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Watertight Pipe Penetration Sealing

Guidelines for Pipe Penetration Waterproofing

Introduction

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

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

How to Replace failed Water Stop around existing Pipe Penetrations

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

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

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

Utilizing Multiple Products and Techniques for Pipe Penetration Sealing

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

Oakum Saturation with Foam Grout

Oakum Soakum Installation

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

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

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

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

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

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

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

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

Pipe Penetration Sealing Products

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

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

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

Call us at 714-662-4445.

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Leak-sealing

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SealBoss Swell Caulk Joint Sealer

Swell Caulk Joint Sealer

Introduction

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

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

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

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

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

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

Expanded Applications of SealBoss® Swell Caulk Joint Sealer

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

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

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

Sheet Pile Interlock Sealing

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

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

Adhesive for SealBoss® Swell Tape Integration

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

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

Application Guidelines

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

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

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

Key Benefits of SealBoss® Swell Caulk Joint Sealer

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

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

A Reliable Solution for Demanding Construction Environments

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

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

Conclusion

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

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

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

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

SealBoss Swell Caulk

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Cold Joint Injection

Leaking Cold Joints Sealed

Cold Joints in Concrete Structures and the Polyurethane Polymer Solution

Introduction

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

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

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

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

What are Cold Joints?

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

Cold joints typically occur due to:

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

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

Cold Joint Injection: The Polyurethane Polymer Foam Solution

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

Why Use Polyurethane for Cold Joint Injection?

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

Benefits of polyurethane cold joint injection include:

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

Step-by-Step Cold Joint Injection Process

The cold joint injection procedure typically involves the following steps:

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

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

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

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

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

Advantages of SealBoss Cold Joint Injection Systems

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

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

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

Cold Joint Injection: An Investment in Longevity

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

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

Contact SealBoss for Expert Cold Joint Solutions

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

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

Considering a Solution for Sealing Cold Joints During Construction?

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

Materials and Tools Used

Related Articles

Learn More

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

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Tunnel Water Stop Injection Leak Repair

Tunnel
Water Stop
Injection
Leak Repair

Leak Sealing
Systems

Tunnel Water Stop Injection Leak Repair with Polymer Grout Injection

Introduction:

Tackling Water Leakage in Tunnels: Challenges and Solutions

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

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

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

Tunnel Water Stop Injection Leak Repair Overview

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

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

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

How to stop leaks of high hydrostatic pressures with Injection Grouts

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

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

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

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

Example: SealBoss Acrylates Used to Seal Leaks in Tunnel

What are Acrylate Gels?

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

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

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

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

Tunnel Water Stop Injection Leak Repair

How to Start Acrylate Injection Leak Sealing Injection Repairs

The principal steps to solve a problem are:

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

Will I need more than One Product?

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

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

Which products are shown in the videos?

Products used for Tunnel Water Stop Injection Leak Repair

Related Article

Flooded Tunnel Repair

Call Your SealBoss Technician

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

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Injection Tube System

Injection Tube System / Injection Hose System

What is the Injection Tube System?

The Injection Tube System is a specialized grout delivery mechanism designed to seal cold and construction joints in concrete structures effectively. It is predominantly used in new construction projects where fresh concrete or shotcrete is applied adjacent to existing, cured concrete surfaces, resulting in the formation of a cold joint. By installing the injection tube prior to pouring the new concrete, the system facilitates the precise injection and distribution of resins and grouts into the cold joint after curing. This process provides an immediate and permanent seal, enhancing the structural integrity and waterproofing of the joint.

Key Advantages:

Proactive Sealing Solution: Allows for the treatment of potential leak paths before they become problematic.
Enhanced Durability: Improves the long-term performance of the structure by preventing water ingress and related deterioration.
Efficient Installation: Integrates seamlessly into the construction workflow without significant additional labor or time.
Versatility: Compatible with a variety of sealing materials, such as polyurethane resins and acrylate gels, to suit specific project needs.

