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Dam Spillway Leak Sealed

SealBoss 1510 Polyurethane Foam

SealBoss 1510 Leak Sealing Application

What is the Purpose of a Spillway in Dams?

A spillway serves a critical function in dam systems. Either incorporated into the dam’s structure or built adjacent to it, a spillway facilitates the controlled and secure discharge of surplus water downstream.

SB 1510 Polyurethane Foam in Dam and Spillway Leak Sealing: An Overview

Polyurethane foam, known for its superior adhesive properties and low viscosity, plays a pivotal role in sealing leaks in dams and spillways.

Its unique characteristics, superior adhesive properties and low viscosity, make polyurethane foam an optimal choice for addressing expansive cracks, joints, and gaps in concrete structures. Hydro-active foam penetrates deeply into these openings and crevices, efficiently arresting active and high-velocity water flow, while also filling the cavities to form a waterproof seal that impedes future water seepage.

The remediation process initiates by drilling holes around the leak-prone area within the concrete perimeter. Following this, specialized injection equipment introduces polyurethane foam through the installed injection packers in the drilled holes. Upon injection, the foam expands and fills the concrete voids, establishing a sturdy bond with the surrounding substrate. After curing, the foam evolves into a solid and durable repair, effectively sealing the water leak in the spillway. Polyurethane water stop foam injection offers an effective and economical solution for many dam spillway leak repairs.

Sealing Dam Spillway Leaks with 1510 Water Stop Foam: A Case Study

How to Seal a Dam Spillway Leaks with Hydro-Active Polymer Injection

SealBoss was enlisted to tackle the problem of leaking Cold Joints, a situation that had resisted repair through four prior methods. The caulking previously deployed to seal the joint had been compromised, leading to water erosion and diminished adhesion between the caulking and the concrete. As a result, water was infiltrating through the “V” notched joint at an increasingly concerning rate.

Preparation and Injection Procedure

The repair endeavors focused on sections with active water leaks – characterized by high velocity and volume – visible efflorescence, and loose caulking. Caulking removal was required to expose the cold joint.

In preparation for placing the mechanical packers, the contractor drilled holes. When water began flowing from these holes, it was clear the drill bit had successfully intercepted the joint.

At times, it may be beneficial to keep a drill hole unsealed initially, delaying the installation of the injection packer. This approach can serve as a pressure relief point, helping to alleviate hydrostatic pressure and regulate water flow.

In preparation for the injection procedure and to curb water flow, the Oakum Soakum Technique was employed to address the gushing leaks first. SealBoss 1500 Seal Oakum, soaked in SealBoss 1510 Water Stop Foam catalyzed with a significant amount of SealBoss 15x Accelerator for quick setting and curing, was inserted into the actively leaking crevices and held in place until cured.

After completing the oakum patching process, the next phase involved installing the injection packers. The 13-100 AL packers were set in place following the 1, 2, 3, 45 Degree Injection Guidelines, with a 14″ staggered vertical spacing and about 7″ on either side of the joint to avoid interfering with the rebar.

The injection procedure commenced from the lowest packer, using SealBoss P2002 pumping equipment to inject the catalyzed SealBoss 1510 Water Stop Foam. We suggest occasional injection pauses to let the resin expand and to reduce product wastage.

Success – Dam Spillway Leak Sealed

Through these measures, all the joints were successfully sealed, and active leaks were effectively addressed.

Conclusion

In summary, the usage of polyurethane foam, particularly SealBoss 1510 Water Stop Foam, has proven to be an effective and economical solution for dam and spillway leak sealing.

The method’s success lies in the foam’s ability to penetrate deep into the crevices and gaps, providing a robust, waterproof seal.

The above case study underscores how a strategic, methodical approach can result in successful sealing of active leaks, reaffirming the significance of this solution in the field of dam and spillway maintenance and repair. As we look forward, we can anticipate that such techniques will continue to evolve, further enhancing the efficiency and effectiveness of leak repair in dam spillways.

