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SealBoss Injection Job Checklist

Concrete Injection Job Checklist

Confirm the material, pump, packers, site conditions, documentation, cleanup plan, and field records before injection begins.

This planning checklist connects products, equipment, and method without treating epoxy, polyurethane, and acrylate injection as one universal procedure.

Use This as a Readiness Checklist

Use this page to plan mobilization, confirm field readiness, organize quality-control observations, and document the work. It does not replace the current product data sheet, SDS, application guideline, equipment manual, project specification, or direction from a qualified technical representative or design professional.

Quick Guide: Crack Injection Procedure

Crack injection requires careful preparation, the correct material and equipment, and close observation throughout the work. Use this guide as a general sequence alongside the job checklist. The exact procedure depends on the injection material, crack condition, structure, equipment, and approved application method.

1. Prepare Equipment and Protective Gear

Gather the required injection material, pump, hoses, applicator, packers or ports, couplers, tools, cleaning materials, and spare components. Confirm personal protective equipment and jobsite safety requirements from the current SDS, project safety documents, and site rules.

2. Inspect and Document the Injection Area

Examine the crack, joint, or leak area before work begins. Record visible conditions, moisture or active water, access limitations, possible material exits, and adjacent areas that may require protection.

3. Prepare the Crack and Surrounding Surface

Remove loose material, dust, debris, coatings, or contaminants as required by the approved procedure. Preparation methods vary by injection system and substrate condition.

4. Install Packers or Ports

Select and install the specified mechanical packers or surface-mounted ports. Packer type, drilling angle, depth, and spacing must follow the approved application method and actual project conditions.

5. Prepare the Injection Material

Confirm the exact product and component system. Follow the current product data sheet and application instructions for conditioning, mixing, proportioning, accelerator use, and equipment setup. Do not substitute components or alter ratios without technical authorization.

6. Apply a Surface Seal When Required

Some injection methods—particularly certain epoxy procedures—may require the exposed crack surface to be sealed between ports. Use the specified material and allow it to develop the required condition before injection.

7. Begin the Injection

Start at the location identified in the approved injection sequence. Connect the pump to the first packer or port and proceed according to the product, equipment, and application instructions. The correct sequence may vary with crack orientation, water condition, structure, and injection objective.

8. Monitor the Procedure

Observe material flow, pressure response, packer or port stability, returns at adjacent locations, and any unintended leakage or discharge. Stop and request technical review when conditions differ materially from the approved plan.

9. Allow the Material to React or Cure

Follow the current product documentation for reaction, cure, hold, or waiting requirements. These periods vary significantly among epoxy, polyurethane, and acrylate systems.

10. Remove or Finish Packers and Ports

Remove, cut back, or leave packers and ports in place as directed by the approved procedure. Patch or finish the injection locations according to the project requirements.

11. Clean Equipment and Manage Waste

Thorough equipment cleaning is essential. Follow the current SealBoss cleaning instructions for the specific material and equipment system, and handle or dispose of all waste and cleaning materials in accordance with the SDS, site requirements, and applicable regulations.

12. Complete the Final Inspection

Document the completed work, material use, injection observations, and any remaining conditions. Acceptance should be based on the project specification and the criteria established by the responsible contractor, technical representative, or design professional.

Important: This quick guide is a general planning reference. Always follow the current SealBoss product data sheet, SDS, application guideline, equipment manual, and project-specific requirements for the exact material and system being used.

Stop before starting: Product and method selection must be based on the repair objective and actual project conditions.

Material

Confirm the exact product variation, components, condition, current documents, and approved cleaning materials.

Equipment

Match the pump, hose, applicator, packers or ports, couplers, spares, and power requirements to the system.

Method

Use the approved preparation, installation, monitoring, shutdown, and field-record procedure for the application.

Project Information

Complete these fields before mobilization or at the pre-job meeting.

Project and location: ______________________________
Date and shift: ____________________________________
Contractor and crew lead: ___________________________
Repair objective: __________________________________
Injection product and variation: ____________________
Pump and applicator: _______________________________
Packer or port system: _____________________________
Project specification or method statement: __________
Technical contact: _________________________________

1. Confirm the Repair Objective

The repair objective has been clearly documented.
The condition has been identified as dry, damp, wet, or actively leaking.
The substrate type, thickness, accessibility, and visible condition have been reviewed.
Crack movement or structural requirements have been referred to the appropriate design professional where applicable.

Access to one or both sides of the structure has been confirmed.
Likely material travel paths, exits, drains, voids, and occupied spaces have been considered.
Project acceptance criteria have been established by the responsible party.
The selected injection material category is appropriate for the stated objective, subject to technical confirmation.

