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Retaining Wall Repair

Injection Methods Compared

Understanding Retaining Wall Repair:

Polyurethane vs. Epoxy Injection Methods

Retaining walls play a pivotal role in infrastructure and landscape, offering both functional support and aesthetic appeal. These structures, while robust, are susceptible to environmental factors and age related weakening that can lead to cracks, spalls, water leakage, or other forms of structural damage.

Addressing these issues promptly and effectively is crucial to ensure the longevity and safety of the wall. In the realm of deep penetrating, effective sealing and high strength structural retaining wall repairs, two methods have emerged as frontrunners: Polyurethane and Epoxy injection.

This overview explores the intricacies of both methods, comparing their advantages, applications, and effectiveness to guide you in making an informed decision for your retaining wall repair needs.

Retaining Wall Repair
with Leak Sealing Polyurethane Water Stop Foam Injection

Retaining walls serve as crucial components in construction projects, especially when dealing with slopes or elevated terrains. Their primary function is to combat soil erosion and bolster the stability of structures by resisting the pressures of soil and water. Yet, like all structures, retaining walls are prone to wear and tear, often manifesting as water leakage and subsequent erosion.

Enter polyurethane injection, a game-changer in the realm of retaining wall repairs. This method stands out not only for its efficacy but also for its cost-efficiency. Unlike traditional repair methods that might involve extensive excavation, the use of heavy machinery, or prolonged construction periods, polyurethane injection offers a swift and minimal-disruption solution. The essence of this method lies in the foam grout injected, which forms a resilient waterproof barrier, crucial for walls constantly exposed to moisture and hydrostatic pressure.

At its core, polyurethane injection foam is engineered to expand upon water contact. Typically, this foam is introduced into cracks or voids within a structure. Upon encountering water, a chemical reaction is triggered, causing the foam to swell and occupy the space. This unique expanding property is invaluable for tasks like leak sealing, ensuring that the foam aptly fills gaps and halts further water penetration.

The combination of low viscosity, fast expansion and curing, flexibility, good chemical resistance and adhesion, make polyurethane injection foam grout an effective choice for leak seal and water stop injection applications.

Here are some advantages of using PUR foam for stopping water migration through retaining walls:

Cost-effective — Polyurethane injection is a cost-effective solution for repairing a leaking retaining wall. It requires less labor, time, and materials compared to traditional methods of repair, such as excavation and replacement
Water Stop Leak Sealing and Waterproofing — The injected polyurethane resin expands on contact with moisture and creates a waterproof compression seal that prevents further water infiltration into the retaining wall
Minimal-Invasive — Polyurethane injection requires minimal disruption to the surrounding area, making it a convenient solution for homeowners and business owners. It does not require excavation, heavy machinery, or lengthy construction timelines
Quick — Polyurethane injection can be completed quickly compared to traditional methods, minimizing the time that the retaining wall is out of commission and minimizing disruptions to daily activities
Durable — The injected polyurethane resin creates a strong and flexible bond with the concrete surface, making it a durable and long-lasting solution for sealing a leaking retaining wall

Summary

Polyurethane injection is a cost-effective, waterproof, minimal-invasive, quick, durable, versatile, and eco-friendly solution for sealing a leaking retaining wall. If you are facing a leaking retaining wall, consider using this method for an efficient and effective repair solution.

Retaining Wall Repair
with Epoxy Resin Injection For Structural Strength

Retaining walls play an indispensable role in both landscape and infrastructure, acting as bulwarks against soil erosion and providing essential structural support. Yet, like all structures, they are vulnerable to the elements, facing challenges like natural degradation, water-induced damage, and the relentless pressure from the soil. Over time, these factors can result in cracks, voids, and other structural concerns. Left unaddressed, these issues can jeopardize the wall’s stability and safety. This is where epoxy resin injection comes into play, offering a robust solution to restore and reinforce a retaining wall’s strength.

Here is a closer look at the benefits of using epoxy resin injection for retaining wall reinforcement:

Structural Strength Repair — Retaining walls can lose their structural strength due to natural wear and tear, crack development, water damage, and soil pressure. Epoxy resin injection can fill and reinforce the damaged areas, restoring the retaining wall’s strength and stability. Epoxy resin, known for its high compressive and tensile strength, can fortify damaged areas, resisting both compressive and tensile forces. Its ability to prevent crack propagation and bear significant pressures and loads makes it a prime choice for restoring walls facing soil and water pressures
Durability — Epoxy resin injection is a durable solution for retaining wall repair. Epoxy resin is resistant to water, many chemicals, and typical ambient heat. It also resists wear and tear, making it a long-lasting solution that can withstand the test of time
Cost-effectiveness — Opting for epoxy resin injection can be a financially savvy decision. When compared to the steep costs associated with wall replacement—which often involves excavation, demolition, and rebuilding—epoxy injection emerges as a cost-effective alternative
Minimal-Invasive — Epoxy resin injection is a minimal-invasive solution for repairing retaining walls. It does not require excavation, heavy machinery, or lengthy construction timelines, minimizing the disturbance to the surrounding area
Quick — Time is of the essence in repair projects. Epoxy injection offers a faster turnaround than many traditional methods, ensuring the retaining wall is swiftly restored to functionality, with minimal disruption to daily routines

Summary

Epoxy resin injection is a reliable and efficient solution for structural retaining wall repair, offering a range of advantages such as durability, high compressive and tensile strength, cost-effectiveness, and minimal-invasiveness.

For any structural repair project, it is highly recommended to seek guidance from a professional engineer to assess the suitability of epoxy injection. Additionally, it is important to hire a skilled and experienced epoxy injection contractor who can perform the repair in accordance with the specifications. This ensures that the repair is conducted safely and effectively, and that the structure is restored to its optimal condition. It is crucial to prioritize safety and quality when it comes to structural repairs — expert advice and hiring competent professionals can help to achieve these goals.

Conclusion

Retaining Wall Repair – Polyurethane or Epoxy Injection

Polyurethane foam injection can be applied effectively in a wet environment where active water leaks are present. When the foam is injected, it expands and creates a water-resistant barrier that forms a permanent, flexible or semi-flexible seal upon contact with water. In most cases, there is no need to surface seal cracks before injecting the foam. Injection packers can be installed in wet environments and injection is not impacted by active water flow. While water-bearing cracks can lead to structure deterioration and erosion over time, they often do not compromise the structural integrity of the building if recognized early and sealed promptly
While structural epoxy injection can effectively restore a retaining wall’s strength and integrity, it is most effective in a dry environment. Epoxy is not well-suited to stop active water leaks. The injection area requires more preparation work, and it is recommended to surface seal cracks before injecting the epoxy. Surface ports do not adhere well in very wet environments. This repair method is more time-consuming and labor-intensive compared to polyurethane foam injection, and it can be more expensive

In summary, both polyurethane foam injection and structural epoxy injection are effective repair methods for retaining walls. Polyurethane foam injection is a highly effective method for preventing water infiltration, stopping active water flow, and efficiently and permanently sealing cracks. Structural epoxy injection is most suitable for application in environments that are not actively leaking and require additional support for significant structural damage in the wall.

Ultimately, the choice of injection repair method will depend on the specific project requirements.

It is always recommended to consult with a qualified professional to determine the best approach for your retaining wall repair needs.

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Retaining Wall Crack Injection Repair

Using Leak Sealing Foam

Retaining Wall Crack Injection Repair using Leak Sealing Foam offers a swift and dependable solution to address cracks responsible for water infiltration and subsequent erosion. Here is a quick guide to this repair process:

1. Site Preparation
Begin by ensuring the site is ready for the repair. Clear away any debris, dirt, and loose materials to provide a clean working surface.

2. Crack Assessment
Identify and evaluate the cracks in terms of their depth and length. While visible cracks are obvious targets, it’s crucial to be vigilant about potential hidden cracks that might escape a cursory glance. Such concealed cracks might necessitate a more thorough examination.