Products Used

Dam Spillway Leak Seal Systems

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Dam Erosion and Sediment

Dam
Erosion and Sediment

Dam Erosion and Sedimentation Control
with Polyurethane Grout Injection Systems

Dam Erosion and Sedimentation Control with Polyurethane Grout Injection Systems

Introduction:

Erosion and sediment accumulation in dams can present great challenges, threatening the structural integrity and functionality of these important infrastructures. In the face of such risks, polyurethane grout emerges as a game-changer, offering a durable and versatile solution to tackle these problems. This article underscores the advantages of polyurethane grout for dam repair, highlighting its role in ensuring long-term safety and efficiency.

Polyurethane Grout for Erosion, Sediment, and Leak Control

Erosion: A Silent Threat to Dams

Erosion in concrete dams, as well as in earth dams, is more than a maintenance issue; it is a significant risk to their stability and safety. Water seeping through cracks, joints, and fissures gradually erodes concrete and soil, potentially leading to severe damage or failure. Addressing erosion is crucial for maintaining the dam’s structural integrity and ensuring its long-term viability.

Polyurethane Grout: An Answer to Dam Erosion Challenges

Polyurethane grout stands out as an effective solution to combat erosion. Its flexibility, as opposed to the rigidity of cementitious grouts for example, allows it to adapt to the dam’s natural movements without losing its sealing capabilities. Its quick curing time, hydro-active nature and water stop capabilities are a boon for minimizing operational downtime, especially in essential hydroelectric power generation or water supply dams. Versatile in use, including water stop crack injection, as well as soil stabilization, permeation and consolidation applications, polyurethane grout can be utilized in various dam types and scenarios, addressing a wide range of leakage, sedimentation, and erosion-related issues.

Economic Benefits of Polyurethane Grout

Using polyurethane grout is not only versatile and structurally sound but also economically advantageous. Its durability translates to fewer long-term repairs and reduced maintenance costs. For hydroelectric dams, the quick cure time of polyurethane grout minimizes energy production downtime, making it a cost-effective solution.

Sediment Accumulation: An Underestimated Issue

Sediment build-up in dams, often unnoticed until it becomes problematic, can reduce storage capacity and increase structural pressure. This build-up can also impede water flow, interfere with spillways, clog turbines, and affect water quality, which is especially important in drinking water sources.

Polyurethane Grout in Sediment Control

Polyurethane grout is invaluable in managing sediment challenges, in earthen and concrete dams. It can be used to create impermeable barriers, seal cracks, crevices, and joints, and solidify and stabilized substrate, effectively stopping sediment inflow.

Energy Efficiency in Dam Management

In dam management, optimizing energy production is crucial. Structural weaknesses and leaks can negatively effect a dam’s energy generation. Using polyurethane grout to seal these leaks supports maximum energy output and prolongs the infrastructure’s integrity and lifespan.

Environmental Safeguards and Polyurethane Grout

The environmental implications of dam leaks can be significant. Leaks may carry contaminants into natural waterways, harming aquatic life and ecosystems. NSF-Certified Polyurethane Grouts offer an environmentally safe solution for leak sealing, contributing to environmental sustainability.

Dam owners and operators can take several steps to address erosion and sedimentation effectively, including but not limited to:

Comprehensive Inspection: Conduct thorough inspections to identify areas affected by erosion.
Expert Consultation: Seek advice from engineers and contractors specializing in dam maintenance.
Quality Material Selection: Opt for high-quality polyurethane grout from reputable manufacturer.
Professional Contractor Hiring: Choose experienced contractors with a proven track record in using polyurethane grout.
Regular Monitoring: Implement regular monitoring and inspections post-repair to ensure ongoing effectiveness.

Contact SealBoss for Expert Assistance

For specialized expertise in dam repair and sealing leaks, SealBoss offers decades of experience in developing premium polyurethane grouts. We provide custom recommendations, insights, and referrals to qualified contractors skilled in crack and joint repair, curtain wall grouting, and waterproofing.

