing and structural reinforcement.

A key focus is the use of Polymer Injection Grouts, particularly acrylate gels and polyurethane resins, which offer reliable waterproofing and long-term stability. We delve into the properties and applications of these materials, outlining a step-by-step approach to leak diagnosis, material selection, and injection techniques.

Additionally, the article highlights SealBoss’s specialized products designed for underground water ingress repair, emphasizing the critical role of proper training and equipment for successful application. Whether addressing minor seepage or severe structural leaks, this guide provides essential insights for ensuring tunnel integrity and longevity.

Tunnel Water Stop Injection Leak Repair Overview

Tunnels, essential to modern infrastructure, vary in design and function but share a common challenge—water intrusion. Below is an overview of the tunnel types most susceptible to leaks and the potential risks they face:

Utility Tunnels – These tunnels house essential systems such as electrical wiring, water pipes, and gas lines. Water infiltration can lead to pipe corrosion, electrical failures, and even hazardous gas leaks, compromising both safety and service reliability.
Vehicle Tunnels – Water seeping through tunnel walls or accumulating on road surfaces creates hazardous driving conditions. Pooled water can reduce tire traction, increasing the risk of skidding, accidents, and severe traffic disruptions.
Subway Tunnels – Built beneath densely populated urban areas, subway tunnels are highly vulnerable to leaks from surrounding soil and aging infrastructure. Persistent water intrusion can disrupt train operations, cause service delays, and lead to costly maintenance and repairs.
Rail Tunnels – Water intrusion in rail tunnels poses significant risks, particularly to electrical components and track stability. Excess moisture can weaken the track bed, cause rail misalignment, and in extreme cases, contribute to derailments.
Pedestrian Tunnels – Water leaks in pedestrian tunnels create slippery surfaces, increasing the risk of slips and falls. Persistent dampness also encourages mold and bacteria growth, leading to poor air quality and potential health hazards.

Waterproofing and leak repair solutions are essential to maintaining tunnel safety, functionality, and longevity. Addressing water intrusion early can prevent costly damage and serious operational disruptions.

How to stop leaks of high hydrostatic pressures with Injection Grouts

Water ingress can cause immediate damages as well as lead to increased project costs and may lead to many other issues down the line.

Water ingress poses both immediate and long-term challenges, driving up project costs and leading to structural deterioration if left unaddressed.

Leaks through cracks, joints, and voids can be effectively sealed using advanced injection systems that employ cost-efficient and highly reliable chemical grouts, such as multi-component acrylate gels and single-component polyurethane resins.

When properly engineered, resin injection systems do more than just stop leaks—they also stabilize surrounding soil by transforming loose sands into a firm, sandstone-like consistency and consolidating gravel into a bonded, load-bearing structure. This not only enhances the durability of the tunnel but also improves its overall resilience against future water intrusion.

Example: SealBoss Acrylates Used to Seal Leaks in Tunnel

What are Acrylate Gels?

Acrylate gels, also known as acrylic gels, are highly flexible, ultra-low viscosity, hydrophilic sealing agents designed for non-structural injections. With a consistency similar to water, they effectively penetrate cracks, joints, and voids, making them ideal for grid, curtain, and bladder injection applications, as well as use in injection tube sealing systems.

Thanks to their exceptionally low viscosity and surface tension, polyacrylate gels offer superior penetration capabilities, allowing them to reach even the smallest fissures. Their adjustable gel time enables precise application, adapting to varying job site conditions such as temperature and injection distance.

When in contact with water, acrylic gels expand hydrophilically, creating a compression seal that prevents further leakage. This swelling behavior makes them an effective solution for waterproofing applications. Additionally, acrylate injection equipment can be easily cleaned with water, simplifying maintenance.

SealBoss provides a comprehensive range of high-performance products designed to control water ingress in underground mining operations, tunnels, and other commercial structures facing leakage challenges. Our solutions support waterproofing, soil consolidation, crack and joint repair, sealing, bonding, and cavity filling, ensuring durable and long-lasting protection.

Tunnel Water Stop Injection Leak Repair

How to Start Acrylate Injection Leak Sealing Injection Repairs

The principal steps to solve a problem are:

Diagnosis of the problem
Specification of injection methods
The correct choice of resin, pumps, packers and accessories
Training of installation personnel, a well trained and experienced team is paramount

Will I need more than One Product?

That depends on the conditions of the jobsite. Polyurethane and Acrylate injection systems offer a variety of solutions to problems found in geotechnical applications, in tunneling, waterproofing underground works and civil engineering in general. While there is no single resin that will suit all conditions, the correct resin must be used to achieve the best results possible and to meet the requirements of the specification.

If there are any questions about the various chemical grouts available, please do not hesitate to contact us, we are here to assist in any way we can. Always remember to work safely by wearing eye protection and gloves when handling any type of chemical systems.

Which products are shown in the videos?

Products used for Tunnel Water Stop Injection Leak Repair

Related Article

Flooded Tunnel Repair

Call Your SealBoss Technician

If you have any questions on crack injection water stop procedures or any injection related applications, please contact our team of qualified SealBoss representatives to schedule an on site consultation & full injection systems training. Call us at 714-662-4445.