3. Drilling Injection Point Holes
Once the cracks are mapped out, drill holes into the retaining wall. These should be spaced roughly 12 inches apart, running along the entirety of each crack.

4. Packer Installation
Insert the injection packers into the freshly drilled holes, ensuring they’re firmly anchored. These packers act as conduits for the polyurethane foam during the injection phase.

5. Foam Injection
With the packers in place, it is time to inject the prepared leak sealing foam. Utilizing the appropriate equipment, start the injection at the lowest point, working your way up. Continue this process until the foam either refuses to enter further or you’ve covered the entire crack.

6. Curing and Final Touches
Post-injection, allow the polyurethane foam ample time to cure, adhering to the manufacturer’s guidelines. Once cured, remove the packers and seal the holes using a compatible sealant.

In summary, the use of leak sealing foam for Retaining Wall Crack Injection Repair is a tried-and-true method, ensuring cracks are effectively sealed, preventing any future water ingress.

Retaining Wall Crack Injection Repair Guide

Retaining Wall Crack Injection Repair with SealBoss 1510 Leak Sealing Foam

When it comes to the restoration of older commercial buildings, retaining wall crack injection repair emerges as a crucial method for preserving architectural integrity. A recent case involved a 50-year-old commercial structure that required rehabilitation, particularly for its below-grade retaining wall. This wall, adjacent to a staircase, displayed multiple through cracks and evident efflorescence.

Choosing the Right Repair Product

Given the challenges posed by groundwater seepage, especially after heavy rainfall, SealBoss 1510 Leak Sealing Foam was chosen for the job. This product was injected at high pressure to address the cracks before the concrete wall underwent refacing.

Insightful Inspection

A detailed inspection revealed that the main, larger cracks were accompanied by smaller, branching cracks. The retaining wall, showing clear signs of honeycombing and pitting, was constructed with an 8-inch thickness. However, the design and layout of the rebar remained unknown.

Strategic Packer Placement

The unique challenges of this retaining wall crack injection repair, such as uncertain rebar spacing and the wall’s relatively shallow thickness, necessitated a deviation from the standard. Instead of placing injection packers at the conventional 45-degree angle, they were positioned directly into the cracks.

This “in the crack” packer placement minimized the risk of hitting rebars during drilling. Given the wall’s 8-inch thickness, this method ensured the injection foam penetrated effectively, sealing the structure and halting water flow. Drill holes, spaced roughly 12 inches apart, were drilled to a depth of around 4 inches. These holes were then cleaned with warm water to remove any dust, prepping the crack for injection. Subsequently, SealBoss 13-100AL Evolution high-pressure injection packers were installed, recessing the rubber section by about ½-inch.

More information on recommended injection packer placement can be found here.

Product Conditioning

Considering the low ambient temperatures of 34F/1C, the SealBoss 1510 Leak Sealing Foam was conditioned with a higher ratio of SealBoss 15x Accelerator, approximately 20% by volume, as opposed to the usual 10%.

Injection Process

With the SealBoss P2002 Pump filled with a thorough mix of 1510 Foam and 15x Accelerator, the injection process began. Starting from the lowest packer, the procedure moved vertically upwards. The injection was paused intermittently whenever the catalyzed 1510 foam visibly emerged from the crack. This allowed the foam to cure, ensuring the subsequent hydrophobic resin injection would effectively seal any remaining capillaries within the crack.

The result? Every crack underwent the retaining wall crack injection repair process to specification, successfully halting stopping all water intrusion and seepage.

Jobsite: Bank of America
Scope: Retaining Wall Crack Injection Repair – Active Leaks
Materials Used: SealBoss 1510, SealBoss 15X
Injection Packers: SealBoss 13-100 AL Evolution
Pump: P2002

SealBoss Leak Sealing Foam Injection using angled injection packers

Conclusion

Retaining Wall Crack Injection Repair

The service life of a retaining wall is the estimated time period it can function safely and effectively. By addressing damages early and preventing further deterioration, leak sealing polyurethane can help extend the service life of a retaining wall, ensuring that it can continue to function effectively and safely for a longer period of time.

Injecting leak sealing grout prevents water intrusion, erosion, and deterioration of the retaining wall’s rebar, which helps maintain its structural stability, safety, and integrity. This method provides a practical solution to extend the retaining wall’s life, improve its cosmetic appearance, and ultimately increase its service life.

Retaining Wall Repair Method Comparison

Polyurethane Leak Sealing versus Structural Epoxy Injection

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Midwest Joint Fill Training | SealBoss 6500 Polyurea & JointMaster Pump

Midwest Joint Fill Training
SealBoss 6500 Polyurea & JointMaster Pump

Another

On the Job Training

Joint Fill & Repair

Heartland Warehouse Renovation

Introduction:

This article explores the training and application of SealBoss 6500 Polyurea Joint Filler and JointMaster Pro2 Pump in an aerospace facility renovation, emphasizing the importance of proper floor joint repair in industrial settings.

Focusing on a case study from St. Louis, Missouri, we highlight how a local contractor, new to joint filling, received hands-on training from a SealBoss Technical Representative.

The project involved repairing 6,000 linear feet of floor joints to meet the demands of a high-profile aerospace company, showcasing the effectiveness of professional training and high-quality materials in preparing warehouses for heavy-duty use.

Aerospace Facility Floor Joint Fill and Repair with SealBoss 6500 Polyurea Joint Filler and JointMaster Pro2 Joint Filling Pump

With development of building tilt-up warehouses on the rise across the country, many are not quite suited for the new lessee and required renovations and improvements, as they must be made prior to moving in and the beginning of operations.

SealBoss Expertise Elevates Industrial Floor Solutions

On-Site Expertise from SealBoss

In the bustling heart of St. Louis, Missouri, a SealBoss Technical Representative was summoned to impart specialized training on the SealBoss Floor Repair Systems to a local contracting team. This professional enrichment was tailored to equip the team with the requisite skills for executing imperative renovations, facilitating the seamless transition for an esteemed lessee’s occupancy.

Catering to a High-Profile Client with Superior Products

The project was commissioned by a renowned Aerospace company, necessitating the warehouse to be adept at handling and storing hefty aerospace components. In response to the rigorous demands of such a high-caliber client, the SealBoss 6500 heavy-duty, fast-cure polyurea joint filler was selected. This premium product, boasting an A 80 Shore hardness coupled with 200% elongation, was strategically chosen to ensure seamless navigation of heavy forklift traffic throughout the facility, thereby maintaining operational fluidity.

Innovative Technology: The JointMaster Pro2 Joint Fill Pump

The project team, albeit inexperienced with joint filler technologies and the sophisticated JointMaster Pro2 professional battery-equipped dispensing pump, received comprehensive training from the seasoned SealBoss representative. This hands-on educational approach facilitated a swift acclimation to the cutting-edge equipment, ensuring the crew was well-prepared to tackle the task ahead with confidence.

Project Scope and Ambitions

The undertaking involved the meticulous repair and filling of approximately 6,000 linear feet of floor joints within the warehouse. The ambitious goal was set to accomplish this extensive joint fill within a single day, a testament to the efficiency and effectiveness of SealBoss solutions.

Meticulous Preparation for Optimal Outcomes

Preparatory actions were meticulously carried out the day prior to the main operation. The contractor diligently removed any failing joint fill, addressing adhesion and delamination issues to ensure a clean slate. The joints were then methodically cleaned and outfitted with backer rod to the required depth, setting the stage for an optimal repair process.

Strategic Team Composition for Enhanced Efficiency

A strategic three-man crew configuration was recommended to streamline the workflow: one individual to operate the pump, another to precisely apply the SealBoss 6500 polyurea joint fill, and a third ‘floater’ tasked with shaving the joints within the critical 8-15 minute window and replenishing materials as needed. This efficient division of labor was designed to maximize productivity and ensure a smooth execution of tasks.