Conclusion

Polyurethane grout injection systems are a robust, durable, and economically viable solution for addressing erosion, sediment accumulation, and various leaks in concrete dams and earth dams.

Its versatility and effectiveness make it an essential tool in maintaining the safety, longevity, and operational efficiency of dams. By adopting this innovative solution, dam owners and operators can safeguard their infrastructure and the communities they serve.

Call to Action

For tailored solutions in enhancing your dam’s safety and efficiency with polyurethane grout, contact SealBoss at 714-662-4445 or use our Contact Form. Let our expertise guide you in maintaining your dam’s integrity and functionality.

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Bridge Crack Repair

Structural Epoxy Injection with Professional Equipment

Structural Epoxy Injection & Equipment for Bridge Crack Repair

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

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

Structural Epoxy Injection & Equipment for Bridge Crack Repair

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

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

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

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

Structural epoxy injection offers several benefits, including:

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

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

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

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

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

Montana Department of Transportation
Bridge Repair Project

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

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

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

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

Conclusion

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

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

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

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

Structural Epoxy Injection System Products Used

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Restoration Waterproofing

Restoration - Waterproofing

Restoration – Waterproofing with Injection Resins, Gels, and Foams

Restoration waterproofing projects represent a mix of various complex tasks, each with its unique set of challenges. The first crucial step is identifying the root source of the water infiltration, which at times can be a difficult process.

Diagnosis

A correct leak diagnosis might necessitate various steps, such as performing visual inspections of the inside and outside of the structure, examining the surrounding conditions, conducting flood tests, utilizing dye testing, creating mock-ups, and removing paints and finishes.

Waterproofing Restoration with SealBoss Water Stop Systems
– Resins, Foams, Gels, Packers and Pumps –

Setting Defined Objectives

Before starting a restoration waterproofing project, it is crucial to clarify the goals and expectations for every party involved.

It goes without saying that the primary aim of such a venture typically revolves around halting water intrusion. There are many techniques and products that can be used for this, such as polyurethane injection foams, gels, and resins, as well as acrylate injection gels and even epoxy resins in some circumstances. These methodologies come with their individual costs, levels of site disruption, and project timetables. It is essential that all of these elements are thoroughly considered and presented to the end customer, facilitating an informed decision-making process.

Understanding Water Movement and Migration

It is indispensable to understand some key concepts related to water migration and movement around and within soil, structures, voids, joints, and cracks.

Water is Not Always Visible

The obvious appearance of a leak in a specific location does not definitively imply that other areas are devoid of water ingress. Water invariably seeks the path of least resistance, typically navigating towards any openings, fissures, and low spots. Upon remediation of these lower areas, the water may find its way to other compromised zones.

Leak Detection Techniques

The leak detection process is further complicated if the repairs are undertaken during a period of relative dryness. Under such circumstances, leak migration might not become evident until the advent of the next rain event. For more controlled testing, it may be advisable to deliberately flood the surrounding area, creating conditions that could induce a leak at the time of inspection and repair. Conducting flood testing before, during, or after the repair work can contribute significantly towards pinpointing any areas where the leak may have migrated. Executing waterproofing repairs amidst active leaking can effectively help identify and repair leak migration issues.

Restoration Waterproofing Products

Polymer injection foams, resins and gels serve as viable solutions in restoration waterproofing. Their superior qualities make them ideal for sealing leaks, even in wet environments. Polyurethane foams are adept at sealing large leakages, both in volume and speed, expanding upon contact with water to block infiltrations effectively. On the other hand, super low viscosity resins and gels ensure a long-lasting solution for smaller, more intricate leaks, seeping into hairline cracks and curing to provide a waterproof seal. Implementing curtain injection behind a structure can effectively generate a waterproof, membrane-like barrier, thus sealing wet and damp spots within concrete and masonry structures.

