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Restoration Waterproofing

Restoration - Waterproofing

Restoration – Waterproofing with Injection Resins, Gels, and Foams

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

Diagnosis

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

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

Setting Defined Objectives

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

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

Understanding Water Movement and Migration

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

Water is Not Always Visible

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

Leak Detection Techniques

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

Restoration Waterproofing Products

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

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

In Conclusion

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

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

Restoration – Waterproofing Systems

Popular Water Stop & Leak Sealing Injection Links

SealBoss ® 1510

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Water Stop Foam Grout
Hydrophobic Injection Foam Grout

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

SealBoss ® 1570

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

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

SealBoss ® 1570 LV

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

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

SealBoss ® 15X ACCELERATOR

Accelerator for SealBoss Single Component Injection Foams

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

SealBoss ® 1403 SLV

Leak Sealing Injection Resin
Super Low Viscosity PUR Injection Resin

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

SealBoss ® FLEXGEL

Leak Sealing Injection Gel
Hydrophilic Injection Foam Gel
Hydrophilic Gel

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

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Acrylic Gel

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

Restoration - Waterproofing

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Sealing Tie Holes

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

Introduction

Tie holes, also known as tie-rod holes, are small openings left in concrete structures after removing tie rods used in formwork. These holes can leak under hydrostatic pressure. An effective solution is polyurethane polymer foam injection.

In this article, we explore how a contractor effectively sealed tie holes and shrinkage cracks in water tanks for a rural water district. Utilizing the SealBoss Injection System, the team successfully resolved these challenges. This case study underscores the critical role of proper training and specialized equipment in preserving the integrity of concrete structures.

What are Tie Holes?

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

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

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

Sealing Tie Holes and Cracks

A Case Study in Effective Water Tank Repair

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

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

Encountering the Challenge

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

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

The Training and Repair Process

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

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

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

Preparation and Injection

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

Hands-On Learning and Independent Operation

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

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

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

Ensuring Long-Term Success

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

Conclusion

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

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

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

Related Articles

Sealing Tie Holes - Water Stop System

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

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Epoxy versus Polyurethane Crack Injection

Epoxy vs Polyurethane Injection

Crack Injection Superheroes

Epoxy Resins versus Polyurethane Resins
A Concrete Crack Injection Comparison

Epoxy versus Polyurethane Crack Injection

Epoxy and Polyurethane Resin Based Crack Repair Systems are the Superheroes of Concrete Crack Repair

When you need to repair a crack in a concrete structure — such as a foundation or wall — from the inside (negative side) of the structure, there are typically two injection techniques and corresponding product technologies that you need to consider — epoxy resin injection and polyurethane chemical grout injection.

Epoxy Versus Polyurethane Injection – How to Differentiate the two Injection Methods and Techniques

Epoxy injection is typically performed on dry substrates versus polyurethane injection that works very well on wet and actively leaking substrates.

Fully cured high quality epoxy offers outstanding compressive and tensile strength properties, making epoxy injection the preferred method where structural crack repair is desired.

Polyurethane injection is performed to seal active leaks, prevent moisture migration and to protect structures from corrosion and water related decay. Polyurethanes are designed to interact and expand in contact with moisture, making polyurethane injection technology superior in wet and actively leaking environments.

There is an injection solution to most concrete crack related problems. But, there is no one-size-fits-all solution.

Let us compare some of the main characteristics of each type of crack injection, outlining their strengths and their recommended range of applications.

Injection Repair Conditions and Objectives

Does your crack impact the structure?
Do you need to restore structural strength to the structure?
Does the crack carry water?
Is the crack actively leaking?
Do you need to protect the structure from water ingress and water damages?

Comparison of the Characteristics of Epoxy and Polyurethane Polymers and Elastomers

Epoxies and polyurethane polymers are chemical resins with different reaction profiles and physical properties.

Epoxy is a strong adhesive or glue that does essentially not expand. While curing epoxy creates a strong bond with the concrete substrate and ultimately provides a repair of high compressive and tensile strength properties.

Epoxy is a two component system, one component is the epoxy resin and the second is the hardener. The components are blended in the static mixer of the injection pump applicator immediately before crack injection. Injection epoxies cure chemically within a specified time and harden further over days and weeks.

Polyurethane injection foam is primarily a water activated sealant or leak-seal grout with expanding properties during reaction. The cured product creates a compression seal of varying flexibility.

