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Water Treatment Plant Maintenance

Maximizing Performance and Longevity

Water Treatment Plant Maintenance
and Water Reclamation Facility Solutions

Introduction

Water Reclamation District Maintenance and Water Treatment Plant Maintenance in general are the backbone of modern infrastructure, ensuring clean and safe water for consumption, sanitation, and industrial use. Effective, ongoing maintenance of these facilities is critical to maintaining continuous, efficient operations.

At SealBoss, we understand the importance of maintaining water reclamation districts and  water treatment plants. We provide comprehensive solutions to address common challenges, such as leak sealing, crack repair, and water stop systems. By leveraging advanced technologies and reliable products, we help ensure the long-term integrity and functionality of water infrastructure.

Products such as SealBoss 1510 Original Water Stop Foam play a pivotal role in resolving these challenges. This hydrophobic, water-activated grout is highly versatile, suitable for applications such as leak sealing, hairline crack injection, and void filling. When combined with the IP-495 Injection Pump and BP-13-115S Packers, SealBoss 1510 ensures precise, effective repairs for various crack injection scenarios. The resin’s NSF drinking water certification further highlights its suitability for water reclamation district and water treatment facilities.

This article highlights maintenance practices and tools, emphasizing innovative solutions designed specifically to address critical challenges, including sealing leaks, repairing cracks, and installing effective water stop systems.

Water Treatment Plant Maintenance

The Importance of Water Reclamation District and Water Treatment Plant Maintenance

Good maintenance and is critical for several reasons. It ensures the safety of reclaimed as well as treated water, prevents costly downtime, and extends the lifespan of infrastructure components.

Regular maintenance reduces the risk of leaks, structural damage, and system failures, which can disrupt water supply and compromise safety standards.

SealBoss Offers Specialized Training for Water Reclamation and Treatment Plant Maintenance Applications

Proactive maintenance is essential for ensuring structural integrity and operational efficiency in water reclamation and water treatment facilities. SealBoss injection solutions, such as the SealBoss 1510 Original Water Stop Foam, BP-13-115S Packers, and the IP-495 Injection Pump, are designed to tackle common maintenance issues such as leaking cracks and structural degradation.

By combining advanced technologies with comprehensive training, SealBoss supports facility teams in preventing system failure, reducing downtime, and extending the operational life of critical water treatment installations.

Key Challenges

Water treatment plants and water reclamation districts often face a range of ongoing maintenance challenges that necessitate regular maintenance:

  • Structural Cracks and Leaks: Over time, concrete structures in water treatment plants can develop cracks due to pressure, chemical exposure, and natural wear and tear. These cracks can lead to leaks, compromising the efficiency and safety of the plant.
  • Corrosion and Chemical Damage: Continuous exposure to chemicals and water can corrode metal components and degrade concrete, necessitating timely repairs.
  • Equipment Wear and Tear: Pumps, filters, and other equipment experience mechanical wear over time, leading to reduced efficiency and potential failures.
  • Environmental Factors: Fluctuations in temperature, seismic activity, and other environmental factors can impact the integrity of water treatment plant structures.

SealBoss Solutions for Water Reclamation District and Water Treatment Plant Maintenance

SealBoss provides comprehensive solutions tailored to the unique challenges of water containment maintenance. Our products and systems are designed to address cracks, leaks, and structural integrity issues effectively.

Water Treatment Plant Maintenance
Water Treatment Plant Maintenance

Pictures: Repairing Thickener Leaks at Water Reclamation District Facility

SealBoss 1510 Original Water Stop Foam

SealBoss 1510 Water Stop Foam is our most versatile and our best-selling chemical injection grout for stopping water leaks in most crack injection situations.

It is a hydrophobic water-activated, hydro-active water cut-off grout and foam seal grout based on an MDI polyurethane.

Mixed with 15x Accelerator, the resin is 100% solvent-free and 100% solids.

Product Highlights:

  • Hydrophobic, water-activated, hydro-active grout
  • Based on MDI polyurethane
  • Mixed with 15x Accelerator
  • 100% solvent-free and solids-based

Applications include:

  • Crack Injection Foam: Seals cracks in concrete effectively.
  • Water Stop Foam: Ideal for stopping active water leaks.
  • Leak Sealing Foam: Provides durable and reliable leak sealing.
  • Concrete Repair Foam: Restores structural integrity.
  • Void Fill Foam / Filling Voids under Concrete Slabs: Stabilizes and fills voids under concrete.
  • Curtain / Bladder Injection Grout: Creates water-tight barriers.
  • Soil Stabilization Grout: Reinforces and stabilizes soil structures.
  • Hydrophobic Moisture Inert Structure: Offers resistance to water ingress.
  • Hairline Crack Seal Foam: Perfect for sealing fine, hairline cracks.
  • NSF Drinking Water Contact Foam: Safe for applications involving potable water.

