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Tunnel Segment Injection Repair

Mock-up Repair of a Tunnel Segment Using Polyurethane Foam Injection

Introduction
Within the intricate domain of tunnel leak sealing, polyurethane foam injection stands out for its effectiveness in tackling cracks and leaks.

This case study of a mock-up repair delves into the practical application of this method, exploring how a single tunnel segment was successfully leak seal injected with SealBoss 1510 water stop leak seal foam using specialized equipment.

Objective – Tunnel Segment Injection Repair
To seal a crack in its entirety and to its full depth, in a single tunnel segment, using polyurethane foam injection.

Methodology

Problem Identification
A prominent crack was identified in the tunnel segment, making it a prime candidate for repair. To simulate real-world scenarios, the crack was pre-injected with water to mimic a leak.

Equipment & Material Selection

Pump
SealBoss P2002 Injection Pump, known for its reliability and efficacy in such repair scenarios. The SealBoss P2002 Polyurethane Injection Pump boasts a compact design with an integrated stand. Remarkably lightweight yet powerful, it is compatible with most SealBoss® polyurethane products with viscosities between 10 and 1000 cps. This professional-grade pump offers outstanding output and pressure. Its modular design ensures low maintenance and easy cleaning.

Injection Packer
The SealBoss Evolution Long Aluminum Packer was chosen, a leading choice for deep, angled injections. or a successful injection process, mechanical injection packers and ports are crucial. Our extensive stock is curated to cater to diverse client needs, promising timely deliveries.

Foam
SealBoss 1510 Water Stop Leak Seal Foam, recognized for its water-stopping capabilities. SealBoss 1510, commonly referred to as 1510 Water Stop Foam, stands out as our premier and best-selling grout for addressing water leaks in a majority of crack injection contexts. When combined with 15x Accelerator, this hydrophobic, water-activated grout transforms into a foam seal based on MDI polyurethane. Furthermore, this resin is entirely solvent-free and composed of 100% solids.

Injection Strategy
A singular injection packer was placed at a precise angle towards the crack. This strategic positioning was critical to ensuring the foam could reach the full depth of the crack and seal it effectively.

Execution
With the equipment set and the crack prepped, the SealBoss 1510 foam was injected using the SealBoss P2002 pump through the SealBoss Evolution packer. The foam’s expansive properties, coupled with the angled placement of the injection packer, ensured the material filled the entire crack from depth to surface.

Outcome – Tunnel Segment Injection Repair

Upon completion of the injection process, a thorough inspection was conducted to verify the effectiveness of the repair. The results were clear – the crack had been sealed entirely, with complete, uninterrupted foam penetration along the perimeter.

Key Learnings

Strategic Packer Placement
The success of this repair underscored the importance of correctly positioning the injection packer. An angled approach ensured the foam covered the crack’s entire depth.

Reliable Equipment
The SealBoss P2002 injection pump and SealBoss Evolution packer proved indispensable, delivering the foam efficiently to the target site.

Efficacy of SealBoss 1510
This particular foam showcased its prowess in stopping water ingress, highlighting its potential as a top-tier solution for tunnel repairs.

Conclusion
This case study stands as a testament to the efficacy of polyurethane foam injections in tunnel repair scenarios. When executed with precision and the right equipment, even a single injection point can address extensive cracks, ensuring the longevity and safety of critical infrastructure like tunnels.

Tunnel Segment Injection Repair and other SealBoss Tunnel Sealing Solutions

Tunnel Injection Repair Equipment

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

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Basement Crack Injection Kit

Basement Crack
Injection Kit
Pro P2002

Basement Crack Injection Kit – The Ultimate Solution for Leak Sealing and Repair

Tracing the Root Cause

The culprits behind basement cracks often lie in the settlement of backfill or inadequate soil conditions. The resulting stress cracks can pave the way for unwelcome moisture intrusion, leading to further damages and the development of mold and unsightly damage over time.

A Comprehensive Crack Repair System

Enter the SealBoss Basement Crack Injection Kit, your ultimate weapon against leaks. This kit simplifies the repair process by delivering an effective, user-friendly solution to stop water in its tracks. The cured seal is airtight, watertight, and hydrophobic, deterring water incursion with utmost efficiency.

Our easy to use kit comprises a SealBoss P2002 high-pressure injection pump, SealBoss 1510 Water Stop Foam hydrophobic resin coupled with a 15x catalyst, and SealBoss Mechanical Injection Packers. When used in unison, these tools empower you to counteract hydrostatic pressure and fill the crack with a specialized water activated polyurethane foam that reacts with the existing moisture.

For complex structural repairs, consider employing the SealBoss Epoxy Injection System and Epoxy Repair Kits. For an in-depth comparison of the two systems, we invite you to explore our article on Epoxy versus Polyurethane.