Polyurethane foam resin often utilizes an activator or accelerator. Resin and activator are mixed before they are injected. Polyurethane resins are also available in two component chemical cure variants. No moisture needed.

Polyurethanes are extremely versatile. Their chemical and physical properties vary to suit the needs of specific applications and jobsite conditions.

Polyurethane resins vary from rigid and strong to flexible, rubbery and soft elastomer compositions. The initial cure time for crack injection polyurethanes is generally 1 – 10 minutes and is influenced by accelerator usage, temperature and moisture availability.

Differences in The Epoxy and Polyurethane Crack Injection Processes

Epoxy crack injections are typically performed at lower injection pressures (20-200 psi) and with surface mounted ports.

Polyurethane crack injection is often performed at higher pressures to move the expanding foam through the cracks with special injection pumps and packers installed into drilled holes. The injected polyurethane is supposed to fill the crack through the entire thickness of the structure thereby preventing water from entering the crack.

Epoxy Crack Injection

Structural Repair – The tensile strength and compression strength of cured epoxy is typically much greater than the strength of concrete making epoxy a good choice for foundation wall structural crack repair. When tension is applied to a crack due to thermal cycling or other forces, the cured epoxy crack repair will not typically yield. Epoxy is typically rigid and not flexible.
Extended curing time allows the epoxy to penetrate the crack and fine fissures. SealBoss epoxies can be obtained in various viscosities to suit fine to wide cracks.
Dry Substrate Recommended – Epoxy typically has reduced adhesion to wet and saturated surfaces. A dry environment is desired for best results. Actively Leaking Cracks – Epoxy cannot be used for actively leaking cracks. Epoxy resin needs to be contained in a crack until cured sufficiently to achieve full strength.
Epoxy injection is performed through surface mounted ports. Moisture adversely affects the adhesive qualities of the anchoring epoxy used to glue the injection ports onto the crack. Without sufficient bond strength, the anchoring epoxy will not withstand the pressure of the injection.
SealBoss provides mechanical packers and special plastic packers to permit epoxy injection in adverse environments.

Polyurethane Crack Injection

Wet and Dry Applications – Polyurethane injection foams and resins can be used in adverse environments regardless of the condition of the crack and the weather. The crack can be fine or wide, actively leaking, full of mud and/or mineral deposits. (Whenever possible it is advised to flush and clean out a crack prior to injection)
Water Stop and Structure Preservation – The rapid curing of polyurethane is beneficial when stopping a gushing leak. The chemical expansion of the polyurethane foam (typically 2-40 times its original volume) makes polyurethane very effective at filling voids within the concrete. Polyurethane resins and foams play an important role in preserving concrete and rebar.
Not a Structural Repair – Polyurethanes do not provide structural repairs in concrete cracks.
High injection pressures are often required to move PU foam into fine cracks and fissures.
Mechanical packers require drill holes. No matter if the crack is actively leaking, under water or the concrete is deteriorated, mechanical packers are designed to work in adverse environments.

Product Characteristics

EPOXY (EP)

Rigid, very strong adhesive for structural repairs
Mainly for dry or damp environments, potentially reduced adhesion on wet substrates
Excellent to regain structural strength in torn structures: earthquake damage, extended stress damage, shrinkage cracks, corrosion
Not a water-stop material and does not tolerate extended movement – cracks can form next to repair
Two component formulation – Quick reaction time and cure
Viscosities from very low liquid to paste
Very resistant, long term solution
Available in bulk and cartridges
Recommended Products:
Resins: 4040, 4050
Paste/Putty: 4500 Epoxy Quick Seal
Cartridge System: 4000 Epoxy Cartridge System
SealBoss Surface Mounted Ports / Injection Packers

POLYURETHANE (PU)

Flexible to semi-flexible sealants with less structural strength compared to EP
Typically Hydro-Active – reacts with water forming foams (water-stop & leak-seal), gels and solid (non cellular) flexible or semi flexible sealants
Two Component PU Resins can be dry reactive. No water needed
Classified as hydrophobic (foams/resins) for crack injection, joints voids or hydrophilic (foams/gels) for curtain, bladder injection behind structures. Both groups are water activated for use in wet environments
Superior water-stop capabilities
Single or two component, accelerators common. Viscosities low to medium. Very resistant, long term solution
Recommended Products:
Foams: 1510, 1570, 1570 LV
Flexible resin: 1403, 1503 LV-Resin Line
Gel/Foam: Flexgel2
Cartridge System Available

Epoxy versus Polyurethane – Conclusion

In non structural water related repairs PU is generally the material of choice. This is true for most below grade repairs including basements, tunnels, parking garages and manholes. PU is a good void filler and is also used to stabilize dirt and lift structures.