SealBoss Leak Sealing Systems

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Injection

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How to Seal Shrinkage Cracks

Shrinkage Cracks Sealed at Wastewater Treatment Plant

Introduction:

In wastewater treatment plants, maintaining the integrity of concrete structures is crucial for safe and efficient operations. Shrinkage cracks, especially around pipe penetrations, are common but problematic, leading to water infiltration, contamination risks, and structural deterioration. These cracks compromise the durability and safety of facilities, resulting in increased maintenance costs and potential environmental hazards.

Addressing shrinkage cracks requires specialized solutions that comply with stringent safety standards, particularly for structures in contact with potable water. SealBoss’s advanced polyurethane injection systems are designed to effectively seal these cracks, preventing water seepage and ensuring long-term structural integrity. By forming a closed-cell foam upon contact with water, these systems provide a durable barrier against leaks and contaminants.

This article explores the causes of shrinkage cracks, their implications for wastewater infrastructure, and innovative NSF-certified sealing methods that enhance durability and operational safety.

Understanding Shrinkage Cracks in Concrete

What are Shrinkage Cracks?

Shrinkage cracks are a natural occurrence in concrete structures that form during the curing and drying process. Concrete, a blend of cement, aggregate, and water, undergoes a volume reduction, or shrinkage, as the water used in the mix evaporates. This process of evaporation causes the concrete mass to shrink and contract.

Simultaneously, the internal reinforcements or sub-bases that the concrete is poured onto restrict this shrinkage. This restriction generates tensile stresses within the concrete. When these stresses exceed the concrete’s tensile strength, they give rise to drying and shrinkage-related cracks.

Shrinkage cracks, although often very small, are of significant concern in certain structures. Even though they typically don’t compromise the structural integrity of the concrete, they can create pathways for water and other corrosive materials. This is particularly crucial in structures like dams, where minor leaks can have substantial implications.

Moreover, it’s important to note that the shrinkage of concrete and the subsequent development of cracks is an irreversible process. Therefore, any resulting water leakage needs to be addressed with suitable methods such as concrete crack injection.

Effective Sealing of Shrinkage Cracks at a Wastewater Treatment Plant

Scope

At the wastewater treatment plant in Salina, Kansas, leaks were detected around pipe penetrations and shrinkage cracks in the concrete structure during testing. These leaks posed a challenge that needed to be resolved before installing pumps and pipes in the pump room.

Procedure

To address the issue, a Regional Technical Sales Manager from SealBoss conducted an on-site consultation, recommending the use of SealBoss 1510 Water Stop Foam. This hydrophobic polyurethane resin is designed to expand upon contact with water, forming a closed-cell foam that effectively seals shrinkage cracks and prevents water penetration.

The application involved a high-pressure injection process using the SealBoss P2002 injection system, paired with SealBoss 13-100 AL series injection packers. These packers are ribbed to withstand the high pressure of the injection, ensuring a reliable and durable seal. This approach provided a robust solution for sealing the leaks and protecting the integrity of the concrete structure.

Comprehensive Approach

The combination of on-site consultation, high-quality materials, and specialized equipment highlights SealBoss’s commitment to delivering effective and long-lasting solutions for infrastructure maintenance. The successful application at the Salina wastewater treatment plant is a testament to the effectiveness of SealBoss’s comprehensive approach to concrete repair and waterproofing.

Employed Products:

SealBoss 1510 superior penetration through hairline cracks

SealBoss ® 1510 NSF Approved Water Stop Foam

Shrinkage cracks around pipe penetrations are a common issue in wastewater treatment plants, leading to water seepage from tanks and basins. These leaks pose operational and maintenance challenges and require solutions that comply with strict safety and environmental standards.

SealBoss 1510 Water Stop Foam is a hydrophobic polyurethane resin specially designed to address these issues. Upon contact with water, it expands into a closed-cell, semi-flexible foam that effectively seals cracks and stops leaks. This product is NSF/ANSI/CAN 61 certified, making it safe for contact with drinking water. Its chemical-resistant properties and adjustable reaction times provide contractors with flexibility and long-term reliability, even in challenging environmental conditions.

The NSF/ANSI/CAN 61 certification ensures that SealBoss 1510 meets the highest safety standards for drinking water contact. This certification is vital for projects involving water treatment plants, containment structures, and other systems where water safety is a priority. It guarantees that the product will not leach harmful contaminants into the water supply, safeguarding public health and complying with regulatory requirements.

SealBoss is committed to providing safe and effective waterproofing solutions. With a history of serving the industry since 1988, SealBoss products are trusted by contractors, architects, and engineers worldwide. Our Full System Solutions include a comprehensive range of injection accessories, ensuring seamless integration and support throughout every stage of the injection process.

By choosing SealBoss®, you gain access to high-quality, certified materials and reliable technical support from a single, dependable source. This commitment to safety, durability, and efficiency makes SealBoss 1510 Water Stop Foam an essential choice for infrastructure repair and maintenance.

Related Super Low Viscosity SealBoss Chemical Injection Grouts:

SealBoss ® 1403 SLV Super Low Viscosity Polyurethane Resin for injection into very fine cracks.
SealBoss ® 2400 SealGel SLV Super Low Viscosity Acrylate Gel / Acrylic Gel for injection into very fine cracks.