2. Documents to Have at the Jobsite

Current product data sheet for the exact product variation.
Current SDS for every product, component, cleaner, and flush material.
Current SealBoss application guideline.
Current pump and equipment manual.
Packer, port, coupler, and accessory information.

Project drawings, specifications, and approved method statement.
Job hazard analysis or site safety documentation.
Technical clarification and approval records.
Batch, lot, material-use, daily injection, and photo records.
Emergency and technical-support contact information.

3. Materials and Components

Exact product name and variation confirmed.
Required components, accelerators, hardeners, or additives confirmed.
Material quantity estimated from the project plan, with appropriate contingency.
Lot numbers, shelf-life information, storage, and site-conditioning requirements checked.

Containers and components clearly labeled.
Measuring and mixing equipment available where required.
Dedicated tools and containers assigned to prevent cross-contamination.
Patch, surface-seal, finishing, and containment materials available when required by the approved method.

4. Pump, Hose, and Applicator Readiness

Pump type and configuration are compatible with the selected injection system.
Required component ratio and wetted-part compatibility have been confirmed.
Pump is clean, operational, and ready for the selected material.
Hoses, fittings, valves, gauges, seals, couplers, and applicator have been inspected.

Required power, compressed air, extension cords, or other utilities are available.
Spare seals, hoses, fittings, couplers, valves, and wear components are available.
Static mixers, nozzles, or mixing heads are available where required.
The approved priming, testing, startup, flushing, and cleaning procedures have been reviewed.

5. Packers, Ports, and Drilling Equipment

Packer or port type, diameter, length, valve position, and coupler configuration confirmed.
Sufficient quantity plus replacements available.
Drill, suitable drill bits, spares, and depth control available where required.
Hole-cleaning, vacuum, or dust-control equipment available as required.

Wrenches, sockets, drivers, setting tools, and marking tools available.
Surface ports and surface-seal materials available when required.
Port-removal and patching materials available.
Packer or port layout has been marked according to the approved method.

6. Jobsite and Safety Readiness

Crew has reviewed the current SDS, product labels, job hazard analysis, and site requirements.
PPE, ventilation, hygiene, first-aid, and emergency provisions have been confirmed from current safety documents.
Drilling, electrical, pressure, access, dust, and fall hazards have been assessed.
Rebar, utilities, post-tensioning, and embedded items have been addressed as required by the project.

Work-zone barriers and access controls are in place.
Occupied spaces, adjacent property, drains, openings, equipment, and finishes are protected where necessary.
Spill-control, containment, suitable waste containers, and sufficient lighting are available.
Communication between the pump operator and injection personnel has been established.

7. Crack and Injection-Area Assessment

Crack or repair area has been photographed before work.
Location, orientation, visible width, extent, and water condition have been recorded.
Access limitations and visibly unsound, contaminated, loose, or spalled material have been identified.
Visible exits and possible material-loss locations have been identified.

Adjacent joints, penetrations, drains, cavities, and voids have been reviewed.
Areas requiring engineering or technical review have been marked.
The proposed injection sequence and first test location have been established from the approved method.
Required field observations and acceptance criteria have been discussed with the responsible party.

8. Final Pre-Injection Check

Repair limits and injection sequence confirmed.
Drill holes or surface-port locations prepared and cleaned according to the approved method.
Packers or ports installed and secure; surface seal ready where required.
Pump, hose, applicator, and couplers assembled and setup verified against the current manual.

Correct material components staged and mixing or proportioning instructions reviewed.
Required field test or reaction check completed when specified.
Containment, monitoring areas, cleanup materials, and waste containers are ready.
Field record form started, crew responsibilities confirmed, and stop-work conditions reviewed.

9. Injection Quality-Control Record

Record packer or port condition and corrective action.
Monitor pump operation, material flow, adjacent surfaces, openings, and the opposite side where accessible.
Keep communication open between the injector and pump operator.
Stop work when conditions differ materially from the approved plan.

10. Shutdown, Cleanup, and Closeout

Required cure or hold period confirmed from current documents.
Packers or ports removed or left in place according to the approved method.
Holes, surface seals, and injection locations finished as specified.
Pump, hoses, applicators, mixers, valves, and couplers cleaned using the approved chemistry-specific procedure.

Unused mixed material, cleaners, flush material, rinse water, and waste handled according to the SDS and site requirements.
Equipment inspected after cleaning; damaged or worn parts tagged for service or replacement.
Remaining materials stored according to current product documentation.
Final photographs, treated-area map, lot numbers, quantities, daily report, and closeout records completed.