EP is an excellent adhesive for structural repairs of stressed concrete substrates and deteriorated concrete structures.

TIP

When initiating concrete crack injection, it’s advisable to commence with an exploratory grouting or mock-up injection stage. This entails identifying a deep, distinctly defined, and potentially actively leaking crack for the initial injection. This preliminary step facilitates the estimation of required material quantity and necessary injection pressures.

The consumption of material should be closely monitored and measured, and the injection pressures should be accurately assessed.

This process helps us understand the conditions of the project and plan the remaining injection process effectively.

Accessories

EPOXY (EP)

Surface port injection at lower injection pressures 30 – 100 psi — Reason: Injection is typically done in dry environments and surface ports can be attached easily with epoxy adhesive.
Holes do not have to be drilled – there are exceptions
The crack surface between the ports has to be surface sealed to prevent leakage during injection
The viscosity of the epoxy resin stays low during the injection process, resulting in lower injection pressures
Recommended Products:
Surface ports, specialty ports

POLYURETHANE (PU)

Mechanical packer injection at higher pressures 50 – 3000 psi — Reason: PU injection is often performed in a wet environment where adhesives for surface ports cannot be used.
Mechanical packers are installed by drilling a hole into the structure which the packer fits snugly. The packer is tightened mechanically for high pressure injection
PU Foam immediately reacts with moisture in the crack increasing resistance of product flow, resulting in higher injection pressures
Recommended Products:
Complete line of packers: S-Type, R-Type, custom sizes, Hammer-in packers, specialty packers

Conclusion:

PU generally needs higher pressures and therefor the more sophisticated connectors / packers. There are many exceptions. For example curtain injection with PU gel into the space between structure and soil needs lower injection pressures but higher rates of material flow. The filling of larger voids and joint injection also uses lower pressures. PU injection through surface ports is not common, but high pressure epoxy injection through packers is seen more frequently. Reasons could be very thick concrete to be penetrated or damp / wet surface conditions.

Pumps

EPOXY (EP)

Two component equipment for most epoxy resins for ease of use and precise mixing
Epoxy is a very strong adhesive and may render equipment unusable if not cleaned thoroughly
EP is not very moisture sensitive and not moisture reactive. Epoxy does not expand during reaction – which results in lower injection pressures
Pneumatic or manual guns for cartridge systems / smaller jobs
Two component injection pumps achieve high injection pressures for large volume commercial injection projects. Pumps are pneumatic or electric
SealBoss Corp. supplies EP resins and paste also in cartridges
Recommended Products:
Hand held guns, electric pump P3003, pneumatic pump PA3000, 4000 Cartridge System

POLYURETHANE (PU)

Single component equipment for most water activated hydrophobic PU foams, accelerator to be added prior to pumping
Either single or two component equipment for true two component PU resins such as 1400 LV-Resin Line
Either single component or multi-ratio two component equipment for hydrophilic PU Gels based on the application and product.
Single component pumps include inexpensive hand held devices, hand pumps and electric pumps
Multi ratio devices can be manual, electric and pneumatic. SealBoss Corp. supplies PU in bulk and in containers as small as 1 gal units and in cartridges
Recommended Products:
Hand held guns, manual pumps, electric pumps, Signature Line Pumps

Choose Your Pump:

No matter if you are faced with a minor basement leak or a major tunnel gusher of large hydrostatic pressure , we have you covered. You need to have the right tools at hand to achieve the results. SealBoss infrastructure repair pumps provide you with tried and true concrete solutions.

Final Thoughts:

Over the years, injection technology has evolved, becoming both sophisticated and intricate. At SealBoss, we pride ourselves on offering a diverse range of products, pumps, and accessories tailored to meet the ever-growing needs of injection applications.

Our commitment extends beyond just providing products; we offer comprehensive technical support to ensure you find the perfect product-equipment synergy for your project’s success. We invite you to leverage our expertise and training resources. Remember, we are only a phone call away, eager to assist and guide you.