Crack injections can conveniently be performed from within the structure (aka negative side repair), saving you both time and labor.

Leak Sealing Crack Repair Procedure

We put our Crack Injection Kit to work in a residential basement structure that had three prominent cracks showing signs of moisture intrusion. Signs of a previous unsuccessful repair attempt were also evident.

Post a thorough cleaning and strategic planning, we embarked on the repair process using our 1, 2, 3, 45 Degree Injection Guidelines, initiating with hole placement. The positive movement of water from drill hole to crack and inter-hole travel confirmed the readiness for the crack to be sealed.

The cracks, being approximately 3/8” wide, demanded a slowed injection to prevent wastage and overfill. As the catalyzed 1510 hydrophobic resin flowed from the crack, we employed a spray bottle to expedite the hydro-active reaction of the SealBoss 1510, allowing the foam to seal the crack surface as it cured.

One significant vertical crack had penetrated the foundation and was visible above ground. This crack was treated with foam from the floor up to 12” below the sill plate. The exterior was sealed to guide the expansion and avert exterior leakage. All cracks were sealed successfully, with surplus foam removed to prepare the structure for subsequent treatments, including aesthetic improvements.

Please note, we highly recommend consulting a specialist to investigate and correct any underlying and ongoing causes of structural damages, crack formation, and settling — including, but not limited to, backfill settlement and poor soil density.

SealBoss Water Stop & Leak Sealing Injection Pro Kit

Basement Crack Injection Kit

Injection Resin: SealBoss 1510 w/ 15x Accelerator
Injection Packers: 1/2” 13-100 Evolution Aluminum Packers
High Pressure Pump: P2002 Single Component Injection Pump
Cleaning: R70 Pump Flush

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

Enjoy Peace of Mind with the SealBoss Concrete Solutions

With our Basement Crack Injection Kit, not only do you have an effective repair solution at your fingertips, but also a path to restore your basement’s integrity and aesthetics. Gone are the days of continually battling the damaging effects of moisture intrusion. Instead, look forward to the assurance of a drier and healthier environment.

Remember that it’s crucial to address any root causes contributing to your basement’s damage. Regular maintenance, appropriate landscaping, and proper drainage can play a significant role in preventing cracks and leaks in the future. If you’re unsure about these aspects, we recommend involving a professional to help you take the right steps.

Your Partner in Crack Repair

We’re more than just providers of crack repair solutions. At SealBoss, we’re committed to being your partner in navigating basement repairs. From understanding the nuances of polyurethane and epoxy, making the right product choice, to walking you through the repair process, we’re with you every step of the way.

Need technical support, additional information, or advice on our products? Don’t hesitate to reach out to us. We’re here to ensure you have everything you need to succeed in your repair projects and maintain the health and longevity of your structure. Trust in us, because with SealBoss, successful basement restoration begins.

Comprehensive Solutions for All Sizes

We understand that not all repair jobs require extensive tools and materials. For those smaller tasks, check out our tailored Small Job Kits. They’re specially designed to handle minor repairs, ensuring you get the same high-quality results without needing to invest in larger quantities or more extensive equipment.

Small Job Kits and Cartridge Solutions

Popular Water Stop & Leak Sealing Injection Links

Basement Crack Injection Systems

Click Here

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EZ-FIT Injection Packer

EZ-Fit Injection Packer

The Washer:
Where Ease Meets Excellence in Injection.

Introducing the SealBoss® EZ-Fit Injection Packer:

Elevating Precision in Packer Installation

In our quest to enhance the user experience and precision in packer installation, we’ve innovatively designed the SealBoss® EZ-Fit Injection Packer. One of its standout features is the strategically placed washer at the top of the packer body. This washer serves as an intuitive guide, ensuring swift and accurate packer placement.

Gone are the days of second-guessing during packer installation. The moment the washer touches the substrate, the applicator can be confident that the EZ-Fit Packer is perfectly positioned within the drill hole, primed and ready for tightening.

But that’s not all. We’ve fortified the injection port with heavy-duty steel, ensuring its durability and longevity. Complementing this robust design is a soft-grade rubber sleeve, which provides enhanced friction and grip, ensuring a secure and efficient injection process.

Experience the difference with the SealBoss® EZ-Fit Injection Packer – where precision meets performance.

The SealBoss ® EZ-Fit Packer style has a strong following with some experienced contractors while boosting confidence among contractors new to the crack injection business.

Packer Technology since 1988

SealBoss has been a leader in the injection packer technology since 1988. Mechanical packers and injection ports are the gateway to successful injection. SealBoss supplies injection packers to customers worldwide. We offer mechanical packers varying in all key designs including packer material types and dimensions. We also offer custom designs and production for our customers.

