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Concrete Wall Repair

Structural Concrete Wall Repair with Epoxy Injection

Introduction

Concrete walls are integral to the structural stability of countless buildings and infrastructure projects. Over time, however, even the most robust walls can develop cracks due to factors such as settling, weather conditions, and material fatigue. These cracks compromise structural integrity, safety, and longevity, necessitating timely and effective repair solutions.

Epoxy injection systems have emerged as a gold standard in addressing these challenges, offering precision, durability, and cost-effectiveness. By filling cracks and restoring the original strength of concrete, these systems prevent further damage and extend the life of the structure. This article discusses the transformative impact of epoxy injection technology, exploring a major structural repair project that highlights the efficiency and reliability of SealBoss systems in concrete wall repair.

Concrete Wall Repair using Structural Epoxy Resins

Massive Concrete Wall Repair: Advanced Solutions with Epoxy Injection Systems

Structural integrity is vital for the durability and safety of any concrete wall, whether designed for soil retention, seawall protection, or other applications.

Cracks represent one of the most significant threats to this stability, as they can undermine both the strength and longevity of the structure if not promptly addressed. Effective concrete wall repair not only restores structural soundness but also prevents further damage and potential failure. Epoxy injection systems offer precision, efficiency, and long-term durability, making them a premier solution for concrete crack repair. This article explores the application of SealBoss epoxy injection systems in a major structural repair project, showcasing the effectiveness of these advanced systems.

Project Overview: Prestigious Estate Repair

A prestigious estate in Texas faced a significant structural challenge: Several thousand feet of cracks in a major concrete retaining wall. Addressing this critical issue required an immediate and effective concrete wall repair solution to ensure the wall’s long-term stability and safety. An experienced epoxy injection contractor leveraged SealBoss’s epoxy injection technology to deliver outstanding results in this high-profile project.

Step-by-Step Approach to Concrete Wall Repair

Preparation Phase

Thorough preparation is essential for successful concrete crack repair. For this project, the preparation phase spanned an entire week. During this period, the team:

Set Injection Ports: Several thousand surface-mounted tribase ports were strategically installed along the length of the cracks to serve as controlled entry points for the epoxy injection.

Applied SealBoss 4500 Epoxy Paste: This high-performance paste was used to seal the surface of the crack and secure the ports. Its strong adhesion ensured a reliable barrier, preventing leakage during the injection process.

Injection Process

After completing the preparation, the team began the injection stage using the SealBoss P3003-2C pump. This state-of-the-art pump, designed for high-pressure injection, ensured efficient and controlled delivery of SealBoss 4040 epoxy resin deep into the crack. Remarkably, the entire injection process was completed in just 25 minutes, demonstrating the efficiency of SealBoss systems for concrete wall repair.

Materials Utilized

The success of this project relied heavily on the quality and compatibility of the materials used. Key components included:

SealBoss P3003-2C Pump: A dual-component injection pump that ensured precise mixing and application of the epoxy resin.
Static Mixers: These devices ensured uniform mixing of the epoxy components for consistent performance throughout the process.
Surface-Mounted Tribase Ports: Several thousand ports were used to treat the crack effectively, providing targeted delivery and maximizing repair outcomes.
SealBoss 4040 Epoxy Resin: This low-viscosity resin penetrated deep into the crack, offering exceptional strength, durability, and chemical resistance.
SealBoss 4500 Epoxy Paste: Used to secure the ports and seal the crack’s surface, this paste contributed to the long-term durability of the repair.

Key Features of SealBoss Epoxy Injection Systems

SealBoss epoxy injection systems provide a host of features that make them ideal for addressing structural issues in concrete walls:

Low-Viscosity Penetration

SealBoss epoxy resins are designed to penetrate even the finest cracks, ensuring comprehensive sealing and structural bonding. This is particularly effective for narrow and deep cracks that are otherwise difficult to address.

High Compressive and Tensile Strength

Once cured, SealBoss epoxies offer exceptional mechanical properties, restoring the original strength and load-bearing capacity of the concrete structure. This makes them suitable for high-stress applications.