By employing the Injection Tube System, engineers and contractors can ensure that cold and construction joints are securely sealed, thereby extending the lifespan of the structure and reducing the need for future maintenance or repairs.

SealBoss Injection Tube System: Advanced Sealing Solution for Construction Joints

Designed around a solid core, perforated PVC Tube.

The SealBoss Injection Tube System is engineered around a solid-core, perforated PVC tube, providing a robust and reliable conduit for sealing materials in concrete construction joints.

Installation and Waterproofing

Installed within joints prior to the pouring of new concrete, the injection tube proactively waterproofs and seals any cracks or voids that may be present. This system enables the creation of permanent, watertight joint seals, enhancing the structural integrity and longevity of the construction.

Easy to install and reasonably priced – The SealBoss Injection Tube System simplifies the job and provides for watertight joints.

SealBoss Injection Tube

The SealBoss Injection Tube Type 2 features a double-woven membrane that provides superior protection for the inner tube space against water and debris infiltration. A clean inner tube is crucial for optimal injection results, and this design ensures the injection pathways remain unobstructed.

Re-Injectable Applications

For applications requiring a re-injectable system, the SealBoss Injection Tube System can be used in combination with SealBoss® 2400 Acrylate Gel. This combination allows the injection tube to be flushed with water before and after the product sets, enabling multiple injections if necessary. The system’s compatibility with micro-fine cement injections further enhances its versatility, accommodating a wide range of sealing needs.

SealBoss Injection Tube Advantages

SealBoss Injection Tube Type 1 and Type 2 to suit specifications & application requirements
SealBoss ® Injection Tube Type 2 – Double membrane protects tube best from infiltration
Deep penetration water stop seal
Will not fold or crush with concrete weight
Can be injected under flowing water
NSF potable water applications possibles

Applications

Cold Joints.
Expansion Joints.
New and Retrofit Construction
Tunnels, Parking Garages, Slurry Walls, Pipe Joints

The SealBoss Injection Tube System: Efficient and Easy-to-Install Solution for Watertight Cold Joints

The SealBoss Injection Tube System is a highly efficient and user-friendly system designed to create durable, watertight cold joints in concrete structures. Cold joints —formed when fresh concrete is poured next to already-cured concrete— can be particularly vulnerable to water infiltration and stress-induced cracking. The SealBoss Injection Tube System effectively addresses these challenges by sealing the joint areas where leaks are most likely to develop.

A well-known characteristic of concrete is shrinkage while curing. Stress caused during this time and temperature changes provoke the development of small cracks and fissures.

Several design and reinforcement techniques help to control this effect, but cannot control them completely. Fine cracks of sometimes less than 0.1 mm are inevitable. These cracks are considered normal and generally do not cause any problems. However, at cold joints, the tendency to form larger cracks cannot be reduced.

Since old and new concrete do not bond together homogeneously and do not form a monolithic concrete body, stress cracks concentrate mainly in these areas. They easily conduct water and may cause severe damage.

The SealBoss Injection Tube System for sealing cold joints utilizes the natural tendency of concrete to form cracks. A special tube system is installed at the joint where leaks are most likely to occur. The system allows resin injection directly into the joint through a protected porous tube after completion of the structure. The resin penetrates through the perforation of the tube and fills the cracks and voids of the cold joint area thereby sealing the structure.

To be effective, the system must have certain properties. The tube must be sturdy enough to withstand the high pressure of placed concrete and it must resist concrete slurry penetration. On the other hand the injection resin must be able to penetrate the hose at a moderate injection pressure. The installation and injection process must be suitable for construction sites. The SealBoss Injection Tube System is designed to meet these requirements.

Injection Tube System Installation

Before pouring the new concrete the tube shall be attached to the existing surface as tight as possible and usually towards the middle of the future cold joint using suitable clips or by attaching it to the existing rebars. It is crucial that the hose is tightly fixed in the center of the joint area so that it can neither move nor lift during the concrete placement. Six to twelve inches between clips are typically recommended.