Key benefits include:

  • Durability: SealBoss 1510 forms a permanent seal, preventing water ingress.
  • Versatility: Suitable for hairline cracks, larger voids, and various other applications.
  • Ease of Application: Efficient and controlled injection, minimizing downtime.
Water Treatment Plant Maintenance
Water Treatment Plant Maintenance

Pictures: SealBoss System Polyurethane Foam Grout Injection

System Solutions for Water Reclamation District and Water Treatment Plant Maintenance

SealBoss System Solutions: Injection Pumps & Packers

SealBoss InjectionPump System

SealBoss Injection Pumps, particularly the IP-495 Injection Pump, is a cornerstone of effective crack injection and leak sealing operations.

Engineered for reliability and precision, the IP-495 offers high-pressure performance necessary to handle a variety of polyurethane and epoxy injection applications. Its lightweight, portable design ensures ease of use in demanding environments like water treatment plants. The pump’s ability to deliver controlled and consistent material flow makes it an essential tool for achieving successful repairs with SealBoss products, such as the 1510 Water Stop Foam. By streamlining the injection process, the IP-495 significantly reduces downtime and enhances the efficiency of maintenance operations.

SealBoss Injection Packer System – Placement and Spacing

Proper packer placement is a cornerstone of effective crack injection. The spacing and positioning of SealBoss BP-13-115S Packers depend on the width and depth of the crack, ensuring even distribution of the injection material. SealBoss provides training and guidelines to help operators achieve optimal results, as demonstrated during the Clark County training session.

Total System Solutions

SealBoss’s Total System Solutions encompass a range of products and accessories designed to work seamlessly together. From injection pumps to packers and hydrophobic foams, our systems ensure reliable and efficient repairs. These solutions are available through a nationwide distribution network, making it easy for water treatment plants to access the tools they need for maintenance.

Video: Fine Crack Water Leak Sealing Repair with SealBoss PU Injection Systems

Best Practices for Water Reclamation District and Water Treatment Plant Maintenance

Effective maintenance requires a proactive and systematic approach. Here are some best practices to consider:

  • Regular Inspections: Routine inspections are essential for identifying potential issues before they escalate. Inspectors should check for visible cracks, leaks, and signs of wear and tear in concrete and metal components.
  • Proper Training: Training personnel in the use of advanced maintenance tools and techniques is crucial. The training session  demonstrated the value of hands-on experience with SealBoss products.
  • Scheduled Repairs: Addressing minor issues promptly can prevent costly repairs and downtime. Products like SealBoss 1510 enable quick and effective crack repairs, minimizing disruptions.

Environmental Monitoring

Monitoring environmental factors such as temperature, humidity, and chemical exposure helps identify potential risks to the plant’s infrastructure.

Record-Keeping

Maintaining detailed records of inspections, repairs, and maintenance activities ensures accountability and helps in planning future maintenance schedules.

SealBoss’s Commitment to Excellence

At SealBoss, we go beyond providing products — we offer solutions designed to meet the rigorous demands of water reclamation and water treatment environments. Whether you’re sealing a hairline crack or stabilizing a larger structural issue, our systems are engineered for performance, longevity, and ease of use.

Why Choose SealBoss?

  • Proven Track Record – Over three decades of repairs in water treatment plants and water reclamation facilities.
  • Comprehensive Solutions –From crack injection to complete solutions.
  • Expert Support – Our team offers training and technical support to ensure successful implementation of our products.
  • Nationwide Distribution – SealBoss products are readily available through a nationwide network, making it easy to access the tools you need for maintenance.

The Future of  Water Reclamation District and Water Treatment Plant Maintenance

As water treatment and water reclamation plants face increasing demands and aging infrastructure, the need for effective maintenance solutions will continue to grow.

SealBoss is at the forefront of innovation, providing products and systems that address the evolving challenges of the industry. By investing in regular maintenance and leveraging advanced tools like the SealBoss 1510 Water Stop Foam, water treatment plants can ensure their longevity and efficiency.

Conclusion

Ongoing maintenance is essential for keeping water treatment and reclamation systems safe, efficient, and compliant.

Even the newest structures require attention — and SealBoss is here to help.

With proven products, expert support, and nationwide access, we empower facilities to address problems early and build lasting reliability. Contact SealBoss today to learn how we can support your water treatment plant maintenance needs.

Together, we can protect your infrastructure — one repair at a time.

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Watertight Pipe Penetration Sealing

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

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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Cold Joint Injection

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:

  1. Inspection and Assessment
    The area is assessed to determine the severity of leaks, substrate condition, and appropriate injection points.

  2. 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.

  3. 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.

  4. Sealing and Curing
    Once the injection is complete, the resin cures quickly, forming a flexible, watertight seal. Packers are then removed and holes patched.