SealBoss ® EPOXY

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SealBoss ® POLYURETHANE

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Concrete Crack Repair

Using Polymer Grout Injection

Introduction:

Concrete structures are widely favored in construction for their durability and strength, but even the most resilient concrete can develop cracks over time. Addressing these cracks promptly is essential to maintain the structural integrity and aesthetics of the building. One of the most effective methods for concrete crack repair is polymer grout injection, which includes the use of polyurethane resins and foams, acrylates, and epoxy resins. This article delves into the specifics of these polymer-based injection techniques, their applications, and the step-by-step processes involved.

Concrete Crack Repair with Injection Grouting

Injection grouting is a versatile and widely used method for concrete crack repair. It involves injecting a liquid grout into the cracks of a concrete structure under pressure.

The grout then hardens, filling the cracks and while either sealing the cracks with a flexible sealant or by regaining the structural integrity of the concrete with a high strength bonding agent.

For this discussion, we will focus on polymer grouts, specifically polyurethane resins and foams, acrylates, and epoxy resins.

Polyurethane Resin and Foam Injection

Polyurethane resins and foams are highly effective for waterproofing and sealing cracks in concrete structures. They are known for their flexibility, which allows them to accommodate slight movements in the concrete without cracking. Polyurethane injections are particularly useful for concrete crack repair in foundations, basements, and retaining walls where water ingress is a concern.

Polyurethane resins are ideal for waterproofing as they form a watertight seal, preventing water ingress in basements and other below-grade structures. These resins also add structural integrity to the concrete by filling the cracks and preventing further deterioration.

The injection process begins with drilling holes along the length of the crack at regular intervals. The spacing of the holes depends on the size and extent of the crack. The cracks and drilled holes are then thoroughly cleaned to remove any dust, debris, or contaminants, ensuring proper adhesion of the polyurethane resin.

Injection ports, also known as packers, are installed into the drilled holes to prevent leakage during the injection process. The polyurethane resin is injected starting from the lowest point if the crack is vertical or from one end if it is horizontal, continuing until the resin appears at the next port or from the surface.

After the resin has cured, the injection ports are removed and the surface is cleaned. If necessary, the area is ground or sanded to match the surrounding concrete.

Acrylate Injection

Acrylates are another type of polymer grout used for concrete crack repair and curtain injection. They are known for their super low viscosity and rapid setting times, making them suitable for fine cracks and quick repairs.

Due to their low viscosity, acrylates can migrate through very fine cracks that other grouts cannot, making them ideal for situations where other resins cannot penetrate.

The injection process for acrylates begins with drilling holes along the crack at intervals suitable for the size of the crack. The cracks and holes are then thoroughly cleaned to remove any contaminants.

Injection ports are installed into the drilled holes and securely placed to prevent leakage. The acrylate is injected starting from the lowest point or one end of the crack, continuing until the acrylate appears at the next port or the surface. Once the acrylate has cured, the injection ports are removed and the surface is cleaned.

Epoxy Injection

Epoxy injection is a highly effective method for structural concrete crack repair due to its high strength and outstanding bonding properties.

Epoxy resins can restore the original strength of the concrete and are suitable for both fine and wide cracks.

Epoxy resins provide high tensile and compressive strength, making them ideal for restoring the structural integrity of cracked concrete. Available in varying viscosities, epoxy can be used to repair both fine and wider cracks.

The injection process for epoxy begins with placing surface ports over the crack and affixing them using a fast setting epoxy paste. The crack between the packers is sealed using the same fast cure epoxy paste to prevent epoxy leakage.

The epoxy resin is injected starting from the bottom of the crack and working up, continuing until the epoxy appears at the next surface port. After the epoxy has cured, the injection ports are removed. If necessary, the area is ground or sanded to match the surrounding concrete.

Concrete Crack Repair Conclusion

Polymer grout injection, including the use of polyurethane resins and foams, acrylates, and epoxy resins, is a highly effective method for concrete crack repair.

Each type of grout has unique properties that make it suitable for specific applications, from waterproofing to structural repairs. By following the proper procedures and using the right materials, you can preserve and restore the structural integrity and appearance of your concrete.

For any technical support or advice on your concrete crack repair projects, don’t hesitate to contact experts in the field. SealBoss offers comprehensive solutions and assistance to ensure your concrete crack repairs are successful and long-lasting.

SealBoss Concrete Crack Repair

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How to Fix Foundation Cracks

"Concrete Cracks have Met Their Match..."
- Popular Mechanics -

How to Fix Foundation Cracks

Popular Mechanics – Pop Mech Pro, Publishes Article with Detailed Pictures about “How to Fix Foundation Cracks”, using the SealBoss Crack Repair Method with Specialized Leak-Sealant and Injection Packers:

Concrete cracks have been an issue since the beginning of concrete construction three millennia ago. The article explains that modern concrete lacks self-healing properties, which causes cracks to worsen over time and impacts both homeowners and engineers.