The hose must be placed in a manner that it will not touch the outside surface of the structure at any point. To allow sufficient injection pressures, the maximum length of injection tube should not exceed 30 feet.

Conclusion

The SealBoss Injection Tube System offers a sophisticated and reliable solution for waterproofing construction joints in concrete structures. Its proactive design, ease of installation, and adaptability make it an essential tool for engineers and contractors aiming to enhance the durability and integrity of their projects. By preventing water ingress and allowing for straightforward maintenance, it contributes significantly to the longevity and safety of infrastructure worldwide.

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Curtain Injection In Pictures

Curtain Injection in Pictures

And Podcast

Curtain / Bladder Injection - Curtain Wall Grouting Method

Water intrusion is a persistent challenge for below-grade concrete structures, where traditional patching and surface sealers often fall short. The failures of these surface-applied remedies—such as patches, liquid sealers, and membrane applications—stem from their inability to address the root causes of leaks. These methods provide only temporary relief, leaving structures vulnerable to recurring hydrostatic pressure and ongoing water damage.

Curtain wall grouting, including advanced techniques like curtain and bladder injections, offers a reliable, long-term solution to these challenges. Unlike surface treatments, these methods work by creating a robust waterproof membrane and water barrier behind the structure. This approach not only seals cracks and cold joints from within but also fortifies the structure against future water intrusion.

By injecting specialized grouts through the structure to form a protective layer on the positive side, curtain injection ensures a comprehensive and lasting seal. Whether applied through stage grouting or other targeted injection methods, this professional approach delivers durable protection, minimizing service interruptions and maximizing cost-effectiveness in the long run.

Curtain / Bladder Injection is the Reliable Way to Waterproof Your Below Grade Concrete Structure Permanently

Why Patches and Liquid Sealers Often Don’t Stand the Test of Time

Experiencing the frustration of failing patches and paint applications on damp, actively leaking, below-grade structures is something many of us can relate to.

These are typically failed attempts to block hydrostatic water intrusion using surface-applied remedies that serve as temporary solutions at best.

Interior patches and membrane applications, while seemingly addressing the problem, often don’t tackle the root cause and rarely provide a lasting waterproofing resolution.

A Professional Approach to Curtain Injection:

Sealing Cracks Permanently and Establishing a Waterproof Membrane and Water Barrier behind the Structure

Water leakage via cold joints, cracks, and other irregularities in concrete can frequently only be effectively and permanently sealed using advanced injection techniques, such as curtain, bladder, and stage grouting injection methods.

The SealBoss Injection Product offers a professional solution to these issues, filling and sealing the cracks from the inside out. This product is injected through the structure, forming a membrane on the structure’s positive side, thus providing a more effective and lasting waterproofing solution.

The Art of Stage Grouting Technique

In complex grouting scenarios, the stage grouting technique is often the favored approach. This process entails a strategic series of injections carried out in a staged manner, utilizing lower volumes of product in each application.

Each stage of this meticulous process is allowed sufficient time to react, allowing the grout to solidify and establish a natural barrier before proceeding with the subsequent stage of grouting. This carefully phased and controlled deployment not only elevates the overall efficacy of the grouting operation but also ensures thorough and consistent coverage along the exterior of the wall.

Comparative Cost Analysis of Injection Grouting Sealing Methods

Understanding the financial impact of various sealing techniques is essential for making cost-effective decisions. Below is a comparison.

Crack Injection

Direct Costs: Moderate for materials and labor, product is injected directly into the cracks, joints, and voids. Low for equipment.
Indirect Costs: Minimal, as the method is fastest and causes little service interruption.

Curtain Grouting

Direct Costs: Higher for materials and labor, product is injected through the structure into the substrate behind, which results in higher material consumption. Packers are set in distinctive patterns. Moderate for equipment.
Indirect Costs: Higher, due to the lengthier process of preparation and product pumping, which can lead to more significant service disruptions.