Empowering Training Leads to Remarkable Results

Following a succinct yet thorough briefing covering the materials, pump operation, and cleaning procedures, coupled with a brief but intensive 20-minute hands-on training session, the novice crew rapidly adapted to the demands of the project. Achieving an impressive dispensing rate of over half a gallon per minute, the team successfully filled and shaved 6,000 linear feet of joints during the training day, a remarkable feat demonstrating the transformative power of expert guidance and high-quality SealBoss products.

“We Provide Field Service When You Need It!

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

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

We won’t leave a jobsite till I know everyone is comfortable with the systems and can reteach the next person in line.

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

SealBoss ® Technical Support and Sales Team

SealBoss Floor Joint Filler

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Upgrading to Bulk Joint Filling Machine

Transitioning from Polyurea Cartridges to the
JointMaster Pro2 Pump

The Evolution of Joint Fill Application

Introduction:

In today’s competitive construction and floor repair industry, smart investments in technology can significantly impact a contractor’s business growth. This article highlights the strategic advantages of integrating the SealBoss JointMaster Pro2 Joint Fill Pump into your operations.

Beyond a mere equipment upgrade, the JointMaster Pro2 offers enhanced profitability and operational efficiency, marking a departure from traditional cartridge systems.

We will explore how this investment not only recoups costs quickly but also propels business forward by reducing labor costs and project timeframes. Additionally, the piece underscores SealBoss’s commitment to customer success through extensive support and training, ensuring users fully leverage the technology to achieve superior results in their projects.

Elevating Performance with the JointMaster Joint Filling System by SealBoss

A SealBoss’s regional technical representative and an esteemed SealBoss distributor recently convened on-site with a local contractor at a pioneering tilt-up warehousing facility in the heart of the St. Louis area. The main objective of the meeting was to provide insightful training and reliable support, streamlining the contractor’s transition to a more efficient joint-filling method.

Upgrading to JointMaster Joint Filling Machine

This particular day marked a significant milestone for the contractor, as they shifted gears from utilizing SealBoss’s 6500 Polyurea Joint Fill Cartridges to adopting the more advanced, professional SealBoss JointMaster Joint Fill Pump. This transition, aimed at SealBoss 6500 polyurea bulk joint filler applications, promises substantial upgrades in time-efficiency and cost-effectiveness.

SB JointMaster Efficiency – Time-Saving, Cost Effective, Easy Operation

After an informative, 30-minute comprehensive overview touching on the ins and outs of the pump use, along with daily upkeep and maintenance, the contractor was well-equipped to smoothly transition to this innovative system. Immediately noticeable was the leap in labor efficiency and the significant reduction in the time taken to complete tasks.

What had once been a labor-intensive process requiring five workers on their knees applying the product from cartridges was transformed into a streamlined operation handled by a three-man team. Two personnel managed the efficient running of the JointMaster Pump, while the third team member focused on joint preparation. This operator also circled back to refine and shave any crowning of the joints, ensuring a professional and high-quality finish.

The SealBoss JointMaster Joint Fill Pump not only simplifies the workflow but also drastically improves the quality and speed of the process, ultimately enhancing the overall productivity and satisfaction for contractors everywhere.

Assessing the Investment Value of the JointMaster Pro2 Joint Fill Pump

While preparing cost estimations for a substantial project, the contractor swiftly discerned that the initial outlay for a JointMaster Pump could be rapidly offset. Moreover, it promised to yield a robust profit, significantly higher than what could have been generated through conventional cartridge methods.

Significant Savings in Labor, Time, and Material Costs

With the new JointMaster, the contractor can now reach an impressive daily output of 4,000 – 5,000 linear feet of filled joints. Powered by a large deep-cycle battery, the highly efficient, electronically controlled JointMaster machine can operate for a full eight hours when fully charged. Alternatively, if battery operation isn’t preferred, the pump can function efficiently from a standard 110V outlet. 220V pump versions are also available.

Elevating Joint Fill Quality and Ensuring Applicator Satisfaction

The JointMaster machine, equipped with high-precision pump units, delivers product components uniformly. This meticulous dispensation ensures a reliable, even distribution of material within the concrete joints, significantly enhancing the quality of the joint fill.

The machine is also designed with sizable stainless steel hoppers, a feature that enables refilling on the move. This unique capability eliminates any interruption in the workflow, thereby ensuring the application process is a seamless, uninterrupted experience.

In terms of control, the operator is firmly in the driver’s seat, able to regulate the product flow directly via the potentiometer on the applicator. This level of control, paired with the machine’s straightforward operation and rapid progress on job sites, makes for an efficient process that consistently yields satisfying results. This, in turn, heightens the satisfaction of the applicator, affirming the JointMaster machine’s reputation as an operator-friendly, high-quality solution.

Wanted to get back to you on the machine.
Works like a charm.Thanks Again, Jay Kangas

‘She is absolutely beautiful! Very well done machine.
I have pumped several thousand feet through already.’ Stephen Schmid

SealBoss JointMaster Technician

Driving Business Growth

In the midst of conducting cost-benefit analyses for larger scale projects, a contractor quickly came to a profound realization. The initial capital investment required for a JointMaster Pro2 Joint Fill Pump could be quickly recouped. Moreover, it promised to deliver a considerable profit margin, far surpassing what would have been achievable using traditional cartridge systems.

The JointMaster Pro2 Joint Fill Pump, an innovation in the world of polyurea joint filling, isn’t just another piece of machinery—it’s a tangible investment that could substantially enhance your profitability and operational efficiency. Its advanced technology and robust construction, combined with user-friendly operation, significantly reduce labor costs and time spent on each project, offering an impressive return on investment.

This is an investment that speaks volumes about a contractor’s commitment to excellence, modernization, and productivity, reinforcing their reputation in the competitive floor repair industry

An investment in a JointMaster Pro2 Joint Fill Pump isn’t just about spending money on a new tool—it’s about investing in a proven system that facilitates cost-effective, efficient operations and, ultimately, drives business growth.

My journey began right here at SealBoss, where I was directly involved in building and repairing JointMasters

This hands-on experience has equipped me with deep insights and an unparallelled understanding of the mechanics and operation of our products. This allows me to provide in-depth, on-the-spot training confidently, and offer proficient assistance in maintaining your machines.

Covering all SealBoss System Solutions

As an integral part of the SealBoss team, my expertise extends far beyond just offering state-of-the-art pump and material systems for floor joints.

Our commitment extends to providing on-site support and training from the center of the U.S. Whether it’s a new company eager to learn or new employees in need of training, our mission is to ensure everyone can leverage the full potential of our systems.

SealBoss has upheld a strong tradition of exceptional user support for over three decades

We are proud to carry forward this tradition in the years to come. Our highly knowledgeable technical support team is always ready and eager to help. No matter what questions or concerns you may have, rest assured that we are here to guide you through every step of the way.

SealBoss Floor Repair

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JointMaster

Joint Filler Maintenance – Elongation, Separation, Repair

Technical Bulletin

Joint Filler Maintenance
Elongation - Separation - Repair

A Concise Guide for Ensuring Optimal Performance and Longevity of Your SealBoss Joint Filler

Safeguarding the Durability of Your Concrete Joints

Background

The tensile elongation of semi-rigid joint fillers is a common characteristic to consider. Ultimate tensile elongation pertains to the degree of expansion a material can undergo, in terms of its length, before succumbing to fracture under tensile force. It is a common misconception, that employing a joint filler with a high elongation value can facilitate early joint filling in new flooring, with the filler then able to ‘stretch’ in accordance with the joint as it expands due to slab shrinkage.

This reasoning is flawed.

Tensile testing gauges the capacity of the joint filler material to stretch along the test specimen’s length. However, control joints in concrete floors don’t lengthen but rather widen laterally — side-to-side . Thus, the tensile elongation test does not accurately simulate real control joint movement or the joint filler’s capacity to accommodate this movement.