Stop Work and Request Review When

A packer or port moves, loosens, or becomes unstable.
Pressure or flow changes unexpectedly.
Material discharges into an unintended area.
The substrate shows damage or distress.
The pump, hose, applicator, or proportioning system malfunctions.
Material behavior differs from the current technical documentation.
The crew cannot confirm the correct component, ratio, cleaner, or equipment setup.
An unsafe or uncontrolled condition develops.

Product-System Verification

Use these prompts to verify readiness. They are not universal application instructions.

Polyurethane Leak-Seal Injection

Exact polyurethane product and variation confirmed.
Water condition and intended reaction identified.
Accelerator or component instructions confirmed where applicable.
Pump condition and compatibility confirmed.
Required testing, flushing, containment, and cleanup materials available.

Epoxy Crack Injection

Repair objective and structural responsibility confirmed.
Crack moisture and standing-water limitations checked.
Surface-port or mechanical-packer method confirmed.
Surface-seal readiness, mixing ratio, dispensing configuration, and static mixers confirmed.
Cleanup can begin within the period required by current documents.

Acrylate or Gel Injection

Exact component system confirmed.
Pump ratio and wetted-part compatibility confirmed.
Component containers and tools clearly separated.
Required field reaction or gel-time check and site-condition records confirmed.
Dedicated flushing, cleanup, and unintended-travel controls confirmed.

Build the Complete Injection System

A prepared injection crew needs more than the resin.

Products

Equipment

Field Support

Review Current Technical Resources Before Mobilizing

Review the current documents for the exact product and equipment system. Contact a SealBoss technical representative for application-related product, pump, packer, and system information.

Products, Equipment, and Training

Water Infiltration Costs & Injection Grouting | SealBoss

Product packaging & labeling shown are illustrative and may vary.

Water Infiltration Costs & Injection Grouting | SealBoss

Water infiltration costs rise quickly when active leaks are not sealed at the source

Small leaks rarely stay small. Once water finds a path through concrete, every storm, pressure cycle, and wet-dry event can add cost — cleanup, downtime, damage, liability, and eventually structural repair.

Water infiltration is not just a stain on a wall or a puddle on a floor. It is evidence of an open pathway through the structure.

For facility managers, property owners, engineers, and repair contractors, the priority is simple: identify the water path and stop it before the damage spreads. Surface patches may hide the symptom, but professional leak-seal injection grouting is designed to seal the route water is actually using.

SealBoss leak-seal systems are built for that purpose: water stop foams, flexible polyurethane resins, hydrophilic gels, acrylate gels, pumps, packers, ports, oakum systems, pipe kits, and technical support — all focused on stopping active water intrusion at the source.

What Water Infiltration Can Cost

Water Infiltration Costs: What Building Owners May Pay

The cost of water infiltration is not measured only by the crack. It is measured by how far the water has traveled and what it has reached.

Condition / Scope	Typical Cost Range	What It Usually Includes
Single active crack or joint	$300–$1,800 per crack	Interior polyurethane injection of one leaking wall crack, cold joint, or construction joint without excavation
Multiple cracks or larger leak area	$2,000–$7,000 per project	Several injected cracks, a leaking wall section, floor-to-wall joint, slab area, pit, vault, or below-grade structure
Water-damage cleanup after spreading	$4.00–$8.00 per sq ft	Drying, demolition, cleanup, flooring replacement, finish repair, contents handling, and restoration work
Severe long-term infiltration	$20,000+	Corrosion-related damage, concrete spalling, reinforcing steel exposure, structural repair, or partial removal and replacement
Major structural removal and replacement	$100–$300 per sq ft	Extensive demolition, concrete replacement, reinforcement repair, and reconstruction where deterioration has advanced

Cost note: These are general industry-average ranges compiled from published concrete-repair, crack-injection, and commercial water-damage restoration cost guides. Actual costs vary by site conditions, access, water pressure, region, severity, and project requirements.

The lesson is straightforward: the cheapest leak is usually the one repaired before water reaches finishes, flooring, equipment, tenants, inventory, or reinforcing steel.

The Real Problem Is the Water Path

Concrete is strong, but it is not automatically watertight.

Water can enter through shrinkage cracks, cold joints, construction joints, pipe penetrations, honeycombed concrete, slab joints, wall cracks, tie holes, and voids. Below-grade structures are especially vulnerable because hydrostatic pressure can push water through even small openings.

Once water has a connected pathway, it will continue to use it.

That is why the visible leak can be misleading. The water may appear at one location, but the entry point or travel path may be inside the wall, beneath the slab, around a penetration, or along a joint.

