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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

Click Here

epoxy

Contact Your SealBoss ® Technician

Epoxy Injection in Cold Weather

Epoxy Injection
In Cold Weather

Overcoming the Challenges

Cold weather can complicate concrete repair and waterproofing, especially when working with chemical grouts like polyurethane foams, gels and, in this case, epoxy resins. All theses polymer products rely on temperature for proper curing.

Despite an incoming cold front, a mock-up epoxy injection training session had to proceed. With careful preparation and the right tools, such as heat guns to warm resins and surfaces, the team was able to successfully navigate the chilly conditions.

This cold Thursday morning was no exception to the rule. During a mock-up epoxy injection training an impending cold front was on its way toward Oregon and Washington states, resulting in unusually cold temperatures. However, when a crew needs to receive proper technical training on Sealboss Systems, the show must go on.

We Provide Training in All Conditions

A week prior to the training we wanted to make sure that we were prepared so that everybody in attendance could get the most out of the experience. We proactively sent an email to the contractor requesting that they provide the ancillary items necessary to make the training as efficient and effective as possible.

One of the items requested was a focused source of heat in the way of a heat gun. We were very pleased to see that they were prepared with two heat guns which enabled them to speed up the setting process for the crack seal paste. When chemistry is at play, temperature is a very important factor. In almost all cases, heat will speed up reactions between different chemicals.

In cold weather it is critical to precondition the epoxy resins to room temperature prior to use. Epoxy resins may not react below 35-45°F, but will begin to cure again once the temperature rises. A heat gun can be used to warm up the concrete surface prior to installing surface mounted ports and to increase the temperature of the installed epoxy adhesive to approximately 100°F or 40°C to initiate the exothermic reaction and speed up the cure time. Take care to avoid heating the surface or epoxy to over 130°F or 55°C .

While there are many things out of everyone’s control such as the weather, those things that are in our grasp ought to be executed to the best of everyone’s ability thanks to the preparedness from all members involved with this session, the team was able to benefit from and learn the basics as it relates to structural epoxy injection all the way from port setting to clean out of the pump.

Please inquire about training opportunities with your local SealBoss representative.

We are standing by to do what we can to make sure your teams have the requisite knowledge to be successful when it comes to using SealBoss Systems.

Below Grade Waterproofing

Below Grade Waterproofing: Innovative Solutions for Complex Challenges

In the field of construction and building maintenance, below-grade waterproofing poses distinct challenges, particularly when addressing sensitive areas where direct access to the source of leakage is limited, and traditional crack injection methods for waterproofing are not feasible.

A recent case involving a below grade mechanical room with water intrusion issues highlights the innovative approaches and solutions available in today’s construction industry.

Polyurethane Polymer Gel and Foam Injection are effective methods to seal areas that are not easily accessible. With direct and indirect chemical grout delivery methods available, a wide array of below grade waterproofing problems can be resolved.

In this specific case grout injection lances were the delivery method of choice to combine waterproofing techniques such as soil permeation and consolidation grouting and curtain injection grouting to seal a subterranean mechanical room of a hospital.

Below Grade Waterproofing
Using Injection Lances and Polymer Gel

The Challenge: Water Intrusion in a Below Grade Mechanical Room

A mechanical room located below grade was experiencing water intrusion through shrinkage cracks and cold joints. The complexity of the situation was heightened by the fact that the problem could not be addressed from the negative side (inside the mechanical room) due to the placement of conduit and utility pipes. This scenario is not uncommon in below grade waterproofing projects, where access and space constraints often limit traditional repair methods.

Seeking Expert Solutions

In response to this challenge, the engineer overseeing the project reached out to SealBoss, a renowned name in the field of waterproofing and chemical grout injection solutions. SealBoss proposed a soil permeation and consolidation grouting and curtain injection grouting solution using SealBoss FlexGel hydrophilic polyurethane polymer leak sealing foam gel, a method well suited for this complex below grade waterproofing scenario.

The Process – Soil Permeation Injection and Consolidation Grouting with Injection Lances

Once the proposal was approved by all parties involved, the injection process began. The first step involved drilling cores to confirm the layout of below grade structures. During this phase, an unexpected utility bay was discovered, necessitating a modification in the layout of injection points to accommodate these below grade structures.

Installation and Injection Techniques

The installation process involved driving ½” soil injection lances into the core holes and installing female couplers to work with the custom applicator built by the contractor.

SealBoss Grout Injection Lances for soil permeation and consolidation grouting and curtain injection grouting.

This step was crucial for ensuring that the SealBoss FlexGel would be injected precisely where needed. Before the injection of FlexGel, each hole was initially flooded with water using a SealBoss IP495 Pump, specifically dedicated for water injection. This flooding was essential to suspend the strata below and prepare it for the FlexGel injection.

FlexGel Injection: Creating a Waterproof Barrier

Each hole received an initial injection of 3 gallons of water, followed by 1 gallon of FlexGel neat out of a separate dedicated SealBoss IP495 polymer injection pump. A final injection of up to 1 gallon of water through the designated water pump was then administered. During the FlexGel injection, the lance was lifted to create a vertical curtain, effectively wrapping around the found utility bay. Additional material was pumped below the elevation of the bay on either side to flood the cavity between the utility bay and the exterior of the mechanical room, creating a comprehensive waterproof barrier.

Results and Follow-Up

The initial injections were completed within a few hours, but additional cores had to be made to proceed further. A week after the installation, the area experienced heavy rains for three days. The hospital maintenance staff reported that the leak had subsided, marking a successful application of below grade waterproofing using the Curtain/Blanket Injection method with FlexGel.

Conclusion: Below Grade Waterproofing Success

This case study exemplifies the effectiveness of innovative below grade waterproofing techniques in addressing complex water intrusion issues. The use of FlexGel Hydrophilic gel in a Curtain/Blanket Injection method proved to be an efficient solution for a challenging situation, highlighting the importance of choosing the right approach and materials in below grade waterproofing projects. As the construction industry continues to evolve, solutions like these offer hope and reassurance for tackling even the most daunting waterproofing challenges.