  5. 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.

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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

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
SealBoss 2400 A1
SealBoss 2400 A2
SEALBOSS-2400-B-SMALL
SealBoss 2400 B
IP2C-2G 3 component acrylate gel pump
SealBoss IP2C
Stainless Steel Gel Pump

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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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Concrete Leak Sealing

Concrete Leak Sealing

Guide to Concrete Leak Sealing:

Polyurethane Grout vs. Hydraulic Cement & Crystalline Waterproofing

When it comes to repairing and reinforcing concrete structures against leaks, not all solutions are created equal. Each method has unique strengths and is suited to specific conditions, making it essential to choose the right approach for long-lasting results. This guide provides a detailed comparison of three popular options—polyurethane grout, hydraulic cement, and crystalline waterproofing—highlighting their advantages, limitations, and ideal applications to help you make an informed decision.

concrete leak sealing

A Product Comparison

Hydraulic Cement, Crystalline Waterproofing, and Polyurethane Grout

Hydraulic cement, crystalline waterproofing, and polyurethane grout are distinct material groups, each with its own merits and uses. The choice between them should be a strategic decision guided by the requirements of your project.

Understanding Hydraulic and Crystalline Systems

Hydraulic cement and crystalline waterproofing solutions are often utilized due to their cost-effective nature and straightforward application process. They find common use in below-grade concrete structures like parking garages, basement walls, and manholes, where their primary role is to coat surfaces or seal leaking cracks, preventing water infiltration.

Despite their utility in surface-level repairs for static structures, these products share a key limitation – their inability to form a flexible seal that penetrates the depth of the structure. This makes them somewhat akin to ‘band-aid’ fixes – temporary, surface-level solutions.

Their limitations become particularly evident in the face of structural movement, including thermal expansion and contraction of substrates. Such movements often lead to the re-emergence of leaks over time, creating a cycle of recurring repairs. These patchwork solutions, although effective in the short term, can prove to be a less sustainable choice in the long run.

Polyurethane Grout: A Dynamic Solution

For structures prone to any movement over time, including expansion and contraction of materials, polyurethane grout outshines its service applied counterparts. The long-term benefits of polyurethane grout injection often justify the investment.

Let’s consider an illustrative example: a substantial concrete structure, such as below grade wall or potable water tank, several feet thick and reinforced with rebar, that has developed a crack.

In cases where the leak is not too severe – keeping in mind that polyurethane grout injection is the preferred, and often only method for handling aggressive or gushing leaks – a surface patch solution like a hydraulic cement or crystalline system could be employed to halt a minor leak initially.

While this approach may provide temporary relief, it falls short in addressing the fundamental problem – the unending cycle of water infiltration, migration, and trapped moisture within the structural fissures and crevices. The unresolved water intrusion not only propagates moisture migration throughout the structure, but it may also expose the reinforcing bars (rebar) to corrosive effects. This corrosion can lead to expansion, creating additional stress on the concrete structure, potentially worsening the initial problem.

Here is where polyurethane grout shines – Full depth penetration concrete leak sealing

With a full-depth injection of polyurethane grout, you can not only disperse any water inside the structure and seal the entire volume of the crack, but also safeguard the rebar in the process, eliminating the threat of future corrosion. The penetrating and water dispersing ability, flexibility, and durability of polyurethane grout make it an ideal solution for preventing future leaks. Unlike surface patch solutions, it offers a comprehensive, long-term resolution to the issue.

The Role of Structural Movement in Permanent Leak Sealing

The effectiveness of hydraulic cement and crystalline waterproofing significantly diminishes when it comes to dealing with structural movement. This is particularly evident in dynamic below grade concrete structures like parking garages, which experience thermal cycles, vibration due to heavy traffic, and may additionally be situated on expansive soil. Moreover, its high elasticity makes it perfect for application in areas prone to constant vibrations or expansions, like bridges, highways, and large commercial buildings. The recurring nature of leaks due to movements necessitates a structure penetrating and permanent solution: A professional polyurethane grout injection concrete leak sealing system.

The Final Word:

Making an Informed Choice

Selecting the right materials for your concrete leak sealing repair needs is crucial. The long-term benefits of polyurethane grout often make it a superior choice, especially for structures prone to any movement. Unlike its counterparts, it can withstand significant structural movement over time without losing its sealing capabilities. 

As a trusted provider, we’re dedicated to guiding your decisions with reliable, professional, and detailed information tailored to your needs. Remember, making the best choice now will save you time and resources in the future.

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

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Concrete Leak Sealing

Rigid, High Strength, SlabLifter & Void Fill Foam
Two component polyurethane foam with structural qualities to stabilize, lift and cut-off water. Fast reactive formula to gain strength within minutes. 