A lasting repair must address the path, not just the wet surface.

Why Surface Patches Often Fail

Many leak repairs fail because they are applied to the side where the water appears, not the side where the pressure originates.

In below-grade structures, water pressure usually comes from the positive side — the soil side, exterior side, or water-bearing side of the structure. The repair crew often works from the negative side — the interior face of the wall, slab, pit, tunnel, or vault.

That creates the classic patch-and-repeat problem:

The stain is painted.
The joint is patched.
The surface is coated.
The area looks dry for a while.
Water pressure returns.
The leak reappears through the same path or nearby.

A surface repair may improve appearance, but it does not necessarily fill the crack, joint, void, or penetration through the structure. If the water path remains open, the cost cycle continues.

SealBoss Injection Grouting: Stop the Leak Where It Lives

SealBoss leak-seal injection grouting places the repair material directly into the pathway used by the water.

Depending on the condition, trained contractors can inject water-reactive polyurethane foam, flexible resin, hydrophilic gel, acrylate gel, or related leak-seal materials into cracks, joints, voids, and penetrations.

The purpose is not to cover the leak.

The purpose is to fill and seal the route water has created.

That is the difference between cosmetic waterproofing and active leak sealing.

Matching the SealBoss System to the Jobsite Condition

Different leaks require different materials. A high-volume gusher is not the same as a hairline weep. A moving joint is not the same as a static crack. A pipe penetration is not the same as a curtain-grouting condition.

Field Condition	SealBoss System Direction	Product-Line Connection
Active water through cracks or joints	Hydroactive polyurethane water stop foam injection	SB 1510 Water Stop Foam, SB 1500 Leak Seal Foam
High-flow or gushing leaks	Fast-reacting foam with accelerator control	SB 1510 with SB 15X Accelerator
Moving cracks or dynamic joints	Flexible water stop foam or flexible resin	SB 1570, SB 1570 LV, SB 1403, SB FlexGel
Hairline cracks and tight fissures	Low-viscosity or super-low-viscosity resin	SB 1570 LV, SB 1403 SLV, SB 2400 Acrylate Gel
Curtain grouting or wet soil-side conditions	Hydrophilic gel or acrylate gel systems	SB FlexGel, SB 2400 Acrylate Gel
Pipe penetrations and annular spaces	Resin with sealing accessory system	SB Seal Oakum, SB Seal Pipe Kit, Water Stop Foam
Small-job or rapid-response repair	Cartridge or kit-based system	SB Hot Shot cartridges, SB CanSeal Foam Kit
Professional injection projects	Pump, packer, hose, coupler, and accessory system	SealBoss injection pumps, packers, ports, hoses, applicators

Product selection matters. Viscosity, reaction speed, expansion, flexibility, moisture response, and delivery method all affect the outcome.

SealBoss supports contractors with a full system approach: leak-seal materials, injection pumps, mechanical packers, ports, hoses, couplers, oakum, pipe kits, accessories, field guidance, and training resources.

Product, Pump, Packer, Technique

A successful injection repair is not only about the resin. It is about the complete system.

Product

The grout or resin must match the leak type, crack size, water flow, movement, moisture condition, and exposure requirement.

Pump

The pump must deliver material at the right pressure and volume for the structure and leak condition.

Packer / Port

The packer or port must provide a reliable injection point into the crack, joint, or void.

Technique

Drilling angle, spacing, injection sequence, pressure control, and material consumption all influence the final seal.

This is where professional know-how makes the difference. SealBoss products are designed to work as part of a repair system, not as isolated materials.

The Cost Problem With “Almost Fixed”

A leak that returns is not fixed. It is deferred.

The most expensive repair is often the one that looked cheapest at first but had to be repeated. Patch-and-repeat work creates callbacks, continued water damage, tenant complaints, downtime, cleanup costs, and owner frustration.

Contractors who use injection grouting can change the conversation from “patch this spot” to “seal the leak path.”

That is a stronger value proposition for the owner and a better technical solution for the structure.

Common Leak-Seal Applications

SealBoss leak-seal injection grouting systems are commonly used for active water intrusion in:

Below-grade foundation walls
Floor-to-wall joints
Cold joints and construction joints
Shrinkage cracks and structural cracks
Elevator pits
Parking garages
Utility vaults and manholes
Tunnels and dams
Water tanks and wastewater structures
Pipe penetrations
Honeycombed concrete
Seawalls and marine structures
Curtain-grouting and permeation-grouting conditions
Soil and void conditions related to water movement

Each project should be evaluated based on water pressure, access, crack width, movement, substrate condition, and service environment.