Related Links

Below Grade Waterproofing - Water Stop System

SealBoss ® FLEXGEL

Leak Sealing Injection Gel
Hydrophilic Injection Foam Gel
Hydrophilic Gel

Versatile Hydrophilic Polyurethane Foam-Gel
Water activated single component hydrophilic Polyurethane grout. Reacts to a foam with 1 to 3 parts of water added and to a very flexible gel with 4 to 15 parts of water added (by volume). Drinking Water Contact meets NSF/ANSI 61 Section 5 requirements.

IP495 Pump

Polyurethane Injection Pump

Larger Projects, Extended Injection
Electric Motor
Piston System
2500 psi – 1 Comp.

Grout Injection Lances

STAINLESS STEEL

Dimensions
12″
36″
60″

Contact Your SealBoss ® Technician

Concrete Crack Injection – Polyurethane

Concrete Crack Injection Polyurethane

Introduction:

Maintaining the structural integrity and aesthetic appeal of concrete constructions is crucial for ensuring their long-term durability and functionality. Water intrusion, often through leaking cracks, poses a persistent challenge that can lead to structural erosion, aesthetic damage, and costly repairs if not addressed effectively.

Leaking concrete cracks are a common issue across various types of infrastructure, from residential foundations to industrial facilities and public spaces. Repairing these cracks requires advanced techniques that not only stop water infiltration but also reinforce the structural resilience of the affected area.

Concrete Crack Injection using Polyurethane (PUR) Water Stop Foam Injection is a cutting-edge, economical solution that provides a permanent seal for leaking cracks. Renowned for its versatility and efficiency, this method effectively addresses a wide range of water damage issues, including structural weakening, rust stains, and efflorescence buildup.

In this article, we explore the PUR Water Stop Foam Injection process, highlighting its procedure, applications, and advantages. By adopting this innovative technique, engineers and contractors can maintain the integrity of concrete structures, safeguarding them from further damage while extending their service life against the forces of nature.

How to Seal Leaking Concrete Cracks with PUR Water Stop Foam Injection

Zoo Exhibit Crack Repair — The Gorilla Exhibit at Omaha’s Henry Doorley Zoo was closed for renovations and repairs, including the sealing of concrete cracks that had shown signs of water intrusion, structural erosion, and visible stains from rust and efflorescence.

Concrete crack injection with polyurethane foam resin was the choice of repair to resolve water bearing crack leaks. Crack related damages were located at a walkway under a lofted area with multiple windows and decorative shotcrete structures where gorillas could sit and be viewed by people walking through the exhibit.

The cracks were covered in efflorescence could be seen on the walls below the lofted area as well as cracks coming off the cold joints around the precast window framing.

The crack dimensions ranged from hairline to 1/4″ joint seams with varying degrees of water intrusion and active leaks causing heavy efflorescence build up. The roof and lofted area collect and feed water during snow melt and heavy rains.

SealBoss provided an on-site technical representative to consult with the contractor on injection methods using NSF/ANSI 61 Drinking Water Contact Certified injection grout, a high-pressure injection pump and mechanical injection packers.

Concrete Crack Injection – Polyurethane

Which products are shown in the video?

Concrete Crack Injection Polyurethane – Procedure and Repair Method

Prior to injection, the contractor had to first prep the cracks by removing any efflorescence and dirt build-up from the face of the crack using a wire brush.

Once the cracks were visible an injection plan was established to address the leaks working from the low point up.

Using the SealBoss high pressure concrete crack injection system — hydro-active, hydrophobic polyurethane foam resin, injection packers and polyurethane crack injection pump — hydro-active foam resin is injected into the cracks, expanding on contact with moisture and displacing any water in the process while creating an airtight & watertight seal.

Crack Injection Details

A – Standard Injection Procedure

One side of the lofted area had three significant cracks that resulted in substantial active leaks. The east wall presented larger actively leaking cracks. Further, cracks and cold joints from a precast window frame created an area of leakage that needed to be injected.

In those areas, SealBoss 1/2 inch injection packers were placed according to SealBoss Standard Recommendations, roughly 4” from the crack in ½” holes that were drilled at a 45-degree angle back into the crack. SealBoss 1510 Water Stop Foam was injected until positive refusal of the hydro-active resin was visible from the face of the crack as well as on the exterior side of the wall when a through crack was injected.

Starting with the lowest point of the cracks, SealBoss 1510 Leak Sealing Foam Grout was injected until positive refusal was observed on the interior and exterior of the wall. Due to the temperature of the wall, around 36 degrees Fahrenheit, the contractor was advised to condition the resin to room temperature prior to use as well as adding 15% of SealBoss 1510 Accelerator/Catalyst to compensate for the cooler ambient and substrate temperature — cold temperatures slow down the chemical reaction of the injection grout.

B – Custom Injection Procedure

In some areas, more complex leaking cracks and cold joints had to be sealed, requiring a deviation from standard injection packer placement.

Multiple cracks had developed connecting to a larger initial crack, creating a spider-web crack pattern. Due to the complexity of the crack system and intersections of cracks, the injection procedure was modified from the standard alternating “zipper” pattern typically recommended. Cracks were so close in proximity that packers needed to be strategically ‘custom’ placed to increase the chance for each packer drill hole to successfully intersect with the crack — resulting in a less orderly packer placement pattern.

Starting at the low point of crack, the Water Stop Foam was injected till and foam travel was observed at a distance from the point of injection intersecting into other cracks. This meant that multiple cracks could be addressed from one point of injection without the need for drilling too many injection port holes.

As the resin visibly moved up and out of the face of the crack, injection of that specific crack would be stopped so the resin could react and fully expand creating a seal.