Consider the polyurea joint filler with a tensile elongation of 200%. It can stretch laterally — side-to-side — approximately 10% before it starts to split either cohesively (within the filler itself) or adhesively (along the joint filler/concrete bond line). Given that the shrinkage-induced joint widening often surpasses what the joint filler physically can withstand even under the best circumstances, early installation of joint fillers will likely lead to splitting or a loss of adhesion. Concrete shrinkage can cause the Joint Filler to split or separate over time.

This is a normal occurrence and not an indication of joint filler failure, and is clearly stated by the American Concrete Institute in the ACI 302.1R-04 Guide for Concrete Floor and Slab Construction, Section 9.10 – Joint Filling and Sealing

” 9.10.1 Time of filling and sealing—Concrete slabs-on-ground continue to shrink for years; most shrinkage takes
place within the first 4 years. The most significant shrinkage takes place within the first year, especially the first 60 to 90 days. It is advisable to defer joint filling and sealing as long as possible to minimize the effects of shrinkage-related joint opening on the filler or sealant. This is especially important where semirigid fillers are used in traffic-bearing joints; such fillers have minimal extensibility. If the joint should be filled before most of the shrinkage has occurred, separation should be expected between the joint edge and the joint filler or within the joint filler itself. These slight openings can subsequently be filled with a low-viscosity filler recommended by the same manufacturer as the original filler. If construction traffic dictates that joints be filled early, provisions should be made to require that the contractor return at a preestablished date to complete the necessary work using the same manufacturer’s products. Earlier filling will result in greater separation and will lead to the need for more substantial correction; this separation does not indicate a failure of the filler. …” (ACI 302.1R-04 – Section 9.10)

The Product

The SealBoss 6500 is a robust, semi-rigid polyurea joint filler, made entirely from solid materials. Composed of two components, it exhibits a Shore hardness of 80 A and approximately 200% elongation, indicative of its strength and flexibility. The product is primarily engineered for the purpose of filling and safeguarding contraction and construction joints found in concrete floors of industrial, retail, and commercial premises.

The formulation of SealBoss 6500 is purposefully designed to withstand the rigors of high-traffic and heavy-load environments typical of industrial and retail concrete floors. Its pivotal role is not just to withstand the continuous traffic in commercial warehouses and the load from forklift operations, but also to seal and safeguard joint edges. By doing so, it extends the longevity and maintains the integrity of the surfaces it is applied to. This makes it an indispensable solution for businesses that prioritize facility durability and maintenance.

Routine Maintenance and Cleaning

Ensure to sweep the polyurea joint filler daily to eliminate any accumulated dust or debris. For dealing with spills or hardened dirt, employ a solvent-free cleaner to dislodge the grime and proceed with your usual clean-up routine. For commercial floors that undergo auto-scrubbing, adhere to your regular cleaning protocols and perform spot cleaning as necessary.

In case the joint filler requires repair, please consider these steps:

Initiate by cleaning the area to remove any dirt and debris. Use a solvent to wipe off any residual grime, then fill the cavity with the 6500 filler. Use a floor scraper blade to remove any surplus filler, ensuring a level finish.

With a dust-free concrete saw or angle grinder equipped with a Brazed Vacuum saw blade, cut a depth of ½” (12mm) until fresh concrete is evident on both sides of the joint. Proceed to clean the filler surface by removing any dirt and debris, then wipe it with a solvent. Fill the void with polyurea joint filler and use a razor blade to shave off excess filler, resulting in a smooth finish.

Utilize a specialized removal blade, 4”, 6”, or 8”, to remove the full depth of the joint filler until fresh concrete is visible on all three sides of the joint. Once the joint is clean and free of all dust and debris, apply the new SealBoss 6500 as per the installation instructions.

SealBoss 6500 Poly Urea Joint Fill Instructions.

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Specified

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How to Seal Shrinkage Cracks

Shrinkage Cracks Sealed at Wastewater Treatment Plant

Introduction:

In the demanding environments of wastewater treatment plants, maintaining the integrity and functionality of concrete structures is paramount. Shrinkage cracks, a common yet potentially problematic occurrence in concrete, can compromise the efficiency and safety of these facilities. As these cracks form, they not only present a risk to structural durability but also become conduits for unwanted water and contaminant infiltration, particularly in areas around pipe penetrations. This introductory article explores the nature of shrinkage cracks, their implications for wastewater treatment infrastructure, and the innovative solutions employed to address these challenges.

Understanding Shrinkage Cracks in Concrete

What are Shrinkage Cracks?

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

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

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

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

Effective Sealing of Shrinkage Cracks at a Wastewater Treatment Plant

Scope

At the wastewater treatment plant in Salina, Kansas, a critical task emerged prior to the placement of pumps and pipes in the pump room. The challenge was to address the leaks that originated from pipe penetrations and shrinkage cracks in the concrete structure, particularly after the tank was filled for testing purposes.

Procedure

To provide professional assistance, our Regional Technical Sales Manager visited the site. He provided a consultation on how to effectively use SealBoss 1510 Water Stop Foam to halt water penetration through the shrinkage cracks, many of which stemmed from pipe penetrations.

The SealBoss 1510 was applied via a high-pressure injection process, using the SealBoss P2002 injection system, coupled with the SealBoss 13-100 AL series injection packers. These packers are specifically designed with ribs to withstand high-pressure injection, ensuring an effective and durable application of the Water Stop Foam.

This professional, on-site consultation, combined with the use of high-quality, reliable materials and equipment, serves as an example of our comprehensive approach to address and seal shrinkage cracks effectively.

Employed Products:

SealBoss 1510 superior penetration through hairline cracks

SealBoss ® 1510 NSF Approved Water Stop Foam

Shrinkage cracks, a prevalent issue in wastewater treatment plants, often originate in the areas of pipe penetrations.

They can potentially lead to water seepage from tanks and basins, posing operational and maintenance challenges. Addressing these issues requires adherence to stringent specifications for approved materials.

SealBoss’s Water Stop Systems, bearing the NSF/ANSI 61 Drinking Water Contact Approval, not only meet these stringent standards but also provide a robust solution to such leak-related issues.

Our Full System Solutions further consolidate our position as a comprehensive resource for contractors, catering to a broad spectrum of injection needs. Thus, with SealBoss, you gain access to high-quality, approved materials and comprehensive, reliable solutions, all from a single, dependable source.

Related Super Low Viscosity SealBoss Chemical Injection Grouts:

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

SealBoss
Injection Brochure

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Cracks

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Crack Injection Guideline – 1 2 3 at 45 Degree

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Injecting Trust - One Crack at a Time

The SealBoss 1-2-3 at 45 Degree Crack Injection Guideline

Step 1 – Preparing and Mapping Out Packer Placement
Step 2 – Installing the Packers
Step 3 – Executing the Injection Process
45-Degree Angle – Recommended Packer Angle / Positioning Guideline

Optimal Techniques and Considerations

The SealBoss 1-2-3 at 45 Degree Injection Guideline highlights the three fundamental steps of the injection process while emphasizing the importance of a standard 45-degree angle for packer placement. Although the 45-degree angle is a widely accepted practice, certain situations may require deviation from this rule, as discussed in this article.

Additionally, it is advised to target each injection port three times during the injection procedure – as a general rule – to ensure adequate density and penetration of the chemical grout within the structure. Injection Packers that persistently absorb product should be injected repeatedly, as many times as needed, to ensure a lasting seal.

Injection Packer Spacing

Mechanical injection packer spacing, also referred to as port spacing, in the context of leak-seal crack injection is contingent upon several site-specific conditions, such as crack width, substrate thickness, water flow, and product properties.

In numerous instances, an 8-inch (20 cm) to 1-foot (30 cm) on-center spacing serves as a suitable initial distance. Hairline cracks necessitate tighter spacing, as the product is less capable of traveling far. Consequently, the tighter the cracks, the closer the required spacing.