Chemical Resistance

SealBoss epoxy systems are resistant to a wide range of chemicals, including oils, fuels, and solvents. This ensures long-term performance in environments subject to chemical exposure.

Cost-Effective Solutions

By extending the lifespan of the structure and minimizing the need for extensive demolition and reconstruction, epoxy injection systems offer a cost-effective alternative to traditional repair methods.

Video: Concrete Wall Repair with SealBoss Epoxy Injection Systems

Why Choose Epoxy Injection for Concrete Wall Repair?

Epoxy injection has become the gold standard for concrete crack repair due to its many advantages:

Restoration of Structural Integrity: Epoxy effectively bonds concrete components, returning the structure to its original strength.
Prevention of Further Damage: Properly sealed cracks prevent water infiltration, reducing the risk of corrosion, freeze-thaw damage, and chemical deterioration.
Versatility: Epoxy injection systems can address a wide range of crack widths and depths, making them suitable for various applications.
Efficiency: Advanced equipment like the SealBoss P3003-2C pump ensures quick and precise application, reducing downtime.

Long-Term Benefits of Epoxy Injection Systems

Prolonged Lifespan of Structures

By addressing cracks early and effectively, epoxy injection systems significantly extend the lifespan of concrete walls and other structures.

Enhanced Safety

Restoring structural integrity ensures that the repaired wall can continue to bear loads safely, reducing the risk of failure.

Environmental Benefits

Epoxy injection minimizes waste and resource use by repairing, rather than replacing, damaged structures. This makes it an eco-friendly option for concrete wall repair.

Lessons from the Major Structural Concrete Wall Repair Project

This case study provides valuable insights into best practices for concrete wall repair:

Thorough Preparation is Key

Detailed preparation, including the proper placement of surface ports and the use of high quality non sag and quick cure epoxy paste, ensures a seamless injection process and optimal results.

Advanced Equipment Makes a Difference

The SealBoss P3003-2C pump’s light weight, ease of operation, two component ratio precision, and reliability played a crucial role in the project’s success, demonstrating the importance of high-quality tools.

Material Quality Matters

Using premium products like SealBoss 4040 epoxy resin and 4500 epoxy paste ensures correct setting times, suitable viscosities, durability and long-term effectiveness.

Conclusion

Concrete wall repair, as demonstrated in this major structural repair project, benefits significantly from the precision, efficiency, and durability of epoxy injection systems. SealBoss’s advanced materials and equipment, combined with skilled execution, offer a proven solution for restoring and preserving concrete structures. Whether addressing minor cracks or significant structural damage, SealBoss epoxy injection systems provide an effective and reliable pathway to long-term stability and safety. For contractors and engineers seeking efficient, cost-effective solutions, epoxy injection stands out as a best-in-class method for concrete crack repair.

SealBoss ® 4040 LV

SealBoss Highest Quality Epoxy Standard

Injection Epoxy Resin
Multi-Use Epoxy Resin

4040 low viscosity, 100% solids, hi-mod, 2-component, moisture-tolerant, low-viscosity, high strength, multi purpose, epoxy injection resin adhesive

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4500 F

SealBoss Highest Quality Epoxy Standard

Fast Cure Epoxy Paste

Epoxy paste products for surface repairs, to prepare cracks for resin injection, and to bond SealBoss surface ports. 4500 NSF Drinking Water Approved Formula available.

– Commercial Bulk Packaging
– Cartridge System

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

SURFACE PORT

Epoxy Injection Port – Industry Standard Bestseller

Durable plastic design surface mounted port suitable for epoxy injections. Tri-Base design with perforation holes for best possible adhesion with SealBoss 4500 Epoxy Paste Adhesive. Caps included. For EP grouts.

Bestseller – a SealBoss Standard

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

P3003-2C PUR & Epoxy Pump

High & Low Pressure
Epoxy & Polyurethane Injection Piston System

Versatile,
Pumps Epoxy & PU Resin
Electric Drill Operated
Dual Piston System
5000 psi
2 Comp.
Ratio: 2:1 standard, 1:1 custom

Concrete Wall Repair Epoxy System

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Injection

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Bridge Crack Repair

Structural Epoxy Injection with Professional Equipment

Structural Epoxy Injection & Equipment for Bridge Crack Repair

Bridges, crucial for transport and commerce, often face damage from harsh environments and heavy traffic, leading to cracks and structural issues.