Stop the Water Before the Cost Multiplies

Water infiltration rarely gets cheaper with time. Once water is moving through a structure, it can turn a small repair into a much larger building expense.

SealBoss leak-seal injection grouting systems help contractors and facility professionals stop active leaks at the source with professional-grade water stop foams, flexible resins, gels, pumps, packers, accessories, and technical support.

Need Help Selecting the Right Leak-Seal System?

Talk to a SealBoss specialist. Product selection, pump and packer setup, and jobsite guidance.

Or send us a message via the contact page

Pump Cleaning Procedure

SEALBOSS TECHNICAL PROCEDURE
Injection Pumps

Pump Cleaning Procedure

STEP

Purge the System

Immediately after injection work is completed, remove as much injection resin as possible from the hopper, pump, hoses, shutoff valve, and applicator.

Do not begin the flushing process until the pump, hoses, and applicator have first been thoroughly purged of remaining injection resin.

STEP

Flush the System

When necessary, use a compatible solvent in the quantities required to dissolve and displace residual resin from the pump, hoses, shutoff valve, and applicator.

Pump the solvent through the complete system and discharge the contaminated material into an appropriate waste container. Do not recirculate solvent or resin-contaminated cleaning fluid.

Solvent should not remain inside the pump, hoses, seals, gaskets, or applicator. Immediately follow the solvent flush with sufficient SealBoss R70 Pump Flush & Cleaner to completely remove and displace all remaining resin and solvent from the system.

Continue pumping R70 until the discharged fluid is clean and free of visible resin or solvent contamination.

STEP

Recirculate and Condition

After the resin, contaminated cleaning fluid, and solvent have been removed, add clean SealBoss R70 Pump Flush & Cleaner.

Recirculate the clean R70 through the pump, hoses, shutoff valve, and applicator for a minimum of five minutes.

During recirculation, operate the pump at an elevated pressure setting and rapidly open and close the shutoff valve several times. This creates pressure fluctuations and high-velocity flow that help remove residual material from internal pump components, valves, fittings, and hoses.

Never recirculate visibly contaminated, resin-rich, or discolored cleaning fluid. Recirculation should begin only after clean R70 is flowing from the system.

A residual amount of clean R70 may remain in the pump and hoses during storage to lubricate and condition internal components.

Important Cleaning and Storage Requirements

Clean the pump immediately after use.
Never use water to clean, flush, or test a chemical injection pump.
Observe the injection resin’s stated pot life at all times.
Purge catalyzed polyurethane resin before extended work interruptions.
Do not pump cured resin, partially cured resin, or surface skin into the pump.
Never allow solvent to remain in the pump or hoses during storage.
Use only cleaning products that are compatible with the pump, hoses, seals, gaskets, valves, and applicator.
Dispose of resin, solvent, and contaminated cleaning fluid in accordance with applicable regulations.

Flooded Tunnel Repair

Underground Injection Grouting

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.

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.

Related Articles

Tunnel Water Stop Injection Leak Repair

SealBoss ® 1510

Leak-Seal Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam Grout

Our #1 Selling Polyurethane Injection Foam
Water Cut-Off Injection Grout
Unregulated for transport. Drinking Water Contact meets NSF/ANSI 61 Section 5 requirements. 1510 PU Foam & Oakum Pipe Plug Kit

5/8 PLASTIC BUTTONHEAD / ZERK

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.

Contact Your SealBoss ® Technician

How to Seal Leaks | Repair Cracks in Shotcrete

How to Seal Leaks and Repair Cracks in Shotcrete

Shotcrete is a versatile and durable material widely used in construction for creating complex structures, including decorative elements in zoos and theme parks.

However, like any other material, it is prone to developing cracks and leaks over time. Addressing these issues promptly is crucial to maintain the integrity and appearance of the structures. This article outlines a practical example of how the SealBoss Water Stop System was effectively used to repair a decorative shotcrete structure at the Omaha Zoo.

Shotcrete Water Intrusion: Why Risk Is Higher than CIP and How Injection Mitigates It

Shotcrete is a workhorse for tunnels, basements, shafts, tanks, and slope stabilization. But compared with well‑vibrated cast‑in‑place (CIP) concrete, shotcrete has a higher risk of water intrusion—not because the material itself is inferior, but because placement variables (nozzle technique, rebound, and bonding) can create porous zones, laminations, and honeycomb voids.

The good news: injection grouting precisely targets those leak paths without demolition.

