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Retaining Wall Repair

Retaining Wall Repair

Injection Methods Compared
retaining wall repair

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.

SEALBOSS PU ICON

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.

Leak Sealing System
SEALBOO-1510-VIDEO
SB 1510 Foam
sealboss-packers
Injection Packers
Injection Packer Spacing SealBoss Grout
PUR vs Epoxy
SEALBOSS EPOXY ICON

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.

Tenacious Crack-Sealing Epoxy Grout SealBoss 4040 LV
Epoxy System
Tenacious Crack-Sealing Epoxy Grout
SB 4040 Epoxy
epoxy port-SURFACE-PORT-SEALBOSS
SB Epoxy Ports
EPOXY-CRACK-INJECTION-SEALBOSS
Epoxy vs PUR

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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Super Low Viscosity Epoxy Crack Healer & Sealer | SealBoss 4050 SLV

Super Low Viscosity Epoxy Crack Healer & Sealer
Epoxy Resin 4050 SLV

SealBoss ® 4050 SLV Epoxy Grout Applications

  • Structural Epoxy Crack Injection
  • Gravity feed or pressure injection of fine cracks in structural concrete, masonry, rock, wood.
  • Seal interior slabs and exterior above grade slabs

SealBoss 4050 SLV Epoxy Grout Resin – Super Low Viscosity Crack Healer & Sealer

SB 4050 SLV is a 2-component, 100 % solids, super low-viscosity, high-strength, low surface tension, moisture-tolerant, epoxy resin crack healer and deep penetrating sealer designed for high strength repairs, epoxy injection and epoxy crack injection in concrete substrates such as floors, ceilings, walls, foundations and more. SealBoss 4050 SLV is formulated for grouting both dry and damp cracks. 4050 SLV meets ASTM C-881 and AASHTO M-235 specifications.

Key Features:

  • High Strength and Durability: Engineered for high-strength repairs, it is ideal for restoring the integrity of concrete structures

  • Exceptional Penetration: Its low viscosity allows it to seep deeply into fine cracks, ensuring comprehensive healing and sealing

  • Versatile Application: Suitable for use in a variety of concrete substrates including floors, ceilings, walls, foundations, and more

  • Moisture Tolerance: Effectively grouts both dry and damp cracks, offering flexibility in diverse environmental conditions

  • Low Surface Tension: Enhances the product’s ability to penetrate and bond to the concrete, providing long-lasting repairs

  • Compliance with Standards: Meets the rigorous ASTM C-881 and AASHTO M-235 specifications, ensuring quality and reliability

SealBoss 4050 SLV Data Page

SealBoss ® 4050 SLV Super Low Viscosity Epoxy Resin Advantages

  • Easy mix ratio A:B = 2:1 by volume
  • Advanced strong bonding structural resin
  • Super Low viscosity – Low surface tension
  • Stronger than concrete
SealBoss 4050 SLV is our super low viscosiy epoxy crack healer & sealer epoxy resin suitable for hairline crack epoxy injection jobs. We offer a comprehensive selection of epoxy injection equipment and accessories including professional epoxy injection pumps, injection ports, hoses and applicators.

For smaller jobs we provide epoxy resins and other professional grade products in dual cartridges as a convenient alternative to bulk products.

Inquire more about our systems when you call us here at SealBoss. Your representative will be happy to help you out.
Chris Coderre
Regional Sales Manager
Contact Your SealBoss ® Technician

Specified – Epoxy Resin and Polyurethane Grout

- Specified -
Epoxy Resin and Polyurethane Grout

Repairs at Water Treatment Plant 
Sealing Active Leaks in Filter Gallery and Associated Basins Sealed

Overview

At a Texas Water Treatment Plant, active leaks in the filter gallery and associated basins were expertly sealed using specified polyurethane grout and epoxy resin. This article delves into the methods and products used to achieve this.

Active Water Leak Repair
Specified Product:
Polyurethane Grout

The engineering team recommended using Hydrophobic Injection Foam Grout, administered through high-pressure injection equipment, to address all pipe penetrations in the filter gallery and specifically identified cracks with active leaks.