Shortly thereafter, a secondary injection of the same packer was performed to penetrate even deeper into the crack and allow for further continuation of visible vertical foam resin travel.

Cleanup

After all cracks were successfully sealed, the injection packers were removed, and the ½-inch drill holes were patched with hydraulic cement for a clean finish. This step restored the surface integrity and appearance of the repaired areas.

Products Used:

Injection Resin:

Other Tools Used

Cleaning Materials: Xylene, rags, bucket
Additional Tools: 18” x 1/2″ drill bit — 3/8” Crescent Wrench — Dead Blow Hammer
Hammer Drill — Access 110v Power —
Vacuum
Heat Gun

Why Polyurethane Foam Injection?

Polyurethane foam injection is a versatile and effective solution for sealing leaking cracks in concrete structures.

Its advantages include:

Hydro-Active Expansion: Reacts with water to create a watertight seal.
Durability: Provides long-lasting protection against water intrusion.
Flexibility: Can adapt to various crack patterns and sizes.

This method proved to be the ideal choice for the Gorilla Exhibit, ensuring a safer and more enjoyable environment for both animals and visitors.

Conclusion

The repairs at Omaha’s Henry Doorley Zoo highlight the effectiveness of polyurethane foam injection for sealing leaking cracks, even in complex and challenging environments. With proper preparation, high-quality materials, and expert execution, this method offers a reliable solution for protecting concrete structures from water damage.

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.

Contact SealBoss

Concrete Wall Repair

Structural Concrete Wall Repair with Epoxy Injection

Introduction

Concrete walls are integral to the structural stability of countless buildings and infrastructure projects. Over time, however, even the most robust walls can develop cracks due to factors such as settling, weather conditions, and material fatigue. These cracks compromise structural integrity, safety, and longevity, necessitating timely and effective repair solutions.

Epoxy injection systems have emerged as a gold standard in addressing these challenges, offering precision, durability, and cost-effectiveness. By filling cracks and restoring the original strength of concrete, these systems prevent further damage and extend the life of the structure. This article discusses the transformative impact of epoxy injection technology, exploring a major structural repair project that highlights the efficiency and reliability of SealBoss systems in concrete wall repair.

Concrete Wall Repair using Structural Epoxy Resins

Massive Concrete Wall Repair: Advanced Solutions with Epoxy Injection Systems

Structural integrity is vital for the durability and safety of any concrete wall, whether designed for soil retention, seawall protection, or other applications.

Cracks represent one of the most significant threats to this stability, as they can undermine both the strength and longevity of the structure if not promptly addressed. Effective concrete wall repair not only restores structural soundness but also prevents further damage and potential failure. Epoxy injection systems offer precision, efficiency, and long-term durability, making them a premier solution for concrete crack repair. This article explores the application of SealBoss epoxy injection systems in a major structural repair project, showcasing the effectiveness of these advanced systems.

Project Overview: Prestigious Estate Repair

A prestigious estate in Texas faced a significant structural challenge: Several thousand feet of cracks in a major concrete retaining wall. Addressing this critical issue required an immediate and effective concrete wall repair solution to ensure the wall’s long-term stability and safety. An experienced epoxy injection contractor leveraged SealBoss’s epoxy injection technology to deliver outstanding results in this high-profile project.

Step-by-Step Approach to Concrete Wall Repair

Preparation Phase

Thorough preparation is essential for successful concrete crack repair. For this project, the preparation phase spanned an entire week. During this period, the team:

Set Injection Ports: Several thousand surface-mounted tribase ports were strategically installed along the length of the cracks to serve as controlled entry points for the epoxy injection.

Applied SealBoss 4500 Epoxy Paste: This high-performance paste was used to seal the surface of the crack and secure the ports. Its strong adhesion ensured a reliable barrier, preventing leakage during the injection process.

Injection Process

After completing the preparation, the team began the injection stage using the SealBoss P3003-2C pump. This state-of-the-art pump, designed for high-pressure injection, ensured efficient and controlled delivery of SealBoss 4040 epoxy resin deep into the crack. Remarkably, the entire injection process was completed in just 25 minutes, demonstrating the efficiency of SealBoss systems for concrete wall repair.

Materials Utilized

The success of this project relied heavily on the quality and compatibility of the materials used. Key components included:

SealBoss P3003-2C Pump: A dual-component injection pump that ensured precise mixing and application of the epoxy resin.
Static Mixers: These devices ensured uniform mixing of the epoxy components for consistent performance throughout the process.
Surface-Mounted Tribase Ports: Several thousand ports were used to treat the crack effectively, providing targeted delivery and maximizing repair outcomes.
SealBoss 4040 Epoxy Resin: This low-viscosity resin penetrated deep into the crack, offering exceptional strength, durability, and chemical resistance.
SealBoss 4500 Epoxy Paste: Used to secure the ports and seal the crack’s surface, this paste contributed to the long-term durability of the repair.

Key Features of SealBoss Epoxy Injection Systems

SealBoss epoxy injection systems provide a host of features that make them ideal for addressing structural issues in concrete walls:

Low-Viscosity Penetration

SealBoss epoxy resins are designed to penetrate even the finest cracks, ensuring comprehensive sealing and structural bonding. This is particularly effective for narrow and deep cracks that are otherwise difficult to address.

High Compressive and Tensile Strength

Once cured, SealBoss epoxies offer exceptional mechanical properties, restoring the original strength and load-bearing capacity of the concrete structure. This makes them suitable for high-stress applications.

Chemical Resistance

SealBoss epoxy systems are resistant to a wide range of chemicals, including oils, fuels, and solvents. This ensures long-term performance in environments subject to chemical exposure.

Cost-Effective Solutions

By extending the lifespan of the structure and minimizing the need for extensive demolition and reconstruction, epoxy injection systems offer a cost-effective alternative to traditional repair methods.

Video: Concrete Wall Repair with SealBoss Epoxy Injection Systems

Why Choose Epoxy Injection for Concrete Wall Repair?