At times, epoxy resins may be required to restore structural integrity, even in wet or damp conditions. For an in-depth comparison between epoxy and polyurethane injection, please refer to the detailed information provided here.

In Conclusion

Remedial restoration waterproofing is often an iterative, exploratory process that might necessitate adjustments along the way. Setting realistic expectations, keeping open lines of communication among all involved parties, and maintaining a keen eye for detail are important to the efficient and successful execution of a waterproofing process.

A well-executed waterproofing restoration can add years to the lifespan of a structure, safeguarding it against potential damage and preserving its aesthetic and functional value.

Restoration – Waterproofing Systems

Popular Water Stop & Leak Sealing Injection Links

SealBoss ® 1510

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

Our #1 Selling Polyurethane Injection Foam
Water Cut-Off Injection Grout
1510 PU Foam & Oakum Pipe Plug Kit

SealBoss ® 1570

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

Flexible Polyurethane Injection Foam
Flexible Foam, Water-Activated chemical grout.

SealBoss ® 1570 LV

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

Super Low Viscosity Polyurethane Injection Foam,
Water-Activated chemical grout. Drinking Water

SealBoss ® 15X ACCELERATOR

Accelerator for SealBoss Single Component Injection Foams

Accelerator For 1510/1570 PU Injection Foam. Adjust foam gel-time and foam expansion from low foaming to high foaming depending application.

SealBoss ® 1403 SLV

Leak Sealing Injection Resin
Super Low Viscosity PUR Injection Resin

Two Component Flexible Resin
The solution for wet and dry surfaces and moving cracks. Extremely low viscosity for superior penetration in hairline crack injection.

SealBoss ® FLEXGEL

Leak Sealing Injection Gel
Hydrophilic Injection Foam Gel
Hydrophilic Gel

Versatile Hydrophilic Polyurethane Foam-Gel
Water activated single component hydrophilic Polyurethane grout.

SealBoss ® 2400

Leak Stop
Leak Sealing
Acrylate Gel
Acrylic Gel

Poly Acrylate Gel
Hydrophilic poly-acrylate gel / acryclic gel for soil stabilization, curtain-injection, infusion bladder injection into structures and to seal degrading masonry grout.

Restoration - Waterproofing

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Leaky Basement Repair

Leaking Basement Repair Injection System

How to Fix a Leaky Basement

Water damage is a serious issue that can have devastating effects on your home. Not only does it decrease the value and livability of your property, but it can also compromise the structural integrity of your home. A leaky, damp basement is particularly concerning, as it creates a breeding ground for harmful mold and bacteria that can cause health issues for you and your family.

In addition, a damp basement can attract pests such as termites and rodents, causing further damage and infestations. It’s crucial to address any water damage in your basement as soon as possible to avoid these issues and prevent them from escalating. With the right tools and procedures, you can successfully mitigate basement leaks and protect your home from further damage.

Cracks and Cold Joints are Common Areas for Basement Leaks to Occur

Unsealed cracks and cold joints in your basement can be a major source of water damage, as they provide an easy pathway for water to enter your home. This can result in flooding, which not only damages your belongings but also compromises the structural integrity of your home. In addition to damaging walls, coverings, furniture, and storage items, water can also cause electrical hazards and increase the risk of fires.

How do I Stop my Basement from Leaking?

There are many methods to mitigate basement leaks. The construction of the basement and environmental factors have to be considered when choosing the right products and procedures, and it is always advised to consult a professional in the process.

One solution that has been successfully used for over thirty years is the SealBoss Leak Sealing Foam injection system. This system seals leaking basement cracks and cold joints by injecting a foam that expands to fill and seal the gaps, creating a watertight barrier. This method is effective, long-lasting, and cost-efficient, making it a popular choice for homeowners and contractors alike.

Leaky Basement Repair – Joint and Void Filling Injection

Scope

A basement had persistent leakage through cold joints where the wall meets the floor.