Common Leak Sources in Shotcrete

Rebound pockets & laminations behind the finished face or around congested steel
Honeycombs/voids near corners, embeds, and penetrations
Cold/day joints with incomplete bonding between lifts
Interfaces at shotcrete‑to‑rock or shotcrete‑to‑existing concrete
Cracks (shrinkage, thermal, or flexural) that become water carriers

Summary – TL;DR

Shotcrete is more sensitive to workmanship than CIP. That sensitivity increases the odds of rebound pockets, laminations, and honeycombs that become water pathways.
The fastest, least disruptive fix: chemical injection—spot seal and stop active water with hydrophobic/hydrophilic polyurethane (PU) foam injection, or for large scale porosity in below grade structures seal with low viscosity PU foam or ultra‑low‑viscosity acrylate gel (curtain injection) as needed.
Use epoxy only if structural crack repairs are specified and after water control.
Use lowest possible, controlled injection pressure, tight port patterns, and clear pass/fail criteria.

How to Seal Leaks and Repair Cracks in Shotcrete – The Challenge

Leaks and Cracks in Decorative Shotcrete

The Omaha Zoo faced a significant challenge when a decorative shotcrete structure, an integral part of the zoo’s aesthetic appeal, began showing signs of deterioration.

Cracks and leaks had developed, primarily due to an irrigation system installed above the structure. Water seepage through these fissures threatened the durability and appearance of the faux rock face, necessitating an urgent and effective repair solution.

The Solution: SealBoss 1510 Foam and P2002 Polyurethane Pump

To address the leaks and repair the shotcrete structure, a technical representative from SealBoss was called upon. The solution proposed involved the use of the SealBoss Water Stop System, specifically the 1510 Water Stop / Leak Seal Foam and the compact P2002 Injection Pump, along with SealBoss Evolution AL Packers (1/2″, 5/8 BH/Zerk).

The objective was clear: Seal the leaks in the shotcrete and repair the cracks effectively without compromising the structure’s aesthetic value. The SealBoss system was chosen for its proven efficiency in such scenarios.

The Process: Hydro Active Foam Injection Technique

The shotcrete leak seal repair process began with a thorough assessment of the structure to identify all visible voids and cracks. The SealBoss team then employed the hydro active foam injection technique, using the P2002 drill injection machine along with 1/2 AL & 5/8 injection packers.

SealBoss 1510 was injected into the shotcrete cracks until visible penetration was observed on the face of these cracks. This process required multiple injections at various points to ensure that the foam traveled deep into the cracks, forming a dense, closed-cell compression seal upon expansion. One of the remarkable observations during the process was the expanding foam pushing out from the cracks, indicating its excellent travel and coverage within the network of fissures.

The Outcome: A Leak-Free, Restored Structure

Following the injection process, the structure underwent a rigorous inspection to ensure that all leaks were sealed. The SealBoss system proved its efficacy, as the structure passed the inspection with no signs of leakage. The aesthetic integrity of the structure was maintained, with minimal visible impact from the repair process.

Training and Support

SealBoss offers in-person and video training for those interested in learning more about their products and techniques. This training is invaluable for professionals looking to enhance their skills in leak sealing and crack repair in shotcrete structures. Additionally, SealBoss provides access to regional technical representatives who can offer insights into the full range of system solutions and offerings.

Conclusion

The successful repair of the decorative shotcrete structure at the Omaha Zoo is a testament to the effectiveness of the SealBoss Water Stop System. This case study highlights the importance of choosing the right materials and techniques for repairing shotcrete structures. With the right approach, it is possible to extend the life of these structures while maintaining their aesthetic and structural integrity.

For those facing leaking shotcrete challenges, consulting with a SealBoss technical representative can provide tailored solutions to effectively address leaks and cracks in shotcrete.

SealBoss® provides PU water‑stop resins, acrylate gel systems, injection pumps, mechanical packers, and training to execute the sequences above. Share your drawings, leak rates, and access constraints—we’ll assist in proposing a port layout, gel‑time schedule, and material takeoff tailored to your project.

SealBoss ® P2002 Drill Operated Injection Pump Advantages

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

Seal Leaks and Repair Cracks in Shotcrete – Frequently Asked Questions

Is shotcrete inherently leaky?

No. Properly placed shotcrete can be watertight. But its placement method increases the odds of defects (rebound pockets, laminations, honeycombs) that raise the risk of leakage versus CIP. Injection addresses those specific pathways.

Will PU alone fix my problem?

PU foam is ideal for stopping active water quickly. If the wall is generally permeable or seepage is diffuse, add an acrylate gel curtain to create a continuous barrier.

When should I consdider epoxy?

Only if specified and after water is controlled. Epoxy is for structural crack repair and requires dry conditions to bond properly.