Epoxy injection has become the gold standard for concrete crack repair due to its many advantages:

Restoration of Structural Integrity: Epoxy effectively bonds concrete components, returning the structure to its original strength.
Prevention of Further Damage: Properly sealed cracks prevent water infiltration, reducing the risk of corrosion, freeze-thaw damage, and chemical deterioration.
Versatility: Epoxy injection systems can address a wide range of crack widths and depths, making them suitable for various applications.
Efficiency: Advanced equipment like the SealBoss P3003-2C pump ensures quick and precise application, reducing downtime.

Long-Term Benefits of Epoxy Injection Systems

Prolonged Lifespan of Structures

By addressing cracks early and effectively, epoxy injection systems significantly extend the lifespan of concrete walls and other structures.

Enhanced Safety

Restoring structural integrity ensures that the repaired wall can continue to bear loads safely, reducing the risk of failure.

Environmental Benefits

Epoxy injection minimizes waste and resource use by repairing, rather than replacing, damaged structures. This makes it an eco-friendly option for concrete wall repair.

Lessons from the Major Structural Concrete Wall Repair Project

This case study provides valuable insights into best practices for concrete wall repair:

Thorough Preparation is Key

Detailed preparation, including the proper placement of surface ports and the use of high quality non sag and quick cure epoxy paste, ensures a seamless injection process and optimal results.

Advanced Equipment Makes a Difference

The SealBoss P3003-2C pump’s light weight, ease of operation, two component ratio precision, and reliability played a crucial role in the project’s success, demonstrating the importance of high-quality tools.

Material Quality Matters

Using premium products like SealBoss 4040 epoxy resin and 4500 epoxy paste ensures correct setting times, suitable viscosities, durability and long-term effectiveness.

Conclusion

Concrete wall repair, as demonstrated in this major structural repair project, benefits significantly from the precision, efficiency, and durability of epoxy injection systems. SealBoss’s advanced materials and equipment, combined with skilled execution, offer a proven solution for restoring and preserving concrete structures. Whether addressing minor cracks or significant structural damage, SealBoss epoxy injection systems provide an effective and reliable pathway to long-term stability and safety. For contractors and engineers seeking efficient, cost-effective solutions, epoxy injection stands out as a best-in-class method for concrete crack repair.

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 ® 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

Bestseller – a SealBoss Standard

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

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

Concrete Wall Repair Epoxy System

Click Here

Injection

Contact Your SealBoss ® Technician

Polyurethane Injection Kit

Leak Sealing Water Infrastructure Projects Effectively

Introduction:

In large-scale water infrastructure projects, maintaining structural integrity through effective leak sealing is essential. Cracks and leaks in holding tanks, pipelines, and other critical components can compromise the entire system’s efficiency and safety.

A polyurethane injection kit provides a comprehensive solution to these challenges, combining specialized polyurethane grout, durable injection packers, and a portable, high-powered injection machine. Designed to address the demanding requirements of water infrastructure, these kits ensure reliable, long-term repairs that enhance operational stability. This article explores the pivotal role of polyurethane injection kits in large water projects and their effectiveness in achieving lasting leak sealing in complex environments.

Polyurethane Injection Kit: Effective Leak Sealing in Water Infrastructure Projects

For large-scale infrastructure projects like the North Water Treatment Plant in Gilbert, Arizona, sealing leaks in critical areas such as holding tanks is a top priority. This high-stakes project required an advanced polyurethane injection kit to efficiently seal cracks and maintain the plant’s long-term structural integrity.

Using specialized polyurethane grout, injection packers, and a portable injection machine, this comprehensive kit is invaluable for leak repair across diverse climates, from Arizona’s warm, reaction-accelerating conditions to colder environments.

SealBoss 1570 LV Polyurethane Injection Kit: Engineered for Tight Cracks

At the core of the project’s leak-sealing success was the SealBoss 1570 LV Polyurethane Injection Kit, renowned for its precision in sealing fine cracks. This kit’s key component, the SealBoss 1570 LV Water Stop Foam, is a hydrophobic polyurethane grout designed to penetrate ultra-tight spaces. Its low viscosity and centipoise allows it to fill the narrowest fissures at low pressure, making this polyurethane injection kit highly effective for infrastructure repairs that require thorough and lasting sealing.

BP-13-100 AL Aluminum Packers: Reliable Components in the Polyurethane Injection Kit

Included in this specific polyurethane injection kit are the industrial grade and economically friendlyBP-13-100 AL aluminum packers, which ensure secure entry points for grout injection. These aluminum packers feature a crucial anti-return valve, helping to control grout flow and enabling precise, port-to-port injection techniques. Known for compatibility with both polyurethane and epoxy grouts, these packers are reliable for various long-term infrastructure repair projects, making the polyurethane injection kit versatile and cost-effective.

P2002 Drill-Operated Injection Machine: Power and Portability

Another key element in the polyurethane injection kit is the SealBoss P2002 drill-operated injection machine. Compact yet powerful, this machine was designed specifically for professional applications where maneuverability is essential. The P2002 machine allowed contractors to quickly and accurately apply grout, making it an essential tool in the polyurethane injection kit for large projects requiring efficiency and reliability.s

Adapting the Polyurethane Injection Kit for Temperature Conditions

Arizona’s warm climate introduced additional challenges, as chemical reactions in polyurethane can accelerate under heat. Adjustments to the injection timing and material preparation helped optimize the polyurethane injection kit under these conditions, demonstrating the importance of environmental planning. With temperature-sensitive materials, even slight adjustments to the process, such as adjusting the use of accelerator SealBoss 15x, can yield optimal results.