For the Water Stop Injection phase, the SealBoss 1510 Water Stop Foam NSF/ANSI 61 was selected and endorsed as the ideal solution for sealing the cracks effectively.

Structural Strength Repair
Specified Product: Epoxy Resin

Per the guidelines and specifications set by the engineering firm, the holding basins were emptied, and cracks were treated using a low-viscosity Structural Epoxy, applied at reduced pressures.

For reinforcing the structure, the combination of SealBoss 4040 and the 4500F non-sag adhesive paste was chosen and recommended.

Training and Expertise

SealBoss dispatched a technical expert on-site to guide the contractor in utilizing both injection techniques. The training encompassed the use of the approved SealBoss Injection Systems. This included the SealBoss P2002 high-pressure, single-component injection pump, equipped with mechanical injection packers, and the SealBoss PA 3000 low-pressure system, which operates at a 2:1 ratio and features surface-mounted injection ports.

Repair Method

Water Stop and Leak Sealing with Polyurethane Grout

The SealBoss P2002 injection pump was employed for the Water Stop injection, paired with SealBoss 1/2 inch aluminum and 5/8 inch stainless steel Injection Packers for effective grout delivery.

In the filter gallery section, packers were strategically positioned approximately 12 inches apart and 4 inches away from the pipe sleeve/annulus, encircling the pipe. For the designated cracks set to be filled with the SealBoss 1510 Hydrophobic Foam Grout, injection packers were spaced between 8 to 12 inches apart, adhering to the 1, 2, 3, 45 Degree Injection Guidelines.

Injection continued on the cracks until the emergence of the SealBoss 1510 water stop foam was clearly observed on the crack’s surface, indicating a successful fill.

Specified - Epoxy Resin and Polyurethane Grout

Epoxy & Polyurethane Repairs

Specified - Epoxy Resin and Polyurethane Grout 3

Pipe Penetration Injection

Structural Repair with Epoxy Resin System

Before initiating the injection process, the water basins were drained and dried in preparation.

The SealBoss PA3000, our professional, heavyduty pneumatic two-component epoxy pump, was utilized for the low-pressure Epoxy Injection phase. This pump was set-up to a 2:1 pumping ratio, aligning with the SealBoss 4040 LV Structural Epoxy’s 2:1 mixture ratio.

Cracks were meticulously traced, and surface-mounted ports were affixed 6 to 8 inches apart, positioned directly above the crack. These ports were securely anchored using the SealBoss 4500F Quick Seal Epoxy surface adhesive.

After the 4500F adhesive set, the 4040 LV epoxy was methodically injected into the ports. The process began from the lowest port and progressed upwards, leaving the subsequent vertical port open to ensure and verify seamless port-to-port flow.

Specified - Epoxy Resin and Polyurethane Grout

Pre-Repair Inspection

Specified - Epoxy Resin and Polyurethane Grout

Water Bearing Cracks

Products Used

If you have any questions on Specified Epoxy Resins and Polyurethane Grouts, please contact our team of qualified SealBoss representatives.

Schedule an on site consultation & full injection systems training.

Call us at 714-662-4445.

Contact Your SealBoss ® Technician

Foundation Crack Epoxy Injection – Transmission Towers

Foundation Crack Epoxy Injection Transmission Towers SealBoss

Foundation Crack Epoxy Injection - Transmission Towers

Epoxy Injection System Kits and Specialized Training

Our expert Technical Team is adept at offering training in the field of foundation crack repairs, specifically using the epoxy injection method with SealBoss 4040 Epoxy Resin, 4500F Epoxy Paste Adhesive, SB Surface Mount Plastic Ports, and the convenient, easily-operated SealBoss P3003 Epoxy Injection Pump. All these elements are provided at a reasonable cost to contractors through the Pro P3003 Epoxy Injection Starter Kit, offering affordability without compromising the quality.

transmission tower pylons epoxy injection sealboss

Structural Pylon Footing Repair

Highly specialized contracting companies with a unique skill set are charged with constructing and installing transmission towers for power lines across California’s inland regions where renewable energy sources are developed at a rapid pace. With wind turbines and solar farms increasingly dotting the hilltops in California, the enhancement of renewable energy necessitates a robust infrastructure consisting of sturdy electricity transmission towers and well-distributed power lines.