Find More information here

SealBoss Quick Info Crack Injection

SealBoss ® Packer Quick Reference

With offerings spanning the waterproofing, floor repair, and structural repair scopes,
SealBoss ® is your source for proven concrete repair materials.

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Ceiling Crack Injection Shopping Mall

Ceiling Crack Injection

Shopping Mall

SealBoss ® 1510 Water Stop Foam Ceiling Crack Leak Repair

Job Walk Shopping Mall Los Angeles

A concrete crack in the concrete ceiling in a busy shopping mall was actively leaking. Cracks were described as fine and hairline. A two‑person crew mobilised with SealBoss 1510 Water Stop Foam and SealBoss Packer Evolution 13‑100 AL ports performed a hydroactive polyurethane injection during the designated maintenance window.

Following the repair, a job walk was conducted to inspect the injection site. Correct packer placement was observed and it was, verified that foam had fully expanded, and confirmed that the ceiling was completely dry before reopening the area for traffic.

Injection Procedure

After tracing the crack, technicians marked drill points and hole were drilled at an approximately 45‑degree angle to intersect the crack mid‑depth, then fitted with SealBoss 13‑100 AL packers.

Working from the end showing the strongest water flow, the crew pressurised SealBoss 1510 with the injection pump at up to over 1,000 psi. Resin disappeared into the concrete and re‑emerged at the next packer, or beyond, confirming full penetration. After completing the first pass, they paused to allow the foam to expand, then repeated the sequence. Selected ports accepted a third shot to ensure a dense seal.

Before and after pictures. Ceiling leak repair. Hydroactive polyurethane foam grout injection with SealBoss 1510 Water Stop Foam and SealBoss ® Packer Evolution 13-100 AL.

SealBoss ® 1-2-3 at 45 Degree Injection Method

Water Stop and Leak Sealants

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Water Stop

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Hairline Crack Injection

Super Fine Crack Injection

What are Hairline Cracks and how do they develop?

Fine cracks in concrete, thinner than a credit card thickness, are considered hairline cracks. here are a number of reasons concrete structures could form hairline cracks.

Common causes of hairline cracks in concrete structures and foundations

Shrinkage
Concrete shrinks in volume as it dries. During this process of contraction, hairline cracks may develop.

Thermal Movement
Concrete expands and contracts during temperature changes. This process can cause hairline cracks to form in the structure.

Settlement
Foundation settlement can cause stress in a structure and lead to cracking. Voids varying in size from hairline cracks to more severe fractures and fissures can be observed.

Hairline Crack Injection Job Walk Comments

– In the image presented, we highlight a detail we have previously discussed with the injection team during technical training. The almost imperceptible hairline crack beautifully demonstrates the resin’s travel, moving from the drilled hole pointy of injection within the crack and emerging on the wall’s surface.

For effectively treating ultra-thin hairline cracks, it is advisable to utilize a low-viscosity chemical injection grout. This ensures optimal material penetration within the structure. Additionally, injection packers are typically positioned in close proximity to one another and nearer to the crack. This arrangement is due to the anticipated higher injection pressures and the increased challenges associated with material dispersion.

Hairline Crack Injection Products Used

The contractor performed the hairline crack injection with the SealBoss Injection System.

Products used:

We also recommend for hairline crack injection:

Learn More

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

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Water Treatment Plant Repair

SealBoss 1510 Water Stop Foam Injection
Water Treatment Plant Langston, OK

Water Treatment Plant Repair Injection Training on the Jobsite

East Coast Sales Manager Craig Greenfield trains a local general contractor on the SealBoss Leak Sealing & Water Stop polyurethane injection procedure.

Using the SealBoss 1510 Water Stop Foam, P2002 Injection Pump and SealBoss Injection Packers. The newly trained applicator was able stop the active water leaks. A successful repair, a further contractor added to the growing SealBoss team!

Environmentally Safe

SealBoss 1510 Water Stop Foam is approved for contact with drinking water meeting the NSF/ANSI 61 Section 5 requirements. That means they can be used without having an adverse effect on water quality.

Why is the SealBoss System Polyurethane Crack Injection Essential for Leak Seal Applications?

Leaks in concrete structures are often detrimental to property values and safety. SealBoss injection products, such as our Water Stop Foam / HighFoamer formulations, FoamResins and low viscosity injection resins deliver ultimate solutions for hairline cracks, gushing water leaks and many other water stop issues.
How Effective is Concrete Crack Injection for Leak Seal Projects?

Leaks in concrete structures can be permanently repaired with SealBoss concrete crack injection systems. We supply water-activated foams, gels, hydrophobic polyurethane resins, mechanical packers and injection pumps to create watertight seals.

Materials and Tools Used

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