Popular Mechanics’ century-old building in Easton, Pennsylvania, suffered from cracked concrete until local contractor repaired it. They used a specialized leak-sealant from SealBoss and ordinary tools to fill and seal the cracks, preventing further water entry and degradation.

The article discusses the SealBoss 1510 Water Stop Foam solution for fixing concrete cracks, a common issue affecting many structures from homes to bridges.

The article highlights how modern concrete deteriorates over time due to water seepage through cracks.

“After the water-stopping material has hardened into a plastic foam, the contractors removed it from the wall and floor with putty knives and scrapers. They removed the packer with a socket and socket wrench, then filled the remaining hole with mortar. With that, the job is complete.”

— Popular Mechanics, Roy Berendsohn

The solution presented in this article and involves a straightforward repair method demonstrated by the contractor, using ordinary tools and SealBoss 1510 specialized leak-sealant from SealBoss. The process includes drilling holes along the crack, inserting injection ports, and injecting an expanding liquid polyurethane resin mixed with an accelerator to seal the crack effectively.

This method has proven successful in preventing further leaks through the foundation of the century-old building occupied by Popular Mechanics in Easton, Pennsylvania, showcasing its effectiveness in concrete crack repair.

“We were amazed at the simplicity of the process and the good results it produced–we haven’t seen any further leaks through the foundation since the two men completed their work.”
— Popular Mechanics, Roy Berendsohn

References

Link to the article — “How to Fix Foundation Cracks”
Popular Mechanics, Pop Mech Pro, 1/24/2024, by Roy Berendsohn

SealBoss Crack Repair Kits

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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.

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Structural Parking Garage Repairs with High Strength Epoxy Resins

Structural Epoxy Injection System

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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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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

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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 durable construction material, but like all materials, it has its weaknesses. One such weaknesses is the formation of cold joints. Understanding what cold joints are and how to address them is crucial for anyone involved in the construction or repair of concrete structures.

What are Cold Joints?

A cold joint forms when newly mixed concrete is laid adjacent to or over concrete that’s already started to harden. This situation can manifest due to several factors, including disruptions during pouring or delays in the mixing and transportation of the concrete. This leads to the formation of a distinct boundary, a zone lacking cohesion, where the previously set and fresh concrete converge. Such a boundary weakens the overall structural strength of the concrete, rendering it susceptible to water infiltration and potential leakage. Over time, the presence of cold joints can reduce the overall lifespan of the concrete structure.

The Polyurethane Polymer Foam Injection Solution – Injecting cold joints with polyurethane polymers has emerged as an effective solution to address the issues of water migration and leakage.

Injection Process

Using specialized equipment, the polyurethane polymer is injected into the cold joint. The polymer fills the voids and gaps, creating a permanent seal. The polymer acts as a barrier, preventing water from seeping through the cold joint. The injected polymer reinforces the cold joint, reducing the risk of corrosion, cracks or breaks. With the cold joint addressed, the overall lifespan of the concrete structure can be significantly extended.

Addressing Cold Joints with the SealBoss Injection System – Comprehensive Solution to Moisture and Active Leaks

Cold Joints are common locations where moisture and active leaks are frequently observed. Whether stemming from a flawed waterproofing system or its total absence, we offer a comprehensive solution to address the leak and stop any water intrusion.

Our SealBoss Regional Sales Manager was on-site in Kansas City to train and assist with the injection of below grade cold joints that had begun to actively leak due to failures in the pre-existing waterproofing system.

Both vertical and horizontal cold joints were injected with various levels of leak activity. The contractor drilled the injection holes and installed 1/2″ SealBoss mechanical packers for a tight fit. Based on the conditions the 45 angle drill degree method was used as well a direct into the joint placement was chosen.

The applicator then injected SealBoss 1510 using the P2002 high-pressure single component injection pump. Due to the relatively low temperatures of the substrate the product was catalyzed with approximately 15% of SealBoss 15X highfoamer accelerator. All active leaks were successfully stopped and the Cold Joints sealed.

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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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Leaking Crack Repair

Coached by a Top Industry Professional

In the world of construction and maintenance, “leaking crack repair” is a term that frequently emerges, particularly when addressing structures that contain water or are vulnerable to moisture and water intrusion. Addressing these cracks swiftly and efficiently is vital for the structure’s safety and durability.