A previously repair attempt by a contractor using a crystalline product and epoxy coating had failed, water was still pooling on the floor following heavy rains.
The homeowner was in search for a permanent solution to prevent water intrusion into the basement.

Leaky Basement Repair – Detail

A SealBoss technical representative was summoned to provide his expertise on how to seal the basement leaks. >Upon careful examination of the jobsite, it was discovered that the basement floor was approximately 8 inches thick and was poured slightly deeper towards the walls. It was also identified that the source of the leakage was through the cold joint between the wall and the poured slab.

Repair System

It was determined that SealBoss 1510 Water Stop Foam would be the preferred leak sealing injection product to seal the leaks permanently. The product would be injected through SealBoss injection packers using the SealBoss P2002 injection machine, a compact, lightweight, and quiet pump, extremely well suited for this kind of application.

Procedure

The slab was drilled with half-inch holes spaced one foot apart, parallel to the wall, and ten inches from the wall. The holes were drilled at a 90-degree angle and full depth into the slab.

After drilling each hole, the presence of heavy substrate saturation along the wall was confirmed by water filling the hole. It was concluded that there was a void beneath the slab that needed to be filled with foam during the injection process.

Once all the holes were drilled, packers were placed at half depth and only hand tightened for easy removal during injection. The injection process began on the side closest to the crawl space’s stub foundation wall.

The first packer was loosened, then placed at full depth and retightened, while the next packer in line was removed. This allowed for a path of less resistance for any displaced water or soil to escape from below and provided visibility for material travel.

Each packer was injected until catalyzed foam was observed coming out of the adjacent hole. The packer was reinjected a second or third time until refusal or sufficient pressure buildup.

Leaky Basement Repair – Conclusion

This leaky basement repair technique involved a combined joint injection and void filling injection procedure, which was deemed to be the best method for sealing the basement leak efficiently and permanently.

Check out our Leaky Basement Repair Kits

Materials and Tools Used

Leaky Basement Repair Related Articles

Learn More

Feel free to contact us at 714-662-4445 if you have any inquiries, or simply fill out our request form for us to get back to you. Our team is eager to assist you in finding the right solution for your needs. In addition, we offer on-site support from our expert and experienced technical representatives, which can be arranged upon request.

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Epoxy Crack Injection Concrete Repair

Epoxy Crack Injection
Concrete Repair

Epoxy Concrete Crack Injection Systems

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

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

Epoxy Crack Injection

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

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

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

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

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

SealBoss Epoxy Resins

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

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

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

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

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

SealBoss ® Surface Mount Injection Ports

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

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

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

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

Begin the Epoxy Crack Injection at the Point of the Structure

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

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

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

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

Epoxy Crack Injection System – Epoxy Resins, Ports, Pumps

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

SealBoss ® 4040 LV

SealBoss Highest Quality Epoxy Standard

Injection Epoxy Resin
Multi-Use Epoxy Resin

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

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4050 SLV

Super Low Viscosity Epoxy Resin

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

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4500 F

SealBoss Highest Quality Epoxy Standard

Fast Cure Epoxy Paste

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

– Commercial Bulk Packaging
– Cartridge System

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

SURFACE PORT

Epoxy Injection Port – Industry Standard Bestseller

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

Bestseller – a SealBoss Standard

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

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

‘BELOW’ SURFACE PORT

Epoxy Injection Drill Hole Mount Port

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

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

PA3000 The Epoxy Pump Standard

High & Low Pressure
Epoxy Injection & Polyurethane Injection

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

P3003-2C PUR & Epoxy Pump

High & Low Pressure
Epoxy & Polyurethane Injection Piston System

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

SealBoss ® Epoxy

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Epoxy Injection in Cold Weather

Cold Weather
Epoxy Injection Training

Epoxy Injection in Cold Weather

Inclement weather can often pose challenges in the concrete repair and waterproofing industry where applications often rely on the reactive cure of chemical grouts, such as polyurethane foams, gels and epoxy resins.

