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Epoxy versus Polyurethane Crack Injection

Epoxy vs Polyurethane Injection

Crack Injection Superheroes

Epoxy Resins versus Polyurethane Resins
A Concrete Crack Injection Comparison

Epoxy versus Polyurethane Crack Injection

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

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

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

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

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

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

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

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

Injection Repair Conditions and Objectives

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

Comparison of the Characteristics of Epoxy and Polyurethane Polymers and Elastomers

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

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

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

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

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

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

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

Differences in The Epoxy and Polyurethane Crack Injection Processes

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

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

Epoxy Crack Injection

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

Polyurethane Crack Injection

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

Product Characteristics

EPOXY (EP)

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

POLYURETHANE (PU)

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

Epoxy versus Polyurethane – Conclusion

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

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

TIP

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

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

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

Accessories

EPOXY (EP)

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

POLYURETHANE (PU)

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

Conclusion:

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

Pumps

EPOXY (EP)

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

POLYURETHANE (PU)

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

Choose Your Pump:

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

Final Thoughts:

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

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

SealBoss ® EPOXY

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SealBoss ® POLYURETHANE

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Contact Your SealBoss ® Technician

How to Fix Foundation Cracks

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

How to Fix Foundation Cracks

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

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

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

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

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

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

— Popular Mechanics, Roy Berendsohn

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

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

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

References

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

SealBoss Crack Repair Kits

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Parking Garage Crack Injection | Leak Sealing Repair

Parking Garage Crack Injection

Structural and Leak Sealing Repairs

Introduction:

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

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

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

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

Parking Garage Crack Injection Technology

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

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

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

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

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

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

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

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

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

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

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

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

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

Epoxy Versus Polyurethane Comparison – click here.

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

Materials and Tools Used

Related Articles

Structural Parking Garage Repairs with High Strength Epoxy Resins

Structural Epoxy Injection System

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

Check out our Leak Sealing Repair Kits.

SealBoss P2002 Light Weight Professional Injection Pump

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

SealBoss Injection Systems

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

What are Cold Joints?

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

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

Injection Process

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

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

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

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

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

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

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

Considering a Solution for Sealing Cold Joints During Construction?

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

Materials and Tools Used

Related Articles

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Retaining Wall Repair

Injection Methods Compared

Understanding Retaining Wall Repair:

Polyurethane vs. Epoxy Injection Methods

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

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

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

Retaining Wall Repair
with Leak Sealing Polyurethane Water Stop Foam Injection

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

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

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

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

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

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

Summary

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

Retaining Wall Repair
with Epoxy Resin Injection For Structural Strength

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

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

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

Summary

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

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

Conclusion

Retaining Wall Repair – Polyurethane or Epoxy Injection

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

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

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

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

Contact Your SealBoss ® Technician

Retaining Wall Crack Injection Repair

Using Leak Sealing Foam

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

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

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

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

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

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

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

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

Retaining Wall Crack Injection Repair Guide

Retaining Wall Crack Injection Repair with SealBoss 1510 Leak Sealing Foam

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

Choosing the Right Repair Product

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

Insightful Inspection

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

Strategic Packer Placement

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

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

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

Product Conditioning

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

Injection Process

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

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

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

SealBoss Leak Sealing Foam Injection using angled injection packers

Conclusion

Retaining Wall Crack Injection Repair

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

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

Retaining Wall Repair Method Comparison

Polyurethane Leak Sealing versus Structural Epoxy Injection

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Concrete Crack Injection – Polyurethane

Concrete Crack Injection Polyurethane

Introduction:

Maintaining the design integrity of concrete structures is paramount, particularly when it comes to preventing water intrusion and ensuring long-term durability.

Leaking concrete cracks pose a significant challenge across various infrastructures, necessitating advanced and reliable repair solutions.

Concrete Crack Injection with Polyurethane (PUR) Water Stop Foam Injection is a modern and economical approach designed to effectively seal leaking concrete cracks permanently. Chosen for its efficacy and adaptability, this method addresses a wide range of issues associated with water damage, including structural erosion and the presence of efflorescence.

Highlighting the procedure and it’s benefits, this article is an introduction to leveraging PUR Water Stop Foam Injection to maintain and enhance the integrity of concrete constructions, ensuring long-term protection against the elements.

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

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

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

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

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

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

Concrete Crack Injection – Polyurethane

Which products are shown in the video?

Concrete Crack Injection Polyurethane – Procedure and Repair Method

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

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

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

Crack Injection Details

A – Standard Injection Procedure

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

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

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

B – Custom Injection Procedure

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

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

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

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

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

Cleanup

After the cracks were successfully injected, the injection ports were removed, and a hydraulic cement patch was used to patch the ½” dill holes.