Yet, the challenging weather conditions, which can include sandstorms, frosty snowstorms, and extreme temperature fluctuations, pose a significant threat to the structural integrity of the concrete supports that uphold this infrastructure.

Restoring Structural Integrity – Foundation Crack Epoxy Injection for Infrastructure Repairs

To counter these challenges, specially trained repair crews are commissioned to restore the structural integrity of concrete foundations and footings for the electricity transmission pylons that support overhead power lines spanning across California’s Central Valley.

The design of the pylon footings can take cylindrical or rectangular shapes, and cracking can manifest horizontally or vertically. Regardless of the orientation or size of these cracks, SealBoss Epoxy systems are proficiently designed to repair, mend and restore the concrete to its predetermined integrity.

Presenting the SealBoss Structural Infrastructure Repair Systems

Among several options, the compact Sealboss P3003 Electric Epoxy Pump Pro-Kit is a popular choice. This system encompasses high-strength, low-viscosity 4040 epoxy resin, quick-setting odourless SealBoss 4500 paste adhesive, surface mount ports with perforated tri-base legs, and the impressively portable, lightweight P3003 epoxy injection machine.

The P3003 epoxy injection system comes standard with a 2:1 ratio by volume setup, with the option for a 1:1 ratio conversion. The system also incorporates the capability to pump SealBoss Polyurethane Water Stop Foams and Leak-Seal Resins. Additional Epoxy pumps, including the large job professional PA 3000 pneumatic epoxy injection machine, are also available for selection.

Epoxy Injection Procedure Outline

  • Identify and Assess Cracks:
    Inspect the concrete foundation for visible cracks and micro fissures. Assess the size, orientation (horizontal or vertical), and depth of each crack.

  • Prepare the Epoxy Materials:
    Condition the SealBoss 4040 Epoxy Resin and the odorless SealBoss 4500 Epoxy Paste adhesive to the appropriate temperatures, especially in cold conditions to ensure a faster set time.

  • Apply Paste Adhesive:
    Apply the SealBoss 4500 Epoxy Paste over the cracks to serve as a surface seal. This paste also acts as an adhesive for the SealBoss Tri-Base surface mount plastic ports.

  • Install Injection Ports:
    Position and install the SB Surface Mount Plastic Ports along the length of the cracks, ensuring secure fastening. These ports should come equipped with caps to prevent epoxy resin back-flow.

  • Inject the Epoxy Resin:
    Once the adhesive paste is set, begin the injection process. Using the SealBoss P3003 Epoxy Injection Pump, inject the low-viscosity SealBoss 4040 Epoxy Resin into the cracks at the lowest speeds, just enough to move the epoxy resin into the crack and allow for continuous flow and deep penetration of the material.

  • Use SealBoss 4050 SLV for Micro-cracks:
    For extreme micro-cracks, consider using SealBoss 4050 SLV super low viscosity epoxy to ensure deep penetration into these smaller cracks.

  • Monitor the Injection:
    Watch for the epoxy material to appear in the next port, indicating sufficient filling of the current crack and time to cap the port and move onto the next.

  • Curing:
    Allow enough time for the epoxy resin to cure fully within the cracks, restoring and reinforcing the structural integrity of the concrete foundation.

  • Finish the Surface:
    After the material has fully cured, grind off the ports and smooth down the surface to achieve the desired look and finish.

These procedures should be done carefully and patiently, keeping in mind that the main goal is to ensure a completely sealed and controlled environment for the epoxy to set up properly.

Foundation Crack Epoxy Injection | Transmission Towers – Procedures

To manage the structural integrity, hairline cracks and micro fissures in the concrete foundations are injected with low viscosity SealBoss 4040 epoxy resin. The odourless SealBoss 4500 epoxy paste serves as a surface seal and adhesive for SealBoss Tri-Base surface mount plastic ports equipped with caps to prevent epoxy resin back-flow. For operations in cold conditions, it is advised to precondition the epoxy products to warmer temperatures to facilitate a quicker setting time. When the environment is cold and time permits, mounting the surface port and applying the crack paste a day prior to injection can ensure an appropriate seal around the cracks and good port adhesion to the concrete substrate.