Sealing the Future – Preserving the Past
Since 1988

Leaking Crack Repair

Sealing the Future – Preserving the Past
Since 1988

The Need for Crack Injection Training

A prominent general contractor, who usually subcontracts such tasks, expressed the need for immediate crack injection training on a specific jobsite. Their primary aim was to acquire the expertise for smaller projects, allowing them to handle leaking crack repair internally on certain timely projects. This proactive approach not only saves time but also ensures that minor issues can be addressed before they escalate.

A Case Study: Water Treatment Tank Crack Sealed

Scope: New Concrete Tank – Water Test Failure – Asses and Seal

The facilities in question comprised three holding cells, separated by two poured-in-place division walls. During a leak test on the outer two tanks, visible cracks were detected. These cracks, deemed non-structural for repair purposes, showed signs of dampness and minor leaks, emphasizing the need for immediate leaking crack repair. Pressure crack injection with a hydrophobic polyurethane expanding water stop foam utilizing an electric injection pump and mechanical injection packers was specified as the method of restoration.

The Repair Process

Materials Used: SealBoss 1570, SealBoss 15x
Additional Tools: SealBoss 13-60S packers, SealBoss 495 Injection Pump, Hammer Drill w/ 12” x ½” bit, PPE

For training purposes, a weeping crack was chosen for repair. This crack, though narrow, spanned about 10 feet in height and meandered across the wall. Given that the newly constructed wall was 14 inches thick, the repair strategy involved guiding the team to drill 5 to 7 inches out from the crack. The drilling was done at a 45-degree angle, aiming back towards the crack, employing the crack stitch method.

Depth of Intersection: The further the drill hole is from the crack, the deeper it will intersect the crack within the structure. This results in a more profound point of injection.

Considerations for Thicker Structures: A deeper injection point is often preferred in thicker structures. However, the length and reach of the drill bit play a crucial role in determining the optimal distance for the drill hole.

Avoiding Dead-End Drill Holes: A drill hole that misses the crack won’t 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.

In summary, while determining the spacing of drill holes, it is vital to balance the desired depth of injection with the capabilities of your drilling equipment to ensure effective grout injection.

To ensure precision, the placement was set parallel to the fissure. A 0.5-inch masonry bit, attached to a hammer drill, was used for the drilling process. Once the clean, crack-intersecting holes were established, SealBoss 13-60S heavy duty steel injection packers were installed.

The repair commenced from the bottom, progressing upwards. The SealBoss 495 injection pump, paired with the SealBoss 1570 NSF/ANSI/CAN 61 drinking water contact certified chemical grout, was used for the leaking crack repair. As the repair proceeded, water and material were observed exiting the substrate. This was a positive sign, indicating effective penetration and successful stopping of the water penetration and sealing of the crack.

Final Thoughts

Leaking crack repair is an essential aspect of maintaining the structural integrity of buildings and facilities. With the right knowledge, tools, and materials, such as those provided by SealBoss Corp., even the most challenging cracks can be effectively addressed. Whether you’re a contractor looking to expand your skill set or a facility manager aiming to maintain your structures, understanding the nuances of leaking crack repair is invaluable. Our SealBoss Water Stop Specialists are always ready to assist you.

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Retaining Wall Repair

Injection Methods Compared

Understanding Retaining Wall Repair:

Polyurethane vs. Epoxy Injection Methods

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

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

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

Retaining Wall Repair
with Leak Sealing Polyurethane Water Stop Foam Injection

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

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

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

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

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

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

Summary

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

Retaining Wall Repair
with Epoxy Resin Injection For Structural Strength

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

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

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

Summary

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

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

Conclusion

Retaining Wall Repair – Polyurethane or Epoxy Injection

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

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

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

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

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Retaining Wall Crack Injection Repair

Using Leak Sealing Foam

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

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

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

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

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

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

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

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

Retaining Wall Crack Injection Repair Guide

Retaining Wall Crack Injection Repair with SealBoss 1510 Leak Sealing Foam

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

Choosing the Right Repair Product

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

Insightful Inspection

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

Strategic Packer Placement

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

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

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

Product Conditioning

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

Injection Process

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

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

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

SealBoss Leak Sealing Foam Injection using angled injection packers

Conclusion

Retaining Wall Crack Injection Repair

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

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

Retaining Wall Repair Method Comparison