Links

Curtain / Bladder Injection Products

Professional Polymers

Premium Packers

Powerful Pumps

SealBoss Injection Pump Systems

Mockups
Curtain Wall Grouting | Negative Side Injection Waterproofing

"The Mockup is Worth its Weight in Gold"
Technical Podcast for the Infrastructure Repair Industry

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Seawall Repair with Polyurethane Foams | Plural Component vs Single Component Foam

Seawall Repair with Polyurethane Foams
Plural Component vs Single Component Foam

Concrete Solutions Since 1988

This article contains an excerpt from the “SealBoss Concrete Solution Network Podcast – Seawall Repair | Bulkhead Repair | Erosion Control | Permeation Grouting”, featuring Jerald Sargent of Slabjack Geotechnical. Jerald has over 30 years of experience in the slabjacking and geo-technical industry. If you’d like to listen to the complete conversation, an audio version of the podcast is posted at the bottom of the article.

In this podcast we talk about the use of single and plural component foams for seawall repairs.

Both foam types have their place in seawall repair but the contractor needs to have a good understanding of their respective characteristics and area of application.

Single component (accelerator activated) foams offer outstanding crack sealing and good soil penetrating, permeation and soil aggregate stabilizing properties.

Plural component foams are excellent void fillers, support and lifter foams, predominantly used for slabjacking and slab lifting.

Single Component Foams are Preferred for Soil Permeation and Soil Consolidation — Plural Component Foams are Good for Filling Voids in Certain Applications

In the following Jerald discusses the use and limitations of Plural Component Foam.

Jerald Sargent: …Sometimes plural components make a lot of sense… where there’s obvious gaps behind the wall or maybe in a you know in a big boulder type of Bulkhead where they just use big rock rather than poured concrete. So plural components are good for filling voids in there and helping to lock [larger] aggregate together…

In most poured concrete walls we stay away from plural component simply because of the risks associated with it.

Going right along with that, one of the things that plural component is not appropriate for is injecting underneath the walls…

There’s virtually no permeation [into the soil] involved with plural component polyurethanes. It’ll [the soil] take up, it’ll absorb a little bit push through a little bit of that but it will not do it to the point where you have a solid structure built below the wall itself.

And I think that it is really important to understand the real limitation of the plural component polyurethane. And we use hundreds of thousands of pounds of a year in our slapjack in operation.

But it really isn’t appropriate in most cases to do a poured concrete wall [soil] stabilization.

To learn more about seawall repair and single and plural component foams you may want to listen to the podcast below.

Looking for a seawall repair contractor? – Call us at 714-662-4445.

Seawall Repair with Polyurethane Foam

Technical Podcast for the Infrastructure Repair Industry

A Concrete Solutions Network / Sealboss ® Production Podcast ©

A Conversation Between Two Industry Professionals
Episode 3

How To Podcast:
Seawall Repair | Bulkhead Repair | Erosion Control | Permeation Grouting

Podcast Details Here

SealBoss Polyurethane Grouts

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Seawall

Contact Your SealBoss ® Technician

Parking Garage Crack Injection | Leak Sealing Repair

Parking Garage Crack Injection

Structural and Leak Sealing Repairs

Introduction:

For effective and long term parking garage crack injection repair, the use of specific injection products for waterproofing and structural crack repair is pivotal.

For leak sealing, polyurethane foam resins, hydrophilic gels, and acrylate / acrylic gels are commonly employed. These resins, when injected, either react with water to form a foam that expands or create a gel product respectively, filling voids and sealing against further water ingress. This method not only prevents water penetration but also adds to the structural integrity of the parking facility.

On the other hand, for structural strength crack injection, epoxy resins are predominantly used. These resins are known for their high-strength bonding capabilities, effectively sealing cracks and restoring the concrete’s original strength. Epoxy resins are particularly advantageous in load bearing environments, providing strength and restoring the concrete’s structural integrity.

Both types of injection product groups are crucial in extending the lifespan of parking structures, ensuring they remain safe and functional for daily use.