Top Benefits of Using a Polyurethane Injection Kit System for Water Infrastructure Projects

Using a polyurethane injection kit offers significant advantages for water infrastructure projects:

Optimized Injection System: The polyurethane injection kit combines specialized grout, durable packers, and a reliable pump, creating a fully integrated system designed for optimal performance. This synergy allows for ease of application, controlled flow, and the best possible sealing results, making the process straightforward and efficient for contractors.
Precision in Tight Spaces: Low-viscosity polyurethane grouts allow thorough penetration into fine cracks, ensuring lasting repairs.
Durability and Flexibility: Polyurethane is highly resilient to water exposure and pressure, ensuring that repairs remain intact over time.
Efficient Application: With portable, powerful equipment like the P2002 injection machine, polyurethane grout can be applied quickly and accurately.

Conclusion - Polyurethane Injection Kits

In summary, our various polyurethane injection kits, exemplified by the SealBoss 1570 LV Kit, integrate all necessary components for effective leak-sealing in large-scale water projects.

The North Water Treatment Plant in Gilbert, Arizona, showcases how advanced polyurethane injection kits can enable reliable, long-lasting repairs, highlighting their critical role in preserving essential infrastructure.

Ready to enhance your water infrastructure projects with reliable, long-lasting, leak sealing polyurethaen injection kits?

Discover the benefits of a polyurethane injection kits today. With a fully optimized systems that combines precision grout, durable packers, and a powerful pump, this kit is designed for efficiency, ease of use, and superior results.

Contact SealBoss to learn more about our injection solutions and find the perfect kit for your project needs.

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Concrete Crack Repair

A Quick Guide to Polymer Grout Injection

Introduction:

Concrete structures are highly valued in construction for their durability and strength, but even the most resilient concrete can develop cracks over time. Concrete crack repair is essential to maintain both the structural integrity and the appearance of concrete buildings and infrastructure. Among the most effective techniques is polymer grout injection, which includes using polyurethane resins and foams, acrylates, and epoxy resins. This guide explores these polymer-based injection methods, their benefits, and detailed processes to ensure effective concrete crack repair.

Polymer Grout Injection for Concrete Crack Repair

Injection grouting is a versatile and widely adopted technique for concrete crack repair. It involves injecting specialized liquid grouts into cracks within the concrete under pressure.

As the grout hardens, it seals the cracks while either creating a flexible waterproof seal or restoring the structural integrity of the concrete using high-strength bonding agents.

This article covers three main types of polymer grouts for concrete crack repair:

Polyurethane resins and foams, acrylates, and epoxy resins.

Concrete Crack Repair with Polyurethane Resin and Foam Injection

Polyurethane resin and foam are excellent and highly effective for waterproofing and sealing cracks in concrete structures. Known for their flexibility, polyurethane-based resin and foam solutions are ideal for concrete crack repairs in foundations, basements, retaining walls, dams and concrete structures where water ingress poses a significant problem.

Benefits of Polyurethane Injection for Concrete Crack Repair:

Flexible waterproof seal: Accommodates movement in concrete
Water stop and moisture barrier: Prevents water infiltration
Structural reinforcement: Inhibiting further deterioration of concrete.

Process Overview:

Drill holes at regular intervals along the crack based on conditions
Clean the cracks and holes
Install injection packers into the drilled holes
Inject polyurethane resin starting from the lowest point
Remove injection ports

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.

Concrete Crack Repair with Acrylate Injection

Acrylate injection grouts are popular for concrete crack repair due to their super low viscosity and fast-setting characteristics. Acrylates are well-suited for fine cracks and are often used in curtain injection to create a waterproof barrier behind the concrete.

Benefits of Acrylate Injection for Concrete Crack Repair:

Super Low viscosity: Penetrates very fine cracks and fissures
Fast setting: Ideal for curtain injection
Versatility: Suitable for various leak and moisture conditions

Process Overview:

For curtain injection drill holes in a pattern at suitable intervals through the structure to create a bladder/curtain seal on the positive side behind the structure
Clean the cracks and holes to remove contaminants
Install injection ports
Inject acrylate grout starting from the lowest point
Remove ports and clean the surface

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.

Concrete Crack Repair with Epoxy Injection

Epoxy injection is widely recognized for its high strength and bonding capabilities,making it an excellent choice for structural concrete crack repair. Epoxy resins not only restore the strength of concrete but also create a durable, watertight seal.

Benefits of Epoxy Injection for Concrete Crack Repair:

High tensile and compressive strength: Restores structural integrity to concrete
Versatility in viscosity: Can repair both fine and wide cracks
Outstanding bonding: Forms a permanent bond with the concrete

Process Overview:

Install surface ports over the crack
Seal the crack between the ports
Inject epoxy resin starting from the bottom of the crack
Remove the ports and finish by cleaning and grinding

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

The injection process for epoxy begins with placing surface ports over the crack and bonding 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.

Conclusion - Why Polymer Grout Injection is Ideal for Concrete Crack Repair

Polymer grout injection—which includes using polyurethane resins, acrylates, and epoxy resins—is one of the most effective methods for concrete crack repair. Each type of grout offers unique properties that make it suitable for specific applications, from waterproofing to structural reinforcement. By following the correct procedures and selecting the right materials, repair professionals can successfully restore and preserve the integrity and appearance of concrete structures.

If you need guidance or technical support for your concrete crack repair projects, consult with industry experts. SealBoss offers comprehensive solutions and expert assistance to help you achieve long-lasting results in your concrete crack repair efforts.

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Types of Concrete Cracks

A Concrete Crack Overview

Introduction:

Concrete structures can experience a range of cracks due to various causes, including environmental factors, structural issues, and material weaknesses. As a concrete repair professional, understanding these different crack types and how to address them using suitable repair methods—such as polyurethane resin, foam injection, acrylate gel, and epoxy injection—is essential for maintaining the integrity and longevity of concrete structures.