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– Cartridge System

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Concrete Crack Injection – Polyurethane

Concrete Crack Injection Polyurethane

Concrete Crack Injection Polyurethane

Introduction:

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

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

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

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

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

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

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

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

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

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

Concrete Crack Injection – Polyurethane

Which products are shown in the video?

Concrete Crack Injection Polyurethane – Procedure and Repair Method

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

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

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

Crack Injection Details

A – Standard Injection Procedure

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

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

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

45 Degree Angle Drilling
Concrete Crack Injection - 1 2 3 - 45 Degree Injection Technique SealBoss
1510 Foam Grout Injection

B – Custom Injection Procedure

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

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

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

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

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

Concrete Crack Injection - Polyurethane Water Stop Foam SealBoss
Leaking Cracks & Cold Joints
Custom Packer Placement

Cleanup

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

Products Used:

Injection Resin:

Other Tools Used

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

Why Polyurethane Foam Injection?

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

Its advantages include:

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

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

Conclusion

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

Call Your SealBoss ® Technician

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

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Flooded Tunnel Repair

Flooded Tunnel Repair

Underground Injection Grouting

flooded tunnel repair sealboss

A Spotlight on SealBoss 1510 Water Stop Foam and SealBoss EZ Flow Plastic Button Head Injection Packers

Introduction

Flooded Tunnel Repair: How to Stop Water Migration, Infiltration and Inflow in Underground Passages

Flooded tunnel repair is an essential process for maintaining the structural integrity and functionality of critical infrastructure like utility tunnels, storm drain systems, and primary sewer lines. These systems, when compromised by cracks, leaks, or structural weaknesses, are at risk of water migration and infiltration—a phenomenon known as Infiltration/Inflow (I/I) in the sanitary sewer industry. If left unchecked, water ingress not only deteriorates infrastructure but also poses significant environmental and safety risks.

With advanced tools, proven products, and effective repair methods, underground tunnel structures and expansive pipe systems can be restored to their intended performance. This article explores innovative techniques for flooded tunnel repair, with a focus on SealBoss 1510 Water Stop Foam and SealBoss EZ Flow Plastic Button Head Injection Packers.


The Challenge of Flooded Tunnel Repair

Journey Beneath: Unveiling the Underground

In this captivating video clip, viewers delve deep into a shadowy underground drainage tunnel, witnessing the significant impact of water ingress. Illuminated only by the beams of headlamps and makeshift lighting, the scene reveals a structure submerged in over a foot of water.

Despite the uninviting environment and jobsite conditions, the skilled injection team remains focused and determined, united by one mission: to repair and seal the structure.

Enter the SealBoss 1510 Water Stop Foam and SealBoss EZ Flow Plastic Button Head Injection Packers – a dynamic duo that promises effective and lasting solutions.

SealBoss 1510 Water Stop Foam: A Game-Changer in Flooded Tunnel Repair

The SealBoss 1510 Water Stop Foam is a polyurethane-based chemical grout renowned for its ability to stop water migration efficiently.

This injection project showcases the power of SealBoss 1510 Water Stop Foam. As the foam is injected, it migrates rapidly, filling cracks, fissures and voids, effectively stopping water ingress. The foam’s expansion and curing properties make it an ideal solution for such challenging environments, ensuring that the tunnel’s water tight integrity is restored.

Key Benefits:

High Expansion Rate: The foam effectively seals even the smallest gaps, preventing water flow.
Fast Curing Time: Once injected, it hardens quickly to form a durable barrier against water.
Versatility: Suitable for use in a variety of underground environments, including tunnels, pipelines, and many underground commercial and residential structures.

The Role of SealBoss EZ Flow Plastic Button Head Injection Packers for Floded Tunnel Repair

Ensuring Secure and Highly Efficient Grout Delivery

The effectiveness of SealBoss 1510 Water Stop Foam depends on precise delivery, which is made possible by SealBoss EZ Flow Plastic Button Head Injection Packers. These innovative injection tools are designed for efficiency, reliability, and ease of use in demanding conditions.

One of the highlights of this injection project is the impeccable, leak-free connection between the injection grout line’s slide coupler and the button head packers that have been installed. This is largely attributed to the purpose driven design of the button head packer and slide coupler, ensuring a secure connection, and eliminating the need for the contractor to manually hold it in place.

Additionally, the expansive inner diameter of both the coupler and button head, combined with the oversized ball valve design, facilitates the pumping and delivery of chemical grout at impressive flow rates and volumes. This guarantees that the foam is dispensed exactly where required.

SealBoss EZ Flow Plastic Button Head Injection Packers are instrumental in efficiently and securely delivering the SealBoss 1510 Water Stop Foam. They ensure the foam is dispensed at high volumes and appropriate pressures, streamlining and enhancing the repair process.

flooded tunnel repair

Conclusion

With the right tools and products in place, underground injection and flooded tunnel repair no longer needs to be a daunting task for crack injection teams. With the combined power of SealBoss 1510 Water Stop Foam and SealBoss EZ Flow Plastic Button Head Injection Packers, even challenging grout injection environments can be tackled with confidence.