Parking Garage Crack Injection Technology

For over three decades, SealBoss Crack Injection Systems have been at the forefront of providing effective solutions for structural repairs and sealing leaks in cracks and joints within parking garage structures. These systems have proven successful in not only preventing water ingress but also in preserving the integrity and functionality of parking facilities.

Injection of concrete parking structure in St. Louis, Missouri using the SealBoss Water Stop System

How to Seal Leaks in Voids, Cracks, Joints, and Seal Around Beams

In a technical support role for a leading infrastructure repair company, the job often involves providing assistance to clients on a wide array of repair projects. These projects range across a diverse spectrum, including concrete repair, waterproofing, slab lifting, soil stabilization, and permeation grouting.

Recently, there was an instance of providing consultation to a contractor. The focus was on addressing water leaks by injecting materials into voids, cracks, joints, and beam pockets that had previously been treated with mastic grout.

How To Podcast:
Leak Sealing Polyurethane Crack Injection
in Concrete and Shotcrete Structures

The area where the leaks persisted were directly below the sidewalk where the concrete meets the asphalt driveway. After inspecting the above ground conditions closely it was determined that the main source of the water intrusion were gutter downspouts. There were no drains installed to manage the directional flow of rainwater away from the structure.

Now that the source and path of water ingression had been established, polyurethane pressure injection of the affected areas was confirmed to be the correct solution to seal the leaks.

The first areas that needed to be sealed were leaking beam pockets which had been previously filled with a mastic patch grout. Over a 30 year period there had been multiple previous attempts by various contractors to repair the leaking areas. No records were available on the various works that had been performed.

It was decided to inject through the wall to the back side of the structure to cut off any water before it could find its way into the beam pockets. This method combines void fill and permeation grouting as product is injected beyond the structure into a space that in this instance is confined by concrete / steel, asphalt and dirt. As the foam disperses under pressure injection and during expansion, it partially migrates / permeates also into the dirt further enhancing the ability to seal the void.

Using two strategically placed SealBoss Evolution 13-100 AL packers, the contractor injected 1510 Water Stop Foam, catalyzed with 10% 15x Accelerator, at several intervals, permitting the resin to expand to a dense foam creating a seal and protecting the beam pocket from any water intrusion from behind the wall.

The injection process was monitored from the inside and outside and the contractor stopped injection once air bubbles and water were observed coming up through the asphalt driveway. Expanding foam displaced water in the affected area. Injection was continued at a slow rate until water displacement finished and increasing resistance indicated full penetration.

Next, the contractor injected all visible and leaking cracks some of which at one point had been injected with a structural / rigid epoxy which had failed. Reason of epoxy failure was determined as either lack of bond due to actively leaking cracks during epoxy injection and/or failure due to crack movement such as contraction and expansion. Polyurethane injection is the preferred method to address actively leaking and water bearing cracks, especially in areas where structural repairs are not necessary. The two foot thick wall was injected with 1510 leak-seal foam in intervals till the crack showed refusal of the resin.

Epoxy Versus Polyurethane Comparison – click here.

On-site support from knowledgeable and experienced technical reps is available upon request, I personally cover from North Dakota and Minnesota down through Texas. Call us with any questions, we look forward to helping you find a solution.

Materials and Tools Used

Related Articles

Structural Parking Garage Repairs with High Strength Epoxy Resins

Structural Epoxy Injection System

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Check out our Leak Sealing Repair Kits.

SealBoss P2002 Light Weight Professional Injection Pump

Polyurethane Grout Injection Pump
Polyurethane Foam Injection Pump
Easy To Use
Easy To Cean
Easy To Maintain
Modular, Compact &
Sturdy Design
Single Component
Electric Drill Operated
Heavy Duty For Daily Use
Pressure Gauge, Hose Set, Hopper Included
Recommended For Beginners & Injection Pros
> 5000 PSI Injection Pressure Possible

SealBoss Injection Systems

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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”
Podcast | “The Mockup is Worth its Weight in Gold”

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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.

Click here for more information on SealBoss Swell Tape & Swell Caulk Products