Injection Packer Placement

In the majority of cases, injection packers should be arranged in a staggered manner by alternating drill holes to the left and right of the crack while drilling at a 45-degree angle toward the crack, thereby forming a stitch grouting pattern. This method enhances the likelihood of intersecting the crack during drilling and reduces the probability of concrete cracking and spalling during packer installation or the high-pressure injection process. Injection should commence from the bottom and proceed upward.

45 Degree Angle Drilling and Packer Placement

The optimal method for packer placement involves positioning at a 45-degree angle. For structures with a thickness exceeding 6 inches (12-15 cm), SealBoss recommends a 45-degree angle as the most effective strategy for intersecting the crack at the midpoint of the structure. This is accomplished by initiating drilling a few inches to the left or right of the crack at an angled trajectory toward the crack itself, rather than drilling directly into it. This technique enables the requisite “inside-out” product flow for optimal crack penetration.

For instance, in a 10-inch thick concrete wall, one should move approximately 4-5 inches (8-10 cm) away from the crack and drill at a 45-degree angle toward it to attain the desired target. Initiating drilling with a straight entry and subsequently angling the drill at the required angle is beneficial.

Typical drill spacing along the crack’s surface ranges between 6-12 inches (10-20 cm) depending on the crack’s thickness. Hairline cracks necessitate closer spacing than larger cracks, as the material will not travel as far. Stagger drill holes from one side of the crack to the other, intersecting the crack during drilling.

Optimizing Drill Hole Distance from the Crack

When determining the spacing of drill holes from a crack for chemical grout injection, it is essential to understand the relationship between the hole’s distance from the crack and the depth at which it intersects the crack. Here is a detailed explanation:

Depth of Intersection: The greater the distance between the drill hole and the crack, the deeper is its intersection with the crack inside the structure, leading to a deeper point of injection.
Considerations for Thicker Structures: In thicker structures, a deeper injection point is usually favored. Yet, it is essential to factor in the drill bit’s length and reach, as they play a crucial role in determining the optimal distance for the drill hole. Always allow for a margin of error and ad at least a margin of 2 inches to the calculated drill bit reach needed.
Avoiding Dead-End Drill Holes: A drill hole that misses the crack cannot facilitate the injection of the chemical grout into the structure. Such holes are termed “dead-end drill holes” and are ineffective for the purpose of grout injection.

Determining the Required Minimum Length for a Drill Bit

When drilling at a 45-degree angle, we encounter a specific triangle called the 45-45-90 triangle, which follows the principles of the Pythagorean theorem.

In this 45-45-90 triangle, both legs, marked “X” are of equal length. X is the distance the drill hole is placed away from the crack. Therefore, when drilling at a 45-degree angle, if we assume the crack is perpendicular to the surface, the depth at which the drill hole intersects the crack will be the same as the distance of the drill hole from the crack. To determine the minimum drill depth, or the distance from the drill hole surface to the crack, use the formula:
Distance from crack X √2, which is approximately 1.414.

To simplify and account for variations we use the factor 1.5 to calculate the absolute minimum drill hole depth necessary to intersect the crack.

For a 5-inch distance from the crack, the calculation would be: 5 × 1.5 = 7.5 inches. Therefore, the drill hole should be at least 7.5 inches deep to guarantee intersection with the crack for injection in near perfect conditions.

For a 6-inch distance from the crack, the calculation would be: 6 × 1.5 = 9 inches. Therefore, the drill hole should be at least 7.5 inches deep to guarantee intersection with the crack for injection in near perfect conditions.

Now add at least 2 inches of drill bit reach to the calculation. It is essential to remember that not all cracks might run perfectly perpendicular to the surface, so always consider the specific conditions of your project.

In summary, while determining the placing of drill holes, it is important to balance the desired depth of injection with the capabilities and reach of your drilling equipment to ensure effective grout injection.Remember, the effective reach of a drill bit and its actual length differ.

Always ensure your drill bit has the necessary length to effectively intersect the crack!

General Injection Packer Preparation – Drill and Flush

Safety Gear

Consistently wear appropriate protective gear and goggles, adhering to data sheet and SDS instructions.

Cleaning

If required, clean the crack or joint’s face using a wire brush, pressure washing, or similar method. A clean surface facilitates the identification of cracks and problematic areas.

Spacing

Mechanical injection packer spacing, also known as port spacing, is contingent upon various site conditions such as crack depth and width, substrate thickness and state, water flow rate, and the product’s physical and chemical properties.

An 8-inch (20 cm) to 1-foot (30 cm) on-center spacing is suggested for the majority of situations. Hairline cracks necessitate tighter spacing compared to wider cracks. The tighter the cracks, the closer the required spacing, as the product must travel deeply enough into the structure to form a permanent seal.

Determine the spacing, pattern, and depths of the drill holes. Based on the crack’s width, space the packers at a distance of approximately 6-18 inches (10-45 cm). The tighter the cracks, the closer the required spacing. Hairline cracks result in limited water stop and leak-seal grout travel, necessitating tighter packer spacing, while wider cracks permit easier flow and broader packer spacing.

Stagger drill holes from one side of the crack to the other (left/right), thus forming a stitch grouting pattern. This technique increases the chances of intersecting the crack during drilling while decreasing the likelihood of cracking and spalling the concrete during packer installation and the high-pressure injection process.

Typically, injection should begin at the bottom and move upward, pushing the product against gravity and water flow, thereby achieving a higher density in the process.

Exceptions to the 45 Degree Injection Rule – Straight Drilling

As with any rule, the catchy SealBoss 1-2-3 at 45-Degree Rule has its limitations and exceptions. Here are three notable examples:

Drilling into Joints
Drilling into joints, such as concrete tunnel segments, is predominantly performed in a straight manner.
Thinner Stuctures
Concrete structures with a thickness of less than 6 inches may not permit angle drilling, as this can result in cracking and spalling of the concrete.
Badly Deteriorated Substrate
Similar issues can occur in severely deteriorated concrete substrates and in concrete of inferior quality. In such situations, it is recommended to drill and install packers directly into the crack without completely penetrating the structure.

SealBoss offers an extensive range of injection equipment and pumps to accommodate your project. Consult a SealBoss technician for detailed information and assistance. We look forward to helping you with your project.

Drill Dust

When drilling deeper holes, periodically extract your drill bit to remove drilling dust and prevent your drill from binding up.

Rebar

Most concrete structures contain rebar steel reinforcement to provide structural strength. In an ideal, crack-free structure, concrete protects the rebar from corrosion by insulating it from moisture and air while maintaining a high pH environment. However, when cracks form, this shield is compromised, allowing air, environmental gases, and water to cause carbonation, and subsequently corrosion of the rebar, which forms rust expands to expands its original volume. The expansion of rusted rebar exerts high forces against the concrete, resulting in further deterioration, cracking, and spalling. Chemical grout injection protects rebar and can mitigate these processes.

Rebar often slows down the drilling process. When your drill bit contacts rebar, the sound changes, the quantity of drilling dust may be reduced, and the progression slows down or may even stop.

Some drill bits enable drilling through rebar, although this is generally not recommended and may even be prohibited, as it can weaken the concrete structure. In such cases, relocating the drill hole is the only option. If you repeatedly hit rebar, consider drilling straight into the crack. Dead-end drill holes, the holes that are not used for injection, must be patched and sealed before injection to prevent leakage.

Flushing / Cleaning Drill Holes Prior to Injection

Overview

Drilling debris can thicken the product during injection, resulting in higher injection pressures and reduced penetration in fine cracks. It is best practice to remove concrete dust and debris from the drill holes by flushing with a water hose until clean water is observed. You can use a water hose to flush debris from the hole.

Vacuuming out the dust can also be helpful if flushing is not possible.

Blowing out the debris is another option; however, be aware that dust can be an inhalation hazard, and appropriate gear is mandatory.

Flushing / Cleaning of holes is not necessary if water is actively running from your drill holes.