This project serves as a powerful example of how cutting-edge materials and innovative tools can effectively restore the integrity of underground infrastructure, such as tunnels and pipelines. As the industry continues to evolve, solutions like these will remain at the forefront, enabling contractors to tackle water migration and infiltration with precision and reliability.

Investing in quality products and adopting proven repair techniques ensures not only the longevity of critical infrastructure but also the safety and well-being of communities that depend on it.

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SealBoss ® 1510

Leak-Seal Foam Grout
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EZ FLOW PLASTIC INJECTION PACKER | PLASTIC PORT

High Volume Easy Flow Packer | EZ Flow Packer Design

Plastic packer with large inner diameter for high volume product flow. The packer is threaded and equipped with a removable, sleeve for good grip. Free-floating large ball valve for high volume applications. Buttonhead top for secure connection and minimal leakage. Suitable for PU grouts, Acrylate Gels (Acrylic Gels). Also available with zerk fitting.

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Types of Concrete Cracks

Types of Concrete Cracks

A Concrete Crack Overview

Introduction:

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

For Concrete Crack Repair Details read our Quick Guide

Types of Concrete Cracks

  • Shrinkage Cracks in Concrete

    Shrinkage cracks occur when hardened concrete loses moisture during the curing process, causing it to contract. These cracks are common in driveways, slabs, and foundation walls. As concrete dries over time, this moisture loss can lead to shrinkage if the concrete is restrained, resulting in cracks. These cracks may be larger and can appear throughout the structure.

    Cause: Uneven moisture loss and restraint in the structure.
    Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or, in some cases, epoxy injection to regain structural strength.

  • Plastic Shrinkage Cracks in Concrete

    Plastic shrinkage cracks form while the concrete is still in its plastic (unhardened) state. They result from rapid moisture evaporation from the surface, often due to high temperatures, low humidity, or strong winds. These shallow cracks resemble a spiderweb pattern and typically affect newly poured slabs.

    Unlike regular shrinkage cracks, which develop after the concrete has hardened and contracted over time, plastic shrinkage cracks appear within the first few hours after pouring, making them a common issue in newly poured slabs or exposed surfaces. These cracks are typically shallow and widespread across the surface, while regular shrinkage cracks are generally larger and occur throughout hardened concrete structures.

    Cause: Rapid moisture loss from the surface during curing.
    Repair Solution: Typically Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress. Acrylate gel in some cases.

  • Spalling Concrete Cracks

    Spalling occurs when sections of concrete break away from the surface, exposing the reinforcing steel. This typically results from corrosion within the steel, causing it to expand and exert pressure on the surrounding concrete.

    Cause: Corrosion of embedded reinforcing steel.
    Repair Solution: Epoxy injection to fill and bond the cracks, combined with a surface coating to prevent future corrosion.

  • D-Cracking in Concrete

    Durability cracking, or D-Cracking, results from concrete’s inability to withstand freeze-thaw conditions. It usually manifests as cracks running parallel to joints or linear cracks, often with discoloration around the affected area. D-Cracking is primarily caused by the use of coarse aggregates that trap moisture, which expands during freezing and leads to cracking over time.

    Cause: Coarse aggregates that absorb moisture and expand during freezing.
    Repair Solution: Polyurethane injection, which remains flexible during freeze-thaw cycles.

  • Corrosion Cracks in Concrete

    Corrosion cracks develop due to the rusting of steel reinforcement embedded in concrete. As the steel corrodes, it expands, creating internal pressure that leads to cracking.

    Cause: Rusting of embedded steel.
    Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.

  • Stress Corrosion Cracks in Concrete

    Stress corrosion cracks arise from a combination of tensile stress and a corrosive environment. These cracks are common in marine structures, bridges exposed to de-icing salts, or industrial facilities where chemical exposure is prevalent. This phenomenon often involves the interaction of aggressive chemicals (like chlorides or sulfates) with embedded steel reinforcement, resulting in cracks that may propagate rapidly under continued stress.

    Cause: Interaction of tensile stress with corrosive chemicals.
    Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.

  • Overloading Cracks in Concrete

    Overloading cracks develop when concrete structures bear more weight than they were designed to handle. These cracks usually occur in heavily trafficked areas like driveways or industrial floors where heavy machinery operates.

    Cause: Excessive loads exceeding the design capacity.
    Repair Solution: Most likely high-strength epoxy injection to restore structural integrity.

  • Concrete Expansion Cracks

    Expansion cracks develop when concrete expands due to heat, exerting pressure on the structure. Like most materials, concrete expands when heated, and if it lacks sufficient space to expand, the resulting internal stress can cause cracks. Expansion joints are often installed to provide relief and absorb the stress of expanding concrete.