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.

Permeation Grouting Injection Pipes

How to Use & Select Injection Pipes / Lances

Permeation Grouting Injection Pipes, also known as Grout Injection Lances or Soil Lances, are designed to transport your injection grout deep into dirt, sand and other types of soils.

As we demonstrate in the video, our injection lances come in three distinct versions to provide the best possible polymer grout delivery in a variety of soil compositions.

Please don’t hesitate to contact us here at Sealboss for more information about our extensive injection equipment and accessory selection. Your representative will be happy to assist.

Soil Stabilization and Permeation Grouting Applications

Advantages

Easy to use, ram injection lances penetrate soil without need for large equipment
Injection lances can be individually combined to reach specified injection depth
Lack of peripheral gap after installation permits controlled flow of injection grouts

Applications

Extremely suitable for lower depth applications in penetrable soils
Permeation grouting
Soil stabilization
Consolidation of soil & sands
Underpinning buildings
Grout curtain injection
Lifting injection applications
Stabilization of industrial machine foundations and slabs

Injection Lance Types

Stabilize and consolidate loose dirt with SealBoss polyurethane grouts and gels. Penetrate the soil with the SealBoss Lances of your choice to the desired depth.

Blow Out Tip
Pin pointed injection from the tip of the installed lance
Perforation Holes Lances
General grout injection / permeation into the soil from the perimeter of the installed lance
Perforation Holes Lances with Flap Valves
General grout injection / permeation into the soil from the perimeter of the installed lance. Flaps protect the pipe during installation and when in place from the entering of debris into the inner pipe

For smaller jobs and tight space grout delivery applications check out our Grout Injection Needles

SealBoss ® Injection Lances

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lances

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Sealing Tie Holes

Tie Holes a.k.a. Tie-Rod Holes in Concrete Structures

What are Tie Holes?

Tie holes are small openings in concrete structures that result from the removal of tie rods. Tie rods are essential components used in concrete formwork, which is the mold into which concrete is poured to achieve the desired shape. These rods help maintain the alignment and stability of the formwork during the concrete pouring and curing process.

Tie holes may start to leak under hydrostatic pressure caused by a source of water on the opposite side of the structure.

Polyurethane Polymer Foam Injection is an effective method to seal leaking tie rods permanently.

Sealing Tie Holes and Cracks

A Case Study in Effective Water Tank Repair

In the world of construction, particularly in the construction of water tanks, shrinkage cracks and tie-holes are common issues that can lead to slowly weeping or even significant leaks. These problems are often accompanied by visible efflorescence, signaling a need for immediate and effective repair.

A recent project by a contractor in a rural water district expansion north of Atlanta, Georgia, perfectly illustrates how these challenges can be met with the right expertise and equipment.

Encountering the Challenge

During the construction of water tanks in this project, the contractor encountered both shrinkage cracks and tie-holes showing signs of leakage.

To address these issues effectively, the contractor sought on-site support and comprehensive systems training, specifically in the use of SealBoss 1510 NSF Hydrophobic Water Stop Foam and the P2002 High-Pressure Injection Pump.

The Training and Repair Process

The training began with a thorough inspection of the tank to identify the most actively leaking areas.

This was followed by a demonstration of the SealBoss Injection System application. The repair process involved a strategic approach to drilling holes:

The 1, 2, 3, 45 Degree Injection Method was used for the shrinkage cracks, and for sealing the tie-holes, a 45-degree hole was drilled 4 inches from the edge of each tie-hole until the steel insert was reached.

Preparation and Injection

Before the injection process, each drilled hole was pre-injected with water using a spray bottle. Given the ambient temperature of 38 degrees Fahrenheit, hot water (between 70 and 90 degrees Fahrenheit) was used for pre-injection to assist with the catalyzation time of the 1510 foam in the cold concrete. After flushing the holes, the installation of the SealBoss 13-100 AL Evolution Mechanical Packers commenced, followed by the injection process using the P2002 high-pressure injection pump.