Once the ports are securely fastened and the paste adhesive has set, injection can commence. By using the lowest speeds on the P3003 epoxy pump, sufficient to push epoxy resin into the crack, it allows for continuous flow and deep penetration of the material through the crack.

In situations where SealBoss 4040 epoxy resin, a low viscosity 2:1 material is used for most crack dimensions, SealBoss 4050 SLV super low viscosity can penetrate even deeper, reaching into the farthest corners of extreme micro-cracks.

Once the material is visible in the subsequent port, it serves as a signal to halt the application, cap the port, and proceed to the next one. The primary principle of epoxy injection is to maintain a completely sealed and controlled environment to allow the epoxy to set up and restore the structural integrity of the concrete.

After the epoxy has fully cured, contractors can remove the ports and smooth down the surface to achieve the desired aesthetic look.

Request the Best – Comprehensive System Solutions and Tailored Training from SealBoss

SealBoss specializes in providing comprehensive system solutions designed to restore and preserve the structural integrity of infrastructures. Our solutions are engineered to protect structures from environmental damage including water intrusion, corrosion, and damage from seasonal frost expansion.

Our complete Pro-Kit systems are user-friendly and designed for quick deployment, capable of getting a crew operational in just a few hours.

SealBoss’s on-site training is also available to ensure your project is executed correctly and achieves success. Our commitment to delivering superior-quality service, coupled with our product innovation and industry expertise, makes us a trusted partner in the infrastructure repair and maintenance sector.

Relevant Epoxy Injection Links

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Hi Mod Gel Epoxy Paste Adhesive | SealBoss 4500 F

Hi Mod Gel Epoxy Paste Adhesive
4500 F

SealBoss ® 4500 F Epoxy Paste Applications

  • Adhesive for surface mounted epoxy injection ports
  • Seals cracks and around surface mounted ports prior to injection grouting
  • Structural bonding of concrete, masonry, metals, wood
  • Repair of concrete as an epoxy mortar binder
  • Structural strength sealant around windows and doors

SealBoss 4500 F Hi-Mod Gel Epoxy Paste

SB 4500 F is a 2-component, 100 % solids, high-strength, moisture-tolerant, structural, hi modulus epoxy paste adhesive gel designed for placement of epoxy injection surface mounted ports, surface sealing of cracks in concrete and for use as an epoxy mortar binder. 4500 F meets ASTM C-881 Types I, II & IV, Grade 3, Classes B & C.

SealBoss 4500 F Data Page

SealBoss ® 4500 F Epoxy Paste Advantages

  • Easy mix ratio A:B = 2:1 by volume
  • Advanced strong bonding structural resin
  • Low viscosity – Deep penetrating bond in structural concrete
  • Stronger than concrete
SealBoss 4500 F is our fast setting hi-mod structural epoxy paste adhesive suitable for surface sealing of concrete cracks and placement of surface mount ports prior to epoxy injection.

SealBoss ® offers a comprehensive selection of epoxy injection equipment and accessories including professional epoxy injection pumps, injection ports, hoses and applicators.

For smaller jobs we provide epoxy resins and other professional grade products in dual cartridges as a convenient alternative to bulk products.

Inquire more about the SealBoss System when you call us here at SealBoss. Your representative will be happy to help you out.
Chris Coderre
Technical Sales Manager, West U.S. | West Canada
Contact Your SealBoss Technician

Two Component Epoxy Applicator | Anti Return Valve System

How to Use
SealBoss Two Component Epoxy Applicator

This SealBoss® Epoxy Injection Pump Two Component Applicator Gun is equipped with two high pressure quality shut-off ball valves and two anti return valves to prevent material backflow.  The applicator system is designed for use with Plastic Static Mixers of various dimensions.

SealBoss PA 3000 Epoxy Injection Pump equipped with two component epoxy resin applicator. 

Contact Your SealBoss ® Technician

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