    Cause:     Thermal expansion without adequate expansion joints.
    Repair Solution: Polyurethane foam injection, which is flexible enough to accommodate movement.

  • Heaving Cracks in Concrete

    Heaving cracks typically occur in cold climates where freeze-thaw cycles are common. When water within the concrete freezes, it expands considerably, causing the concrete slab to lift or “heave.” As temperatures rise and the ice melts, the slab settles back down, leading to the formation of cracks due to the constant movement. This can be prevented by allowing space for expansion and contraction.

    Cause: Freeze-thaw cycles and temperature changes.
    Repair Solution: Flexible polyurethane foam that can expand and contract with temperature variations.

  • Crazing and Crusting Cracks in Concrete

    Crazing refers to shallow, fine cracks resembling spider webs that appear due to premature drying. Crusting, on the other hand, occurs when the top surface dries faster than the bottom during stamping. While these cracks are not usually structural concerns, they can impact aesthetics and lead to moisture ingress.

    Cause: Uneven drying during the curing or stamping process.
    Repair Solution: Low-viscosity polyurethane foam for sealing and moisture protection.

  • Disintegration Cracks in Concrete

    Disintegration cracks are a result of the gradual breakdown of concrete, starting with surface scaling and leading to large pieces breaking away. Disintegration often results from chemical attacks like carbonation or sulfate exposure and poor construction practices.

  • Cause: Chemical attacks or poor-quality aggregates.
    Repair Solution: High-strength epoxy injection to reinforce the structure and sealant application to prevent further chemical exposure.

     

  • Re-Entrant Corner Cracks in Concrete

    Re-entrant corner cracks occur at areas with abrupt changes in geometry, such as around columns, pipe penetrations,  sharp corners column bases, pipe penetrations, around rounded objects like manholes, and intersections where slab and wall joints meet. As the concrete dries, uneven shrinkage around these regions creates stress concentrations that lead to cracking.

    Cause: Stress concentration around corners or openings.
    Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or, epoxy injection to regain structural strength.

  • Alkali-Silica Reaction (ASR) Cracks in Concrete

    Alkali-Silica Reaction (ASR), also known as concrete cancer, is a harmful chemical reaction between highly alkaline cement paste and reactive silica in aggregates. This reaction produces a hygroscopic gel that absorbs water, expands, exerts internal pressure, and progressive loss of concrete strength leading to map cracking, also known as pattern cracking or alligator cracking. This distinct crack pattern consists of randomly-oriented, web-like cracks on the surface of concrete elements that move in multiple directions.

    Cause: Reaction between alkaline cement and reactive silica.
    Repair Solution: Polyurethane resin, foam injection, depending on the severity and circumstances, to seal the cracks, prevent moisture ingress, or epoxy injection to regain structural strength.

Choosing the Right Repair Method for many Types of Concrete Cracks


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

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


Conclusion

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

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

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

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

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

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

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Elevator Pit Waterproofing

elevator pit waterproofing

Elevator Pit Waterproofing

Elevator Pit Waterproofing: Essential Solutions for Leak Sealing

 

Introduction to Elevator Pit Waterproofing

Elevator pit waterproofing is vital for maintaining the structural integrity and operational safety of hydraulic elevator systems, particularly in commercial and industrial buildings. Polyurethane grout is a highly effective solution for elevator pit leak sealing and waterproofing. When injected into cracks, joints, or structural defects, polyurethane grout reacts with water to form a solid, impermeable barrier. This foam expands to fill voids, cutting off all water entry points and creating a long-lasting, watertight seal. Its application is especially beneficial in elevator pits, where complex leak challenges are often present, offering a durable and reliable solution that enhances the overall safety and longevity of the system.

The Importance of Elevator Pit Maintenance

Elevator pits are critical components in hydraulic elevator systems, yet they are often overlooked. These pits play a key role in ensuring the elevator’s safety, reliability, and efficiency. Regular maintenance of elevator pits is essential to prevent operational failures and safety risks, particularly those associated with water ingress.

Water Leakage: A Critical Concern

Water leakage in elevator pits, whether from groundwater intrusion or pipe leaks, poses significant risks to both the elevator system and building compliance. Accumulated water can mix with hydraulic oil, creating hazardous environmental and safety conditions. Without effective waterproofing, this combination can result in environmental contamination, fire hazards, and regulatory non-compliance.

Risks of Ignoring Water Leakage

Ignoring water leakage in elevator pits can lead to severe consequences:

  • Environmental and Safety Hazards
    The mixture of hydraulic oil and water creates contamination and potential fire risks
  • Equipment Damage
    Prolonged exposure to water can lead to corrosion and failure of key elevator components, increasing maintenance costs and causing system downtime
  • Legal and Regulatory Implications
    Non-compliance with environmental standards due to oily water leakage can result in fines, legal action, and costly cleanup processes

Taking prompt action to seal leaks and waterproof elevator pits is critical to avoiding these risks.