What injection pressures should I use?

Start low and increase only as necessary. The goal is flow‑based infiltration along leak paths, not fracturing the concrete.

How will I know it worked?

No visible flow, a dry face after 24–72 hours, and no damp telegraphing beyond the grid.

In below grade structures damp spot or wet areas may show up later if water table rises or dried out soil becomes saturated. Water may migrate to areas that have not been treated.

SealBoss Injection Systems

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Sealing Tie Holes

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

Introduction

Tie holes, also called tie-rod holes, are small openings in concrete structures created after removing tie rods used in formwork. While essential during construction, these holes can become problematic, especially when exposed to hydrostatic pressure, leading to leaks. A proven and reliable solution to this challenge is polyurethane polymer foam injection.

In this article, we dive into a real-world example of a contractor effectively sealing tie holes and addressing shrinkage cracks in water tanks for a rural water district. By utilizing the advanced SealBoss Injection System, the team achieved lasting results, showcasing the importance of specialized training, the right equipment, and strategic application in preserving concrete structures.

This guide provides valuable insights into the problem of tie holes, effective sealing techniques, and the critical role of expertise in ensuring durable repairs.

What are Tie Holes in Concrete Structures and How to Seal Them Permanently

Tie holes are small openings left in concrete structures after the removal of tie rods, which play a critical role during construction. Tie rods are essential components of concrete formwork—the temporary mold used to shape poured concrete. These rods ensure proper alignment and stability of the formwork during the concrete pouring and curing processes.

Over time, tie holes can become a vulnerability in the structure, as they may begin to leak when exposed to hydrostatic pressure. This typically occurs when water from an external source presses against the opposite side of the concrete structure, leading to potential water infiltration.

Sealing Tie Holes with SealBoss Systems — Polyurethane Polymer Foam Injection is widely regarded as one of the most effective and long-lasting solutions.

This advanced sealing technique permanently stops leaks in tie holes, providing durable protection against water penetration. Its efficiency and reliability make it a top choice for maintaining the structural integrity of concrete constructions.

By understanding the importance of sealing tie holes and utilizing proven methods like polyurethane foam injection, you can prevent water damage and extend the life of your concrete structure.

Sealing Tie Holes and Cracks

A Case Study in Effective Water Tank Repair

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

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

SealBoss ® 1510

Concrete Leak Sealing

Leak-Seal Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam Grout

Our #1 Selling Polyurethane Injection Foam
Water Cut-Off Injection Grout
Semi-Flex Foam, Water-Activated chemical injection grout. Our most versatile product. Water activated hydrophobic polyurethane foam, expands up to 30-40 times.

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 foamer to high foamer depending application.

P2002 Injection Pump Standard

Polyurethane Injection

Light Weight, Modular Design
Electric Drill Operated
Single Piston System
6000+ psi – 1 Component

13-100AL Evolution

ALUMINUM MECHANICAL PACKER

Dimensions
1/2″ X 4″
13 x 100mm

13-100AL Evolution

Standard Packer

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.

Bestseller – a SealBoss Standard

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Crack Injection Guideline – 1 2 3 at 45 Degree

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Injecting Trust - One Crack at a Time

Introduction

Cracks in concrete structures are more than just cosmetic issues—they can compromise integrity, allow water intrusion, and accelerate rebar corrosion. The SealBoss 1-2-3 at 45 Degree Crack Injection Guideline provides a proven, systematic approach to crack injection that ensures effective leak sealing and structural protection. By following three critical steps—preparing and mapping packer placement, installing the packers, and executing the injection at a 45-degree angle—contractors can achieve durable, high-quality results. This article outlines best practices, technical details, and important considerations to help professionals optimize their injection process and maximize success, one crack at a time.

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

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

Optimal Techniques and Considerations

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

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

Injection Packer Spacing

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

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

Injection Packer Placement

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

45 Degree Angle Drilling and Packer Placement

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

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

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

Optimizing Drill Hole Distance from the Crack

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

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

Determining the Required Minimum Length for a Drill Bit

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

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

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

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

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

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

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

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

General Injection Packer Preparation – Drill and Flush

Safety Gear

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

Cleaning

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

Spacing

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

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

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

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

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

Exceptions to the 45 Degree Injection Rule – Straight Drilling

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

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

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

Drill Dust

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

Rebar

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

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

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

Flushing / Cleaning Drill Holes Prior to Injection

Overview

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

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

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

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

Drill Hole Water Flushing Detail

Low Pressure Flush

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

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

Using a Dedicated Flushing Water Pump

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

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

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

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

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

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

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

Final Thoughts

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

Additional Injection Packer Installation Recommendations

Mechanical Packer Fundamentals

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

Mechanical Packers Installation

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

SealBoss Hammer-In Ports

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

Packer Connectors

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

Zerk Type Connector

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

Button Head / Slide Coupler

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

SealBoss Packers

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

Injection Products

Before You Start Injection

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

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

Injection Procedure

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

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

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

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

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

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

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

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

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

SealBoss Oakum Soakum Technique

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

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

Quality Injection Job

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

Packer Removal

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

SealBoss R70 Pump Flush for Clean-up

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

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

Inquiries, Comments, or Requests?