For Concrete Crack Repair Details read our Quick Guide

Concrete Crack Repair – A Quick Guide to Polymer Grout Injection

Types of Concrete Cracks

Shrinkage Cracks in Concrete
Shrinkage cracks occur when hardened concrete loses moisture during the curing process, causing it to contract. These cracks are common in driveways, slabs, and foundation walls. As concrete dries over time, this moisture loss can lead to shrinkage if the concrete is restrained, resulting in cracks. These cracks may be larger and can appear throughout the structure.
Cause: Uneven moisture loss and restraint in the structure.
Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or, in some cases, epoxy injection to regain structural strength.
Plastic Shrinkage Cracks in Concrete
Plastic shrinkage cracks form while the concrete is still in its plastic (unhardened) state. They result from rapid moisture evaporation from the surface, often due to high temperatures, low humidity, or strong winds. These shallow cracks resemble a spiderweb pattern and typically affect newly poured slabs.
Unlike regular shrinkage cracks, which develop after the concrete has hardened and contracted over time, plastic shrinkage cracks appear within the first few hours after pouring, making them a common issue in newly poured slabs or exposed surfaces. These cracks are typically shallow and widespread across the surface, while regular shrinkage cracks are generally larger and occur throughout hardened concrete structures.
Cause: Rapid moisture loss from the surface during curing.
Repair Solution: Typically Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress. Acrylate gel in some cases.
Spalling Concrete Cracks
Spalling occurs when sections of concrete break away from the surface, exposing the reinforcing steel. This typically results from corrosion within the steel, causing it to expand and exert pressure on the surrounding concrete.
Cause: Corrosion of embedded reinforcing steel.
Repair Solution: Epoxy injection to fill and bond the cracks, combined with a surface coating to prevent future corrosion.
D-Cracking in Concrete
Durability cracking, or D-Cracking, results from concrete’s inability to withstand freeze-thaw conditions. It usually manifests as cracks running parallel to joints or linear cracks, often with discoloration around the affected area. D-Cracking is primarily caused by the use of coarse aggregates that trap moisture, which expands during freezing and leads to cracking over time.
Cause: Coarse aggregates that absorb moisture and expand during freezing.
Repair Solution: Polyurethane injection, which remains flexible during freeze-thaw cycles.
Corrosion Cracks in Concrete
Corrosion cracks develop due to the rusting of steel reinforcement embedded in concrete. As the steel corrodes, it expands, creating internal pressure that leads to cracking.
Cause: Rusting of embedded steel.
Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.
Stress Corrosion Cracks in Concrete
Stress corrosion cracks arise from a combination of tensile stress and a corrosive environment. These cracks are common in marine structures, bridges exposed to de-icing salts, or industrial facilities where chemical exposure is prevalent. This phenomenon often involves the interaction of aggressive chemicals (like chlorides or sulfates) with embedded steel reinforcement, resulting in cracks that may propagate rapidly under continued stress.
Cause: Interaction of tensile stress with corrosive chemicals.
Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.
Overloading Cracks in Concrete
Overloading cracks develop when concrete structures bear more weight than they were designed to handle. These cracks usually occur in heavily trafficked areas like driveways or industrial floors where heavy machinery operates.
Cause: Excessive loads exceeding the design capacity.
Repair Solution: Most likely high-strength epoxy injection to restore structural integrity.
Concrete Expansion Cracks
Expansion cracks develop when concrete expands due to heat, exerting pressure on the structure. Like most materials, concrete expands when heated, and if it lacks sufficient space to expand, the resulting internal stress can cause cracks. Expansion joints are often installed to provide relief and absorb the stress of expanding concrete.

Cause: Thermal expansion without adequate expansion joints.
Repair Solution: Polyurethane foam injection, which is flexible enough to accommodate movement.
Heaving Cracks in Concrete
Heaving cracks typically occur in cold climates where freeze-thaw cycles are common. When water within the concrete freezes, it expands considerably, causing the concrete slab to lift or “heave.” As temperatures rise and the ice melts, the slab settles back down, leading to the formation of cracks due to the constant movement. This can be prevented by allowing space for expansion and contraction.
Cause: Freeze-thaw cycles and temperature changes.
Repair Solution: Flexible polyurethane foam that can expand and contract with temperature variations.
Crazing and Crusting Cracks in Concrete
Crazing refers to shallow, fine cracks resembling spider webs that appear due to premature drying. Crusting, on the other hand, occurs when the top surface dries faster than the bottom during stamping. While these cracks are not usually structural concerns, they can impact aesthetics and lead to moisture ingress.
Cause: Uneven drying during the curing or stamping process.
Repair Solution: Low-viscosity polyurethane foam for sealing and moisture protection.
Disintegration Cracks in Concrete
Disintegration cracks are a result of the gradual breakdown of concrete, starting with surface scaling and leading to large pieces breaking away. Disintegration often results from chemical attacks like carbonation or sulfate exposure and poor construction practices.
Cause: Chemical attacks or poor-quality aggregates.
Repair Solution: High-strength epoxy injection to reinforce the structure and sealant application to prevent further chemical exposure.
Re-Entrant Corner Cracks in Concrete
Re-entrant corner cracks occur at areas with abrupt changes in geometry, such as around columns, pipe penetrations, sharp corners column bases, pipe penetrations, around rounded objects like manholes, and intersections where slab and wall joints meet. As the concrete dries, uneven shrinkage around these regions creates stress concentrations that lead to cracking.
Cause: Stress concentration around corners or openings.
Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or, epoxy injection to regain structural strength.
Alkali-Silica Reaction (ASR) Cracks in Concrete
Alkali-Silica Reaction (ASR), also known as concrete cancer, is a harmful chemical reaction between highly alkaline cement paste and reactive silica in aggregates. This reaction produces a hygroscopic gel that absorbs water, expands, exerts internal pressure, and progressive loss of concrete strength leading to map cracking, also known as pattern cracking or alligator cracking. This distinct crack pattern consists of randomly-oriented, web-like cracks on the surface of concrete elements that move in multiple directions.
Cause: Reaction between alkaline cement and reactive silica.
Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.