Drill Hole Water Flushing Detail

Low Pressure Flush

For low-pressure flushing, simple tools like a plastic water squeeze or spray bottle suffice. This method can remove debris from the drill hole and introduce water into the drill hole.

If available on site, a water hose can be used to flush the drill holes.

Using a Dedicated Flushing Water Pump

A dedicated water injection pump is suitable for both low-pressure drill hole flushing with a hose and on-site pressure crack flushing with water through injection packers.

While drill hole flushing serves to remove debris from the hole only, high-pressure water flushing can provide insights into material flow, expected product penetration distance, and introduce moisture to enhance product reactivity.

For such high-pressure applications, a dedicated water flushing pump is essential.

After clearing the drill hole, an injection packer is positioned. The water pump is then linked to channel water under high pressure via the injection packer into the into the crack, flushing it in the process.

If the crack remains unresponsive to taking on water, it might indicate that the hole is not linked to the crack. In such cases, a new drill hole has to be established and retested with water.

While high-pressure flushing is not typically required for most injection projects, it can offer benefits in specific scenarios.

It is imperative not to use the same pump for water injection that you use for dispensing polyurethane resin. Given that polyurethanes are activated by water, even the slightest moisture can result in pump malfunction.

Final Thoughts

Equipment limitations may render flushing infeasible; however, most injections will succeed without additional water introduction, even in seemingly dry crack environments. If the product does not immediately contact water, it will cure over time as natural moisture in the concrete stimulates curing and hardening, potentially at a slower pace.

Additional Injection Packer Installation Recommendations

Mechanical Packer Fundamentals

For optimal performance, packers and drill holes must possess adequate quality to endure injection pressures without leakage or displacement within the crack. Notably, even superior packers may rupture or leak under certain conditions. SealBoss Mechanical Packers, available in various sizes and designs, are recommended for pressure injection. These packers feature a threaded shaft with a rubber base; upon insertion, tightening the shaft compresses the rubber within the drill hole, generating a compression seal. Standard packer diameters range from 1/4 to 3/4 inches, with industry norms between 3/8 and 5/8 inches. In poured concrete substrates, drill holes serve as solid channels directing resin to the crack, enabling the use of shorter packers. In substrates with potential voids, such as block walls, stone, and brick, SealBoss advises employing longer packers to ensure a definite grout delivery channel to the crack being sealed.

Mechanical Packers Installation

To seal against the drill hole, mechanical packers require tightening, which expands the rubber seal. Packers may be pre-tightened by hand to seat the rubber snugly, approximately 1/4 inch (5 mm) inside the drill hole. Correct installation prevents concrete cracking around the drill hole’s exterior. Depending on packer design, using an appropriate ratchet/nut, wrench, or electric driver for tightening is highly recommended. Packers should be securely tightened to withstand injection pressures without over-tightening.

SealBoss Hammer-In Ports

SealBoss Hammer-In Ports are also frequently utilized. These ports are seated using a hammer at moderate force, with an electric driver or hand tool and a suitable socket employed to screw the zerk fitting into the port. Hammer-in ports typically do not achieve the same injection pressures as mechanical packers and should be reserved for applications where maximum injection pressures are not essential.

Packer Connectors

Packers are typically equipped with a quick-connect system, either a zerk type or button head/slide coupler type.

Zerk Type Connector

The zerk type is most prevalent. Applicators must push the coupler over the zerk fitting and maintain alignment with the packer. To disconnect, applicators “break” the connection by pushing the connector sideways.

Button Head / Slide Coupler

The button head type provides a more secure connection. The operator slides the coupler on and off the packer, ensuring a secure, tight connection that is less prone to unintended disconnection and leakage. When executed properly, the applicator does not need to hold the coupler in place, a significant advantage in overhead injection and instances requiring large product volumes through one packer.

SealBoss Packers

SealBoss offers an industry-leading array of injection packers and ports for diverse situations and requirements. Contact a SealBoss representative for packer recommendations tailored to your project.

Injection Products

Before You Start Injection

Before injection, review the product datasheet instructions. Ensure your pump is in fully operational condition and completely devoid of moisture before preparing SealBoss Water Stop and Leak Sealing Products for injection.

It is prudent to flush the pump with SealBoss R70 before using any resin/foam grout.

Injection Procedure

When products are prepared for injection, have a cup available to dispose of some resin to ensure purity. Start the pump at the lowest pressure setting. After connecting your grout injection hose to the secured and tightened packers, initiate the injection process.

Use the shut-off valve at the injection hose’s end whenever the hose is moved, remember that some pumps need to be manually stopped .

Starting from the bottom, securely connect your injection line to the packer and commence with the lowest pressure capable of moving resin into the crack. Generally, injection pressure will decrease as material flows, but pressure may need to be increased as products thicken and move into tighter cracks and fissures.

Maintain a slow injection rate as resin begins to show and flow from the crack. Pausing and restarting the process for a minute may be necessary to allow material reaction and thickening.

Monitor consumption rates and cease injection when consumption equals leakage. A typical observation involves reduced water flow from the crack’s face and/or reacting material exiting the crack’s face. This indicates successful penetration and results.

If the product does not advance along the crack, disconnect and proceed to the next port. Applicators must ensure sufficient material is injected into each crack to achieve optimal product density for a durable seal.

It is recommended to inject three to five packers while observing product flow, travel, and refusal from the crack.

Reinjecting those three to five packers—typically up to three times (1-2-3 at 45 degrees) or until product refusal—is crucial. The crack must be adequately filled with as much product as possible without excessive product loss from the crack. Sufficient material consumption and product density in the injected area must be monitored to achieve a solid and successful repair.

Injection Packers that continue to consume considerable product amounts should be injected a third time or as often as necessary to create a permanent seal.

SealBoss Oakum Soakum Technique

In cases where excessive resin flows out or washes out due to high water flow, resin-soaked SealBoss Oakum can be employed to form a temporary plug, allowing the product time to react, expand, and seal.

Caution: Be prepared for the possibility of product ejection from the structure or around drill holes, as well as packer blowouts. High-pressure injection equipment may cause product to travel further than anticipated, potentially appearing several feet from the injection point. Small cracks may become visible after the injection process.

Quality Injection Job

Injection often necessitates a two-person team, with one individual operating the valve and hose while another manages the pump. Create a dense seal! Inadequate material consumption alone can yield differing results in the same injection application. If the crack is not accepting any product, it may be due to insufficient drilling depth or crack direction on the opposite side. In such cases, drill from the opposite side of the crack and ensure intersection with the crack.

Packer Removal

Once the material has fully cured, packers can be removed by loosening the shaft. Some applicators opt to leave the rubber base in the wall and patch the drill hole, while others remove the entire packer before patching. In certain injection applications, packers may remain in place permanently. This decision is at the discretion of the applicator or owner. A final cleaning of the crack’s face is necessary to remove cured product using a wire brush, pressure washing, or other appropriate methods. The substrate is then prepared for the final finish.

SealBoss R70 Pump Flush for Clean-up

DO NOT CLEAN WITH WATER. If allowed on the job, initially flush all dispensing equipment with a small amount of solvent, such as xylene, to cut the product. Follow this step by generously flushing with SealBoss R70 Pump Flush & Cleaner to protect hoses and lubricate the pump. Avoid using solvents for the final flush, as this can reduce the lifespan of your equipment.

Exception – Equipment for SealBoss 2400 Acrylate is cleaned with water. Consult the data sheet for details.

Inquiries, Comments, or Requests?

Podcast | “Leak Sealing Polyurethane Crack Injection | Concrete / Shotcrete”
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Water Stop Injection Pro Kits

Engineer Focused Leak Sealing Injection Training

Elevating Structural Integrity with Water Stop Injection Pro Kits: A Paramount Educational Initiative

The Paramount Group recently hosted an enriching educational event tailored for UG2 Engineers across its six San Francisco properties, featuring a dynamic “lunch and learn” session coupled with an engaging hands-on demonstration led by SealBoss Corp. Concrete Solutions. This event marks a significant stride in addressing the escalating challenge of groundwater intrusion, a problem intensified by the recent unprecedented downpours across Northern California. The widespread impact has led to a notable shortage of specialized contractors, escalating the urgency for effective solutions.