Products Used:

Injection Resin:

Other Tools Used

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

Call Your SealBoss ® Technician

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

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How to Seal Shrinkage Cracks

Shrinkage Cracks Sealed at Wastewater Treatment Plant

Introduction:

In the demanding environments of wastewater treatment plants, maintaining the integrity and functionality of concrete structures is paramount. Shrinkage cracks, a common yet potentially problematic occurrence in concrete, can compromise the efficiency and safety of these facilities. As these cracks form, they not only present a risk to structural durability but also become conduits for unwanted water and contaminant infiltration, particularly in areas around pipe penetrations. This introductory article explores the nature of shrinkage cracks, their implications for wastewater treatment infrastructure, and the innovative solutions employed to address these challenges.

Understanding Shrinkage Cracks in Concrete

What are Shrinkage Cracks?

Shrinkage cracks are a natural occurrence in concrete structures that form during the curing and drying process. Concrete, a blend of cement, aggregate, and water, undergoes a volume reduction, or shrinkage, as the water used in the mix evaporates. This process of evaporation causes the concrete mass to shrink and contract.

Simultaneously, the internal reinforcements or sub-bases that the concrete is poured onto restrict this shrinkage. This restriction generates tensile stresses within the concrete. When these stresses exceed the concrete’s tensile strength, they give rise to drying and shrinkage-related cracks.

Shrinkage cracks, although often very small, are of significant concern in certain structures. Even though they typically don’t compromise the structural integrity of the concrete, they can create pathways for water and other corrosive materials. This is particularly crucial in structures like dams, where minor leaks can have substantial implications.

Moreover, it’s important to note that the shrinkage of concrete and the subsequent development of cracks is an irreversible process. Therefore, any resulting water leakage needs to be addressed with suitable methods such as concrete crack injection.

Effective Sealing of Shrinkage Cracks at a Wastewater Treatment Plant

Scope

At the wastewater treatment plant in Salina, Kansas, a critical task emerged prior to the placement of pumps and pipes in the pump room. The challenge was to address the leaks that originated from pipe penetrations and shrinkage cracks in the concrete structure, particularly after the tank was filled for testing purposes.

Procedure

To provide professional assistance, our Regional Technical Sales Manager visited the site. He provided a consultation on how to effectively use SealBoss 1510 Water Stop Foam to halt water penetration through the shrinkage cracks, many of which stemmed from pipe penetrations.

The SealBoss 1510 was applied via a high-pressure injection process, using the SealBoss P2002 injection system, coupled with the SealBoss 13-100 AL series injection packers. These packers are specifically designed with ribs to withstand high-pressure injection, ensuring an effective and durable application of the Water Stop Foam.

This professional, on-site consultation, combined with the use of high-quality, reliable materials and equipment, serves as an example of our comprehensive approach to address and seal shrinkage cracks effectively.

Employed Products:

SealBoss 1510 superior penetration through hairline cracks

SealBoss ® 1510 NSF Approved Water Stop Foam

Shrinkage cracks, a prevalent issue in wastewater treatment plants, often originate in the areas of pipe penetrations.

They can potentially lead to water seepage from tanks and basins, posing operational and maintenance challenges. Addressing these issues requires adherence to stringent specifications for approved materials.

SealBoss’s Water Stop Systems, bearing the NSF/ANSI 61 Drinking Water Contact Approval, not only meet these stringent standards but also provide a robust solution to such leak-related issues.

Our Full System Solutions further consolidate our position as a comprehensive resource for contractors, catering to a broad spectrum of injection needs. Thus, with SealBoss, you gain access to high-quality, approved materials and comprehensive, reliable solutions, all from a single, dependable source.

Related Super Low Viscosity SealBoss Chemical Injection Grouts:

SealBoss ® 1403 SLV Super Low Viscosity Polyurethane Resin for injection into very fine cracks.
SealBoss ® 2400 SealGel SLV Super Low Viscosity Acrylate Gel / Acrylic Gel for injection into very fine cracks.

SealBoss
Injection Brochure

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Cracks

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Crack Injection Guideline – 1 2 3 at 45 Degree

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Injecting Trust - One Crack at a Time

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

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

Optimal Techniques and Considerations

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

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

Injection Packer Spacing

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

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

Injection Packer Placement

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

45 Degree Angle Drilling and Packer Placement

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

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

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

Optimizing Drill Hole Distance from the Crack

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

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

Determining the Required Minimum Length for a Drill Bit

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

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

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

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

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

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

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

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

General Injection Packer Preparation – Drill and Flush

Safety Gear

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

Cleaning

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

Spacing

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

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

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

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

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

Exceptions to the 45 Degree Injection Rule – Straight Drilling

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

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

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

Drill Dust

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

Rebar

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

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

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

Flushing / Cleaning Drill Holes Prior to Injection

Overview

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

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

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

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

Drill Hole Water Flushing Detail

Low Pressure Flush

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

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

Using a Dedicated Flushing Water Pump

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

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

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

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

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

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

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

Final Thoughts

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

Additional Injection Packer Installation Recommendations

Mechanical Packer Fundamentals

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

Mechanical Packers Installation

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

SealBoss Hammer-In Ports

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

Packer Connectors

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

Zerk Type Connector

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

Button Head / Slide Coupler

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

SealBoss Packers

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

Injection Products

Before You Start Injection

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

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

Injection Procedure

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

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

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

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

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

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

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

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

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

SealBoss Oakum Soakum Technique

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

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

Quality Injection Job

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

Packer Removal

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

SealBoss R70 Pump Flush for Clean-up

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

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

Inquiries, Comments, or Requests?