Hands-On Learning and Independent Operation

The P2002 pump, known for its simplicity and drill-operated mechanism, was explained in detail. The training emphasized understanding injection pressure and the patience required for successful application.

Initially, the technician assisted with the pump operation, but within 10 minutes, the crew was able to inject independently.

Each packer was injected until there was positive refusal of material around each tie hole, and the same process was applied to the cracks.

Ensuring Long-Term Success

Once the crew gained confidence in operating the system, the focus shifted to cleaning and maintenance of the pump, ensuring its longevity and effectiveness for future projects.

Conclusion

This project north of Atlanta, Georgia serves as a prime example of how proper training and the right equipment can effectively address leaking tie holes and shrinkage cracks in new water tank construction.

The use of SealBoss 1510 NSF hydrophobic foam and the P2002 high-pressure injection pump, combined with hands-on training and a strategic approach to sealing, provided a durable solution to the problem of shrinkage cracks and tie-holes.

This case study not only highlights the importance of addressing these construction challenges promptly but also demonstrates the value of expert guidance and training in ensuring the longevity and integrity of water storage facilities.

Related Articles

Sealing Tie Holes - Water Stop System

SealBoss ® 1510

Concrete Leak Sealing

Leak-Seal 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.

SealBoss ® 15X ACCELERATOR

Accelerator for SealBoss 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.

P2002 Injection Pump Standard

Polyurethane Injection

Light Weight, Modular Design
Electric Drill Operated
Single Piston System
6000+ psi – 1 Component

13-100AL Evolution

ALUMINUM MECHANICAL PACKER

Dimensions
1/2″ X 4″
13 x 100mm

13-100AL Evolution

Standard Packer

Economical packer with removable anti-return valve in zerk permits port-port travel technique by removing the zerk fitting. Suitable for PU, EP, Polyacrylate, and Silicate grouts.

Bestseller – a SealBoss Standard

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Polyurea Floor Joint Filler | Fast Setting

Polyurea Floor Joint Filler | Fast Setting
SealBoss 6500

Fast Concrete Floor Joint Filler
SealBoss ® 6500 QuickFix

Fast setting formula reduces downtime
Self Leveling
Semi-Rigid / Flexible Formulations available
Outstanding Bond Strength & Penetration Properties
Tough physical properties reduce floor joint repairs and maintenance
Reduces the rate of joint deterioration in older floors
Will cure in temperatures as low as -20° F (-29°C)
Custom Colors
Use In Combination With SealBoss 6060 Concrete Floor Crack & Spall Repair Resin
Product is available in Cartridges

SealBoss 6500 is a rapid setting polyurea joint filler, engineered to seal and protect floor joints in industrial and commercial environments. Such as heavy duty warehouses and distribution center facilities, stained and polished concrete floors in retail stores, schools and many other floor settings with high traffic.

Click here to learn about our UV-Resistant Joint Filler SB 6500 UVR

6500 QuickFix Polyurea Joint Filler is a self leveling chemical cure filler product. Let me just touch on some of the highlights.

SealBoss 6500 polyurea cures within minutes of application. The product is available in two variations of flexibility and shore hardness. The product provides excellent bond strength within minutes of cure. Unlike to epoxy joing fillers, SealBoss 6500 cures at very low temperatures. SealBoss 6500 standard color is grey but custom colors are available.

Our fast cure SealBoss 6500 Polyurea Joint Fill and SealBoss 6060 QuickFix Concrete Crack and Spall Repair products are the recommended choice for timely floor repairs in commercial warehouses and other areas of traffic. The floor repair materials are also available in cartridges.

Inquire more about the outstanding SealBoss 6500 and SealBoss 6060 concrete repair products when you call us here at SealBoss. Your representative will gladly help you out.