As a consequence of the recent record-shattering downpours, groundwater intrusion has grown into a pervasive issue affecting a multitude of properties across Northern California. This concurrent impact on the region has given rise to a scarcity of specialized contractors equipped to handle such challenges, further complicating the situation for affected parties.

Training Spotlight: Empowering Contractors and Engineers with Water Stop Injection Pro Kits

In response to this urgent need, Paramount Group has taken a strategic step by empowering their on-site engineering teams with advanced Water Stop Crack Injection Pro Kits.

The initiative includes comprehensive training sessions aimed at enhancing the teams’ proficiency, ensuring the secure and adept use of these state-of-the-art tools. This forward-thinking approach not only enhances the engineers’ capabilities but also ensures rapid, in-house resolution of groundwater intrusion challenges, upholding the highest standards of property maintenance.

By supplying Water Stop Crack Injection Pro Kits and organizing comprehensive training sessions, the company guarantees the secure and efficient application of waterproofing and leak sealing injection grout systems.

This initiative is projected to yield substantial cost savings, potentially amounting to thousands of dollars annually per property. It underscores Paramount Group’s dedication to innovative problem-solving and the continuous professional growth of their engineering personnel.

We take great pride in offering comprehensive educational programs targeted at engineers, distributors, and contractors worldwide, focusing on the practical application of our products and technology. These sessions are designed to foster a deeper understanding of effective leak sealing techniques and the strategic use of Water Stop Injection Pro Kits.

For more details about our comprehensive classroom services, hands-on training, and informative “lunch and learn” sessions, please reach out to our expert technical sales team at 714-662-4445. Engage with us to elevate your engineering solutions and safeguard your properties against the challenges of water intrusion.

It brings us great pride to provide all-inclusive educational programs for engineers, distributors, and contractors around the globe, focusing on the effective utilization of our products and equipment.

For additional information regarding our classroom services, on-the-job training, and lunch and learn sessions, please don’t hesitate to reach out to our knowledgeable technical sales staff at 714-662-4445.

Water Stop Injection Pro Kits

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Hydrophilic Waterstops

SealBoss Swell Tape and Swell Caulk

Introduction to Hydrophilic Waterstops

Hydrophilic waterstops have emerged as an essential component in modern concrete construction, particularly in ensuring the watertight integrity of various below grade structures such as parking garages, subterranean warehouses, stores and tunnels.

SealBoss, a leader in the field of specialized below grade waterproofing, offers an array of hydrophilic waterstops that are renowned for their high quality and cost-effectiveness.

These products are specifically designed to meet the demanding water containment requirements of today’s construction projects.

The Functionality Behind Hydrophilic Waterstops

The term “hydrophilic” refers to the affinity for water, and in the context of waterstops, it signifies the material’s ability to swell upon contact with water. This swelling action is crucial as it forms a hydro-active compression seal that effectively blocks water infiltration.

Unlike traditional waterstops, the hydrophilic variants offered by SealBoss do not rely solely on adhesion to the substrate, but adapt to leakage by expansion, making them suitable for joints involving diverse materials.

SealBoss Swell Tape – Swelling Joint Sealer Strip: A Versatile and Effective Solution

One of the flagship products in SealBoss’s hydrophilic waterstop range is the SealBoss Swell Tape. This strip-applied, preformed hydrophilic polymer waterstop tape is specifically engineered for the waterproofing of concrete joints. The unique formulation encapsulates hydrophilic polymers into a rubber base, creating a highly effective, durable, and moisture-activated swellable compression seal. When exposed to moisture or water, the material swells, thereby generating a compression seal that ensures water tightness.

Applications of SealBoss Swell Tape

The versatility of SealBoss Swell Tape makes it an ideal solution for a broad spectrum of applications. These include:

Sealing construction joints in buildings and infrastructures
Waterproofing pipe penetrations to prevent leakage around pipes
Ensuring watertight integrity in manhole joints
Application in precast concrete segments for structures like bridges and tunnels
Addressing cold joints, where new concrete meets old concrete
Use in tunnel segment joints for subterranean constructions
Waterproofing poured wall joints in both residential and commercial buildings

SealBoss SwellCaulk: Complementary Hydrophilic Waterstop Caulk

In addition to the Swell Tape, SealBoss offers the SealBoss Swell Caulk – a hydrophilic waterstop caulk designed to complement the Swell Tape system.

SwellCaulk serves as both a waterstop and an adhesive, enhancing the effectiveness of the Swell Tape in concrete joint applications. It is especially recommended for complex joint configurations where additional sealing and adhesion are necessary.

Conclusion: The SealBoss Hydrophilic Waterstops Advantage

The SealBoss range of hydrophilic waterstops, including the Swell Tape and Swell Caulk, represents a significant advancement in water containment technology.

Their effectiveness, versatility, and ease of application make them an excellent choice for a wide range of construction projects.

By choosing SealBoss products, construction professionals can ensure the long-term integrity and durability of their structures against water infiltration.

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SealBoss ® JOINT SEALERS

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Injection Packers

Injection Packers for High Pressure Crack Injection Applications Overview

Injection Packer Materials – Injection Packers bodies are constructed from various materials including steel, brass, aluminum, zinc, or plastic.
Dimensions – Injection Packers are available in many sizes, lenghts and diameters to meet the application demands, injection products, injection pressures, and injection volume and flow requirements.
Mechanical Packers – Injection Packers, specifically the mechanical injection packer types, short “Mechanical Packers”, are fitted with a compression rubber sleeve mechanism, to lock securely into the packer placement drilled hole.
High Injection Pressures – Mechanical Injection Packers, are designed to work in high pressure injection conditions from several hundred psi up to several thousand psi. (100 – 10,000 psi or 6 – 600 bar).
Injection Packer Application Procedures – Injection Packers are often placed in a staggered pattern along the crack in a 45 degree angle. This is known as the standard SealBoss 1 – 2 – 3 – 45 Degree Method. Other methods and packer placement techniques also apply depending on the requirements of the application.

Injection Packers are designed to safely and securely connect your Injection Equipment to the concrete substrate, in order to deliver the injection chemical resin – often under high injection pressures – to the area of repair.

Injection packers must be of suitable construction and sturdiness, as they have to withstand low and high injection pressures as needed, and allow for adequate flow of product. Their design must permit easy installation and removal, as needed – while being cost- effective.

SealBoss Packer Power: Where Cracks Meet Their Match!
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Injection Packers Details Explained

Information About Injection Packers
Packer Materials & Types

Injection packers and ports are essential tools for successful grout and epoxy injection in construction and repair projects. These tools are generally categorized into two types: insertable mechanical injection packers and surface-mounted ports.

SealBoss offers a wide selection of injection packers made from steel, brass, aluminum, zinc, various metal alloys, and plastic.’

Each material and design caters to specific substrates, applications, and contractor preferences, ensuring a tailored solution for any injection scenario.

Mechanical Injection Packer Features
Premium mechanical packers incorporate a rubber sleeve with a threaded shaft. When tightened, the sleeve compresses to form a seal within the drilled hole. A soft, expandable rubber ensures optimal grip and supports high injection pressures.

SealBoss Steel Injection Packers are most robust, high-performance packers designed for high-pressure resin injection in demanding applications.
Known for their strength and durability, SealBoss steel packers are suited for high-pressure injections, icnluding polyurethane, epoxy, and acrylate/acrylic gels. Available in multiple designs, most include a rubber sleeve and a larger top washer for secure installation.

These packers are an efficient, industry standard setting, and effective solution for structural repair and waterproofing, trusted by professionals worldwide.