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

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Highway Spall, Crack, and Pothole Repair

Highway and Road Repair Polymers

Introduction

In the comprehensive field of highway and road maintenance, addressing the challenges of spalls, cracks, potholes, and birdbaths in a quick and timely fashion is crucial for ensuring the public safety and longevity of road infrastructure. Advanced polymer products have significantly enhanced traditional repair methods, providing solutions that are not only convenient, rapid and extremely durable but also environmentally friendly.

Who hasn’t felt the frustration of constantly scanning the road for large cracks and gouges, only to still end up jolting through an unexpected major pothole?

This article provides an overview into the intricacies of highway damage, the pivotal role of polymer products in contemporary repair techniques, and provides a quick guide on the application of high strength and fast curing polyurethane repair systems by the example of SealBoss ® Highway and Road repair QuickFix polymer. We show how this innovative product line can be effectively utilized to combat common roadway damages, thus contributing significantly to maintaining safe and efficient transportation networks.

Play Video about SEALBOS-6060-POLYUREA-ROAD-REPAIR

Quick Road Repair Solution

Highway Spall, Crack, and Pothole Repair: Advanced Solutions not only for Highways

The maintenance and repair of highways are critical to ensuring the safety and efficiency of transportation systems.

The same is true however for any road in our communities and cities.

Spalls, cracks, and potholes are common issues that can lead to significant structural damage and pose risks to drivers. SealBoss® 6060 QuickFix offers a solution how these repairs can be conducted quickly and with permanence.

Understanding Road Damage

Road and highway damage typically manifests as spalls, cracks, or potholes.

These damages can be caused by a range of factors, including thermal expansion, freeze-thaw cycles, excessive load, and environmental degradation. Addressing these issues promptly is vital to prevent further deterioration and ensure road safety.

The Role of Polymer Products in Highway Repair

Polymer products, particularly polyurethane-based compounds like SealBoss 6060 QuickFix, have emerged as effective solutions for repairing highway damages. These products offer several advantages over traditional repair methods, such as asphalt patching or cementitious repairs.

Key Advantages

Extremely Rapid Setting Time: Enables quicker return to service, minimizing traffic disruptions.
Deep Penetration: Ensures comprehensive repair by filling even the smallest cracks and voids.
Flexibility and Strength: Accommodates some structural movements while providing durable repair.
Chemical Resistance: Withstands exposure to various chemicals, fuels, oils, and environmental factors.
Ease of Application: Simplifies the repair process, allowing for efficient use even in challenging conditions.

SealBoss 6060 QuickFix: A Closer Look

SealBoss 6060 QuickFix is a two-part polyurethane product designed for the quick and effective repair of concrete and asphalt surfaces. Its low viscosity allows for deep penetration into fine cracks and pores, ensuring a strong bond, and semi-flexible, long-lasting repair.

Properties

Fast Cure: Moderate traffic loads can resume within 15 minutes at 70°F (21°C).
Temperature Versatility: Effective in temperatures ranging from -20°F (-29°C) to 120°F (49°C).
Aggregate Compatibility: Can be used with various aggregates for different repair needs.
100% Solids and VOC Free: Environmentally friendly with no harmful emissions.

Application Guidelines

To achieve the best results with SealBoss® 6060 QuickFix, a systematic approach to application is advised.

Surface Preparation

Cleaning: Remove all debris, oils, and loose materials. For deep cracks, saw-cutting and thorough dust removal are recommended.
Drying: Ensure the repair area is completely dry before application.
Roughening: Expose clean, rough concrete or asphalt surfaces for better adhesion.

Mixing and Application

Mixing: Equally proportion components A and B is important. Use appropriate application equipment such as the SealBoss JM Pro2 Pump System.
Application Method: Apply the mixed product to the bottom of the crack or pothole, working upwards in layers. For deep repairs, alternate between applying the product and adding aggregate until the desired grade is achieved.
Curing: Allow the product to set, with traffic resumption times varying based on temperature conditions.
Equipment Care: Keep all equipment dry and clean to prevent contamination and ensure effective application.
Professional Use: The product is designed for professional use; consulting a SealBoss technician for specific project requirements is advisable.

Conclusion

The use of advanced polymer products like SealBoss® 6060 QuickFix represents a significant leap forward in fast and effective highway repair technology. These materials offer rapid, durable, and environmentally friendly solutions to common roadway damages. By understanding the properties and application techniques of these products, professionals can ensure effective repairs, ultimately contributing to safer and more reliable community roads and highways.

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