Choosing the Right Repair Method for many Types of Concrete Cracks

When selecting a repair method for different types of cracks, consider the crack’s cause, size, and impact on the structure:

Polyurethane Foam and Resin Injection: Ideal for flexible sealing in areas with moisture issues and minor movements. Works well for sealing finest cracks as well as large voids or areas prone to temperature changes, due to its expanding and flexible properties.
Acrylate Gel: Perfect for curtain injection and super fine hairline cracks.
Epoxy Injection: Best suited for structural repairs of cracks requiring high strength and load-bearing restoration.

Conclusion

Concrete cracks are an inevitable challenge for any concrete structure due to the diverse range of factors that can cause them, such as environmental conditions, structural issues, and material weaknesses. Understanding the different types of concrete cracks, such as shrinkage cracks, plastic shrinkage cracks, spalling, D-cracking, and more, is crucial for professionals tasked with maintaining the structural integrity of concrete elements.

By recognizing the root causes of these cracks, repair professionals can determine the most effective methods for restoration. For example, structural cracks due to overloading or stress corrosion may require high-strength epoxy injection to restore the original load-bearing capacity, while cracks resulting from freeze-thaw cycles or moisture ingress are better addressed using flexible polyurethane foam injections. For fine hairline cracks or moisture control in large sections, acrylate gels provide a versatile and efficient solution.

Proper selection of repair materials and techniques not only helps in addressing visible damage but also aids in preventing future deterioration, extending the life of the concrete structure. Each crack type demands careful evaluation to choose the right repair approach, ensuring both safety and durability.

Polymer-based injections, including polyurethane resins, foams, acrylates, and epoxies, offer comprehensive solutions for addressing a wide variety of concrete cracks. They provide the versatility to handle anything from superficial fine cracks to deep structural fissures, making them indispensable for professionals committed to maintaining the integrity of concrete elements.

By integrating these repair methods into their toolkit, professionals can confidently tackle any concrete crack repair challenge, ensuring long-term durability and safety for the structures they manage. As always, consulting experts and selecting high-quality products for each specific application remains key to achieving successful and lasting results.

To learn more about how to approach specific concrete crack repair projects, explore our Concrete Crack Repair Quick Guide

Concrete Crack Repair – A Quick Guide to Polymer Grout Injection

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Manhole Repair – Leak Sealing Injection

Manhole Repair
Leak Sealing Injection

Manhole Repair Systems

SealBoss provides comprehensive system solutions aimed at rehabilitating manholes and repairing leaks, effectively sealing water leaks occurring via cracks, joints, and annular pipe intrusions. Leveraging our repair systems allows for a considerable extension of a manhole structure’s service life, all the while maintaining cost-effectiveness.

Addressing Manhole Damages and Blockages through Inspections and Repairs

Mitigating Infiltration and Inflow (I/I) in Manholes

Manholes are frequently subjected to I/I, which manifests as infiltration through cracks and joints, and inflow of groundwater. These occurrences can significantly elevate treatment costs and contribute to environmental pollution. Furthermore, they may trigger soil and groundwater contamination, sinkholes, and damage to roads and structures.

To prevent and correct these issues, it is crucial to conduct regular inspections and necessary repairs on manholes.

SealBoss provides a selection of cost-effective systems designed to repair manholes, successfully addressing typical and common forms of damage.

If left untreated, deteriorating and leaking manholes can result in substantial, highly expensive damage to both the environment and infrastructure.

Understanding Sanitary Sewer Overflows (SSOs)

Sanitary sewer overflows (SSOs) represent a pressing environmental and public health issue. These overflows, saturated with untreated sewage, act as conduits for bacteria, viruses, and other pathogens.

At times, sanitary sewers may inadvertently discharge untreated sewage, leading to what’s termed as an SSO. Such overflows can not only taint our water sources, resulting in significant water quality degradation but also backflow into residential areas. This not only damages property but also poses a substantial health risk to the public.

Factors Leading to SSOs:

Blockages in the sewer lines
Ruptures or breaks in the sewer lines
Structural defects that permit storm water and groundwater to inundate the system
Power outages affecting the sewage system’s operations.
Flaws in the sewer system’s design
Acts of vandalism disrupting the system

According to data from the Environmental Protection Agency (EPA) as of September 2023, it’s estimated that the U.S. experiences between 23,000 to 75,000 SSO incidents annually. This figure excludes sewage backups into buildings, underscoring the gravity of the issue.

Identifying Common Manhole Failure Causes

Several common causes of manhole failure include:

Infiltration via precast joints
Leakage from precast manhole rings
Groundwater intrusion through cracks
Infiltration via mortar joints
Cracks resulting from shifting soil, traffic load, or soil expansion
Fissures due to micro-biological corrosion

Manhole Repair Using Injection Grout

Addressing Different Types of Manholes – Brick, Precast and Combination Manholes

SealBoss Injection Systems are designed to accommodate manholes constructed from a range of materials.

Introducing the ealBoss Seal-Oakum / Oakum Soakum Technique

e recommend having SealBoss Seal-Oakum on-site to effectively plug larger voids and joints. The Oakum Soakum Technique is explained here.

Understanding Basic Repair Procedures

Repairing Manhole Leaks through Larger Cracks and Brick Construction

Here are the steps:

Drill through the structure to the outside of the manhole to fill any voids and crate a curtain behind the structure
Install Injection Packers
Prior to injection, repair wide pipe penetrations using Seal-Oakum
Start injection at the bottom

Adressing Manhole leaks through Precast Manhole Rings / Joints

Follow these steps:

Drill injection holes into the manhole rings approximately every 60 degrees
Install six injection packers. In case of severe leaks, more drill holes/packers may be required
Prior to injection, repair wide pipe penetrations and broad ring joints using Seal-Oakum
Start injecting process from the bottom

Manhole Inspections and Preventive Maintenance – The Key to Longevity

Regular inspection of manholes is crucial to identify issues early and prevent them from escalating. Implementing a preventive maintenance program for manholes can prevent costly repairs and extend their lifespan. Regular cleaning, sealing of cracks, and routine inspections can ensure their proper function and prevent I/I.