Steel Construction Injection Packers: Set the standard – built to withstand high injection pressures and provide a durable, reliable seal.
Interchangeable Fittings: Come with button head and standard and low pressure zerk fitting options, enhancing versatility for various injection systems.
Anti-Return Valve: Located in the fitting, it prevents resin backflow, maintaining the integrity of the injection.
Port-to-Port Resin Travel: Removeable valve allows for observation of resin movement, ensuring controlled application.
Wide Size Range: Suitable for various applications, from small repairs to large-scale projects.
Compatibility: Works with all injection resins, including low-pressure applications.

Brass, Aluminum, and Zinc Packers
These materials offer economical alternatives to steel with similar functionality. Although they have lower strength, some designs allow the shaft to be broken off after injection, leaving a flush surface—a benefit for certain projects.

SealBoss Aluminum Injection Packers are economical, lightweight options for standard resin injection tasks.

Modeled after the SealBoss S-Type steel, these aluminum packers offer a very budget-friendly solution for typical crack injection scenarios, ideal for professionals looking to reduce costs on routine jobs.

Aluminum Construction: Provides a secure fit and is lighter and more affordable to ship than steel alternatives.
Cost-Effective: The most economical option for crack injection, saving costs on large projects.
Anti-Return Valve: Located in the zerk fitting, preventing resin backflow during application.
Standard Application Use: Suitable for everyday injection needs and non-critical applications.

SealBoss Brass Injection Packers are durable and versatile packers designed for resin injection.

These economical alternatives to steel packers are widely used in construction for their built in zerk fittings, reliability and cost-effectiveness.

Available in a Wide Variety of Sizes, Thicknesses, and Lengths: Options range from compact to extended-length injection packers, designed to meet the most demanding jobsite requirements.
Monolithic Zerk Fitting:No separate zerk fitting ensures smooth installation procedure and secure attachment.
Anti-Return Valve in the Packer Base: Prevents resin backflow, even if the neck is unscrewed or broken off.
Defined Breaking Point: Allows clean removal after use.

SealBoss Standard Zinc Packers are strong, affordable, and reliable packers designed for standard grout injection.
Zinc injection packers are another choice for general injection applications, offering quick installation and efficiency in everyday crack repair and sealing tasks.

Bottom Anti-Return Valve: Enables head removal after grout injection, preventing backflow.
Packer Neck Hexagon: Easy tightening packer neck
Common Industry Size: Provides adequate surface seal area for a secure grip at an economical price.

SealBoss Plastic Buttonhead Injection Packers and Hammer-In Ports for large Volume Injection nad Fast Installation.

These plastic packers offer versatile options for resin grout injections, covering applications that metal-style injection packers may not accommodate.

The SealBoss Hammer-In or Bang-In packers require only a hammer to secure in place. These packers create a compression seal without a sleeve, making them ideal for quick installation. However, they are best suited for low-pressure injections due to a lower friction fit.

Buttonhead Packers: Feature a large anti-return valve and inner diameter for high-volume material flow, ideal for low-pressure applications like curtain injection and slab lifting.
Hammer-In Ports: Quickly installed without the need for tightening, providing a fast, economical alternative to mechanical packers in certain applications.
Wide Compatibility: Suitable for use with epoxy, grout, and various SealBoss injection systems, including manual, pneumatic, and cartridge injections.

Injection Packer Fitting Types

Packers often feature either a zerk or button head fitting for connection:

Zerk Fitting: Commonly used for medium to high-pressure applications, offering quick connection and disconnection.
Button Head Fitting: Suitable for high-volume applications, providing a superior connection with reduced leakage, especially beneficial for single-operator use.

Surface Ports

Surface-mounted epoxy injection ports are suitable for lower-pressure applications or when drilling isn’t feasible. They can be glued directly to the surface or placed within a drilled hole. Many have open designs for quick-release connectors and are equipped with caps to prevent backflow. Ports with zerk fittings are available for higher pressure needs, including specialized corner ports for 90-degree angles.

Find all SealBoss Injection Packers and Surface Ports here

Injection Packer Dimensions and Specifications

Diameter
A packer’s diameter affects injection pressure capacity and fit within drilled holes. Common sizes include 5/8” (16mm), 1/2” (13mm), 3/8” (10mm), and 1/4” (6mm). Larger diameters are generally more resistant to blow-outs and provide a stronger grip, especially for high-pressure and rock applications.

Length
Longer packers, ranging from 4″ to 6″, are ideal for deteriorated concrete or deep injections. They enable secure embedding within the substrate, minimizing the risk of spalling and bridging gaps in the structure.

Valve Placement

Top-Mounted Valves: Zerk and button-head valves allow for observing grout travel during injection. Button-head valves offer a stronger connection with less leakage.
Bottom-Mounted Valves: Positioned on the stem, these valves allow the packer’s head to be removed after injection, keeping the seal intact and facilitating patching.

Conclusion
The 1/2″ (13mm) diameter mechanical injection packer is often a reliable starting point for most projects. Steel packers are ideal for very high injection pressures, though economical considerations may favor alternatives like aluminum, brass, or zinc for a variation of scenarios including jobsite conditions and budget.

Larger diameter injection packer can reduce blow-out risks, while longer packers are recommended for angled drilling and degraded substrates.

High-flow applications at lower pressures may benefit from the 5/8″ button-head packers, while the 3/8″ Hammer-In packers could be suited to low-pressure work in high-quality concrete.

SealBoss offers a diverse range of packers and ports, including surface ports with zerk fittings for smaller epoxy and polyurethane jobs and injection screws for cold joint applications. Ensuring a secure fit and selecting the appropriate packer type is crucial for technician safety and successful injection results.

Injection Packers for Crack, Water Stop and Leak Sealing Injections

SealBoss injection packers connect the injection equipment (applicator and injection pump) with the structural substrate to serve as the port of entry – or filler neck – for a large variety of injection resins and chemical grouts into concrete mediums.

Our Packers are made from a various metals including steel, brass, zinc, aluminum / aluminium or plastic. Packers are typically equipped with either a zerk fitting or button head fitting for easy and secure connection to the applicator. The button head type offers the most secure connection in overhead, high pressure and high volume appplications.

Conditions of the jobsite, environment and material determine the type, material, and build of packer, in order to achieve the best injection results. SealBoss provides a very large selection of injection packers to meet all professional needs.

Injection Packers – Installation Types

Based on injection requirements and injection products to be used, we distinguish between borehole packers and surface mount packers, also known as surface ports.

Cylinder shaped, borehole type injection packers are typically used for high pressure injection with polyurethane bases, water stop and leak-seal resins and injection foams.

Borehole style packers work very well in wet and otherwise demanding environments, such as deteriorating concrete substrates.

We further differentiate between mechanical packers with a tighten-down and screw-in mechanism, and hammer-in technique packers.

The seal of the aforementioned packers is achieved by friction between the packer body in the drill hole and the surrounding substrate.

Surface mounted ports are mostly used for structural epoxy injection where a non-destructive injection process – no drill holes allowed procedure – is specified.

Surface mounted packers or surface ports are glued to the surface of the substrate and rely on the bond strength of the adhesive, such as SealBoss 4500 epoxy paste adhesive. Surface port placement is best performed on a dry substrate and can be difficult in wet environments with active water leaks.

Preparatory work

Step1 – Structure / Substrate / Product Analysis

Condition of structure, environment and climate
Chemical rout / resin specified
Injection pressures expected (high pressure vs low pressure)

Step 2 – Packer Choice

Select suitable injection packers.
Please consult with your SealBoss Technical Rep.

Installation

Installation procedures depend on the conditions found at the jobsite. SealBoss provides detailed information online and in printed publications. Please contact your technical rep.

The size of the drill holes equals the stated diameter of the mechanical packers and hammer-in packers; the borehole depth varies according to the conditions and requirements.

Drill holes are typically made at an angle of approx. 45° depending on the wall thickness and other conditions. All drill dust and debris must be removed from the boreholes.

Final work