Polyurethane Grout: The Effective Elevator Pit Waterproofing Solution

Polyurethane grout is widely regarded as one of the most effective materials for elevator pit waterproofing. This liquid polymer reacts with water to form an expanding foam that fills voids and creates a strong, watertight seal. Its fast-setting nature and durability make it ideal for commercial settings that require minimal downtime.

Key Benefits of Polyurethane Grout for Elevator Pit Waterproofing

  • Durability
    Provides a long-lasting, impermeable seal
  • Cost-Effectiveness
    Reduces long-term maintenance costs due to its longevity
  • Environmental Compliance
    Manages oily water effectively, helping to meet environmental regulations
  • Minimal Disruption
    Quick installation process allows for efficient repairs with minimal disruption to building operations

Regular Maintenance and Preventative Strategies

To ensure the long-term success of elevator pit waterproofing, regular maintenance is essential. Proactive strategies help prevent water accumulation and extend the life of the elevator system.

Key Maintenance Practices Include

  • Regular Inspections
    Early detection of water ingress, corrosion, and hydraulic system issues
  • Cleaning and Debris Removal
    Prevents drainage blockages that can lead to water buildup
  • Drainage System Checks
    Ensures proper function and identifies weak points before they cause significant damage
  • Seal Integrity Checks
    Ensures that the waterproofing seals remain effective over time

In addition, incorporating preventative measures such as water detection systems, climate control, and proper landscaping around the elevator pit can further protect against water-related issues.

Selecting a Waterproofing Professional for Elevator Pits

Choosing the right contractor for elevator pit waterproofing is crucial for achieving long-lasting results. When selecting a waterproofing expert, consider their experience, customer reviews, and transparency in pricing.

Important Factors to Consider:

  • Proven Track Record
    Look for contractors with successful experience in elevator pit repairs.
  • Positive Reviews
    References and reviews from previous clients offer insight into the contractor’s reliability and quality of work.
  • Transparent Pricing
    Detailed quotations and clarity on pricing help prevent unexpected costs.
  • Expertise in Elevator Pit Issues
    A contractor who understands the specific challenges of elevator pits can provide tailored solutions, detailed work plans, and warranties

A long-term relationship with a reliable waterproofing contractor enhances maintenance strategies and ensures ongoing support.

Expert Elevator Pit Repair with SealBoss

SealBoss is a trusted provider of elevator pit waterproofing solutions, offering expert technical guidance and connections to experienced contractors. With SealBoss, property owners and managers can ensure that complex elevator pit leaks are handled efficiently and cost-effectively.

SealBoss can assist in hydraulic elevator pit repairs

  • Technical Expertise
    Customized sealing solutions based on the specific needs of your elevator pit.
  • Contractor Referrals
    Access to skilled contractors with proven experience in elevator pit repairs.
  • Long-Term Partnership
    Ongoing technical support for cost-effective and environmentally friendly waterproofing solutions.

Partnering with SealBoss provides building managers with the confidence that their elevator pit waterproofing needs are addressed professionally and efficiently.

Summary

Elevator pit waterproofing is essential to maintaining the safety, efficiency, and regulatory compliance of hydraulic elevator systems. Water leakage poses serious risks, and polyurethane grout is a proven solution for creating durable, watertight seals. Regular maintenance, including inspections and cleaning, is crucial for long-term protection, and selecting the right waterproofing professional ensures the success of the repair process.

For expert assistance with elevator pit waterproofing, contact SealBoss today at 714-662-4445 for tailored solutions and professional support.

Elevator Pit Waterproofing and Leak Sealing Case Study


On-Site Elevator Pit Waterproofing Injection Training in Nebraska

SealBoss provided on-site support and training to a contractor performing a leak-sealing repair in the elevator pit of a multi-family housing complex in Nebraska. The elevator pit was plagued by persistent water pooling, leading to efflorescence and progressive erosion of the surrounding walls. – More information on effloresence, click here – Without immediate waterproofing intervention, serious structural damage was inevitable.

Identifying the Problem

The main issue involved water seepage through the cold joints between the floor and the poured-in-place wall. One of the walls was constructed with masonry blocks, highlighting the mix of construction methods used, which further complicated the waterproofing process.

The Solution: Polyurethane Foam Injection

After assessing the site, the SealBoss team recommended using SealBoss 1510 Water Stop Foam, in combination with the P2002 Injection System. This high-performance foam was chosen for its ability to expand and fill voids, creating a watertight seal. Its compatibility with the P2002 system allowed for high-pressure injection, ensuring deep penetration and a more effective seal.