Innovative System Solutions with SealBoss

SealBoss provides a wide-ranging selection of manhole repair solutions. This includes a variety of injection systems, water-reactive grouts, structural resins, SealBoss Seal-Oakum, along with injection packers and pumps. These tools are designed to confront a broad spectrum of manhole issues, proving their effectiveness across diverse manhole designs and construction materials.

Conclusion

Addressing the issue of manhole damage is essential for efficient sewage management, environmental preservation, and safeguarding infrastructure. Regular inspections, timely repairs, and effective maintenance procedures can help manage these concerns. At SealBoss, we provide innovative and economical solutions tailored to meet these needs.

Manhole Repair System Example

Experience Hands-On Training with SealBoss P2002 Pro Kit System

We provide comprehensive, hands-on training in the application of high-pressure polyurethane water stop foam injection, using the SealBoss P2002 single-component injection pump, or any other SealBoss Injection System specified.

The equipment and materials used in this training include SealBoss 1510 Water Stop Foam, SealBoss AL 13-100 (½”) high-pressure packers, and SealBoss Seal-Oakum.

During the training, a SealBoss technical expert will be present on-site to provide direct support to the contractor. Our primary goal is to ensure that your work crew gains confidence and comfort in using the application.

TOur training covers the full spectrum of the application process. This includes instruction on pump usage, packer installation, the detailed injection procedure, and the clean-up process. We also educate repair crews on how to apply catalyzed resin-soaked SealBoss Seal-Oakum effectively.

If you have any questions regarding manhole repair, our team of proficient SealBoss representatives is ready to assist. Feel free to contact us to schedule an on-site consultation and comprehensive training on injection systems.

Manhole Repair Crew Training

Manhole Repair System Example

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Epoxy Injection Preparation Tips

Introduction:

Epoxy injection is a highly effective, polymer delivery method through a pumping system for repairing cracks in concrete structures. This process involves sealing all accessible sides of a crack and bonding them with a high and strength, low-viscosity epoxy resin by pressure injection.

Proper preparation is crucial for successful epoxy injection. It begins with cleaning the crack thoroughly, surface sealing the crack, and installing surface mount Tri-Base ports along the crack at specific intervals with a fast setting, non-sag epoxy paste. Following these preparation steps ensures the epoxy resin can penetrate and bond the cracked concrete effectively, restoring its structural integrity in the process.

Epoxy Injection Preparation Tips – Installing Surface Mount Tri-Base Ports

Epoxy Injection is a typically a low pressure to medium pressure crack filling solution where all sides of the crack are sealed and structurally glued together with a high strength low viscosity Epoxy Resin.

To prep for injection, the crack must be cleaned with a wire brush and all dust removed. Any surface contaminants, such as oils or paints, must be removed for the epoxy paste-over to bond properly. If available, use clean compressed air to remove any dust and debris. For best results perform epoxy injection preparation when the crack and surface are dry. Any water seeping from the crack should be stopped prior to epoxy injection. For sealing water bearing cracks click here.

Once the surface is cleaned, the Surface Mount Epoxy Injection Ports are installed directly over the crack 6” – 8” (15-20 cm) apart. The finer the crack, the narrower the spacing should be.

Shown in this example are standard surface mounted Tri-Base ports, however corner ports and ½” drill in ports are available for specific applications.

Tri-Base Ports are mounted by placing epoxy on each of the three tabs on the base of the port. Once ports are placed, the non-sag paste is applied to both sides of the wall, sealing the crack.

When applying paste, the mixed material should be applied generously at roughly 1/8” (3-4 mm) thickness, and mounded up around each port to approximately 1/4″ (6-7 mm) thick or more using a putty knife or other suitable tool. The paste-over should be a minimum of 1 inch (3 cm) wide along the crack. If the paste is not applied thick enough it may crack and epoxy will escape during injection, preventing proper penetration and epoxy flow within the crack itself. Note: The length of time needed for the epoxy paste to fully cure varies with ambient and substrate temperature.

“ Once ports are placed, the non-sag paste is applied at roughly 1/8” thickness and mounded up around each port. If the paste is not applied thick enough it may crack open and epoxy will escape during injection. “

SealBoss Technical Support Team

After the surface paste has hardened, structural strength epoxy resin can be injected starting at the lowest port on the crack, for horizontal or lateral cracks start on one side and work your way over.

Because the crack has been sealed on both sides, the next port in line will need to have the cap removed to allow the displaced air to escape. Once the Epoxy resin can be seen escaping from that next port injection stops, the applicator is disconnected from the injected port and the port is capped.

The applicator is then connected to the next port and the process is repeated. Once the crack has been fully injected and the Epoxy resin has cured, ports and paste can be ground off for aesthetics.

Epoxy does not Flow as Expected – Troubleshooter

Injected crack is not continuous or the area being injected is saturated
Crack is blocked by debris or cured epoxy paste
Surface mount port does not align with the crack
Epoxy has cured in injection nozzle, port or crack
Epoxy resin viscosity too high

Epoxy injection is an efficient and economical method of repairing cracks in structural concrete walls, slabs, columns and piers. If applied in compliance with all recommendations and specifications, high strength epoxy is capable of restoring concrete structures to their strength prior to crack development.

If at any time during your epoxy injection preparation and any other repairs you encounter issues that can’t be resolved, please call us here at SealBoss for support – 714-662-4445. Your technical representative will gladly be of assistance.

At SealBoss, we offer full system solutions for Structural Epoxy Injection Repairs including Electric and Pneumatic Pumps, various Ports, Epoxy Resins, Paste and Cartridge System.