Podcast | “Leak Sealing Polyurethane Crack Injection | Concrete / Shotcrete”
Podcast | “The Mockup is Worth its Weight in Gold”

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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.

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.

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.

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.

Concrete Wall Repair Epoxy System

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Injection

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Cold Joint Injection

Leaking Cold Joints Sealed

Cold Joints in Concrete Structures and the Polyurethane Polymer Solution

Introduction

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

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

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

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

What are Cold Joints?

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

Cold joints typically occur due to:

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

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

Cold Joint Injection: The Polyurethane Polymer Foam Solution

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

Why Use Polyurethane for Cold Joint Injection?

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

Benefits of polyurethane cold joint injection include:

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

Step-by-Step Cold Joint Injection Process

The cold joint injection procedure typically involves the following steps:

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

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

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

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

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

Advantages of SealBoss Cold Joint Injection Systems

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

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

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

Cold Joint Injection: An Investment in Longevity

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

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

Contact SealBoss for Expert Cold Joint Solutions

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

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

Considering a Solution for Sealing Cold Joints During Construction?

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

Materials and Tools Used

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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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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.

In this article we 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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SealBoss News / Blog

Concrete Injection Job Checklist

Use This as a Readiness Checklist

1. Prepare Equipment and Protective Gear

2. Inspect and Document the Injection Area

3. Prepare the Crack and Surrounding Surface

4. Install Packers or Ports

5. Prepare the Injection Material

6. Apply a Surface Seal When Required

7. Begin the Injection

8. Monitor the Procedure

9. Allow the Material to React or Cure

10. Remove or Finish Packers and Ports

11. Clean Equipment and Manage Waste

12. Complete the Final Inspection

Material

Equipment

Method

Project Information

1. Confirm the Repair Objective

2. Documents to Have at the Jobsite

3. Materials and Components

4. Pump, Hose, and Applicator Readiness

5. Packers, Ports, and Drilling Equipment

6. Jobsite and Safety Readiness

7. Crack and Injection-Area Assessment

8. Final Pre-Injection Check

9. Injection Quality-Control Record

10. Shutdown, Cleanup, and Closeout

Stop Work and Request Review When

Product-System Verification

Polyurethane Leak-Seal Injection

Epoxy Crack Injection

Acrylate or Gel Injection

Build the Complete Injection System

Products

Equipment

Field Support

Review Current Technical Resources Before Mobilizing

Water Infiltration Costs & Injection Grouting | SealBoss

What Water Infiltration Can Cost

The Real Problem Is the Water Path

Why Surface Patches Often Fail

SealBoss Injection Grouting: Stop the Leak Where It Lives

Matching the SealBoss System to the Jobsite Condition

Product, Pump, Packer, Technique

Product

Pump

Packer / Port

Technique

The Cost Problem With “Almost Fixed”

Common Leak-Seal Applications

Stop the Water Before the Cost Multiplies

Need Help Selecting the Right Leak-Seal System?

Purge the System

Flush the System

Recirculate and Condition

Important Cleaning and Storage Requirements

Flooded Tunnel Repair

Underground Injection Grouting

How to Seal Leaks | Repair Cracks in Shotcrete

SealBoss Injection Systems

Sealing Tie Holes

Sealing Tie Holes and Cracks

Crack Injection Guideline1 - 2 - 3 at 45 Degree

Crack Injection Guideline1 - 2 - 3 at 45 Degree

Injecting Trust - One Crack at a Time

General Injection Packer Preparation – Drill and Flush

Maximizing Performance and Longevity

Water Treatment Plant Maintenance and Water Reclamation Facility Solutions

Concrete Wall Repair Epoxy System

Cold Joint Injection

Leaking Cold Joints Sealed

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

Epoxy vs Polyurethane Injection

Crack Injection Superheroes

Accessories

Pumps

SealBoss ® EPOXY

SealBoss ® POLYURETHANE

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Water Treatment Plant Maintenance
and Water Reclamation Facility Solutions