Preparing for Injection

Due to the active status of the elevator, scheduling was critical. The contractor worked closely with the on-site technician to temporarily suspend the elevator’s operation, ensuring safety during the waterproofing process

Since original blueprints of the elevator pit were unavailable, the team first drilled test holes to investigate the nature of the cold joint.

These preliminary holes were flushed with water using the BGUN1500 Hand-Operated Pressure Pump and 13-100AL ½” Aluminum Injection Packers to confirm the flow of material along the joint and clean out the drill holes.

The pre-injection served a dual purpose. Besides verifying travel along the joint, it also functioned as a cleaning mechanism, flushing out the drill hole and priming the crack for the injection of the hydro-active 1510 Water Stop Foam.

Injection Process

The successful pre-test led to the strategic placement of 13-100 AL injection packers positioned with approximately 18” spacing. These packers were then drilled around 4” – 6” from the wall through the floor, following the well-established 1, 2, 3, 45-Degree Guideline drilling method.

In the corners, packers were placed about 8” from the corner point and drilled directly into the corner at a 45-degree angle through the floor. Additional packers were set 8” from the adjacent wall and 4” – 6” from the wall face where the joint would be injected.

Once the packers were firmly installed, the injection process began. There was an immediate take of material and travel. The off-gassing from the chemical reaction was noticeably visible several feet from the injection point, signaling the foam’s effectiveness. Shortly thereafter, the cold joint started to resist the resin, indicating the commencement of the curing process. As the foam reacted and solidified, smaller shrinkage cracks became apparent.

Successful Completion

Upon completing the injection, all cracks and cold joints were successfully sealed. This allowed the elevator to return to service with minimal disruption to the building’s occupants. The project highlighted the effectiveness of SealBoss 1510 Water Stop Foam and the importance of strategic planning and execution in elevator pit waterproofing.

Elevator Pit Waterproofing – Key Takeaways from the Project

This endeavor showcases the expertise of SealBoss in effectively managing water leakages in complex environments. It also demonstrates how the proper application of specialized materials, such as SealBoss 1510 Water Stop Foam, can ensure durable and reliable results. The project underscores the importance of adequate planning and coordination in such operations.

Additionally, this experience emphasizes the crucial role of pre-injection tests in ensuring the success of the actual repair. By confirming travel along the joint and cleansing the drill hole, the process ensured a successful application of the Water Stop Foam System.

Conclusion

Elevator pit waterproofing requires careful planning, testing, and the right materials to ensure success. SealBoss provided valuable support and expertise in addressing the water intrusion challenges at this site, delivering time-efficient and cost-effective solutions.

At SealBoss, we are committed to equipping contractors with the knowledge and tools they need for effective leak-sealing and waterproofing projects. Supported by a skilled technical team, we stand ready to assist you with any challenges you may face in the field.

For more information on elevator pit waterproofing or to schedule a consultation, contact SealBoss today. Our team of professionals is here to guide you through every step of your waterproofing project, ensuring long-lasting results and minimal downtime.

Contact Us by Phone: 714-662-4445

“We are committed to ensuring that everyone on the jobsite is well-versed with our systems and possesses the ability to pass on this knowledge to the next person. Supported by our adept technical support team, we stand ready to assist you with any queries you might encounter.

If you’re interested in gaining insights from a seasoned contractor regarding elevator pit repairs, we would highly recommend checking out our podcast through the link provided below.”

Technical Sales Team

Elevator Pit Waterproofing
How To Stop and Seal Active Water Leaks
Podcast

Elevator Pit Waterproofing
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Manhole Repair – Leak Sealing Injection

Manhole Repair - Leak Sealing Injection

Manhole Repair
Leak Sealing Injection

Manhole Repair Systems

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

Addressing Manhole Damages and Blockages through Inspections and Repairs

Mitigating Infiltration and Inflow (I/I) in Manholes

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

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

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

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

Understanding Sanitary Sewer Overflows (SSOs)

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

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

Factors Leading to SSOs:

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

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

Identifying Common Manhole Failure Causes

Several common causes of manhole failure include:

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

Manhole Repair Using Injection Grout


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

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

Introducing the ealBoss Seal-Oakum / Oakum Soakum Technique

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

Understanding Basic Repair Procedures

Repairing Manhole Leaks through Larger Cracks and Brick Construction

Here are the steps:

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

Adressing Manhole leaks through Precast Manhole Rings / Joints

Follow these steps:

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

Manhole Inspections and Preventive Maintenance – The Key to Longevity

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

Innovative System Solutions with SealBoss

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

Conclusion

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

Manhole Repair - Leak Sealing Injection
Old Manhole Injection Repair

Manhole Repair System Example

Experience Hands-On Training with SealBoss P2002 Pro Kit System

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

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

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

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

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

Manhole Repair Crew Training

Manhole Repair System Example

SealBoss Manhole Repair
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