A cost-effective solution is crucial for maintaining bridge safety, and structural epoxy injection has become a popular method to repair cracks and restore integrity without expensive replacements.

Structural Epoxy Injection & Equipment for Bridge Crack Repair

Bridges, crucial for transport and commerce, often face damage from harsh environments and heavy traffic, leading to cracks and structural issues.

A cost-effective solution is crucial for maintaining bridge safety, and structural epoxy injection has become a popular method to repair cracks and restore integrity without expensive replacements.

Bridge Crack Repair:
Enhancing Structural Integrity with Advanced Epoxy Injection Solutions

Bridges serve as vital arteries for transportation and commerce, constantly bearing the brunt of heavy traffic and exposure to harsh environmental conditions. Over time, this wear and tear can lead to cracks and other structural issues that compromise their integrity. Addressing these problems promptly is critical for ensuring public safety and the longevity of these essential infrastructure elements.

When it comes to repairing bridge cracks, contractors and engineers are turning to cost-effective and efficient solutions like structural epoxy injection. This technique has proven to be an industry-standard for restoring the structural integrity of bridges without the costly and time-consuming process of complete replacements.

Structural Epoxy Injection:
A Reliable and Cost-Effective Solution for Bridge Crack Repair

Structural epoxy injection is a cutting-edge method that involves injecting specially formulated epoxy resins into cracks. These resins fill and bond the gaps, significantly enhancing the strength and stability of the entire structure. Let us explore why epoxy injection is a preferred solution for bridge crack repair.

Structural epoxy injection offers several benefits, including:

Cost-effectiveness: By utilizing structural epoxy injection, unnecessary expenditures on demolishing and rebuilding can be avoided. This approach cuts down on both material and labor costs, making it a budget-friendly solution.
Time savings: Compared to traditional repair methods, structural epoxy injection is significantly faster, leading to minimal disruptions and reduced downtime for bridge traffic.
Versatility: Whether the bridge is made of concrete, steel, or masonry, epoxy injection can effectively repair a wide range of structural materials, making it a versatile choice for diverse bridge designs
Improved strength and structural performance: Beyond simply repairing existing cracks, epoxy injection e3nhances the overall performance of the structure by improving load-bearing capacity of the bridge and providing resistance to future environmental stressors and wear.

Professional Equipment for Successful Bridge Crack Repair

Achieving optimal results in bridge crack repair relies heavily on utilizing professional-grade equipment. SealBoss offers a comprehensive suite of tools and materials to ensure precision and efficiency in structural epoxy injection projects.

SealBoss PA3000 Epoxy Injection Pump

The SealBoss PA3000 epoxy injection pump stands out as a pneumatic powerhouse designed for handling extensive bridge crack repair projects and many linear feet of structural epoxy injection per day. With a large stainless steel reservoir and dual-component capabilities, it delivers a continuous flow of epoxy for uninterrupted injection.

Key features of the SealBoss PA3000 epoxy injection pump include:

User-Friendly Design: Designed with ease of operation in mind, minimal training is needed for contractors to operate this pump efficiently, reducing setup time and increasing productivity.
High performance: Capable of maintaining consistent epoxy delivery throughout the day, the pump enables seamless and efficient crack repairs, especially in high-traffic areas.
Versatility Across Applications: The SB PA3000 can be used for various applications, including crack repair, bonding, and sealing in bridges, tunnels, dams, and other critical civil engineering infrastructures
Durability for Harsh Conditions: With robust construction and a modular design, the SealBoss PA3000 is built for easy maintenance and to withstand tough worksite conditions, ensuring long-lasting reliability.

SealBoss Epoxy Injection Ports

SealBoss® Epoxy Injection Ports provide versatile, durable solutions for various epoxy crack injection needs. Engineered to integrate seamlessly with SealBoss Epoxy systems, they support manual, pneumatic, pump, cartridge, and high-pressure applications. Designed to handle rough surfaces, corner cracks, and high-pressure scenarios, these ports offer specialized options like angled and round base designs for efficient and reliable performance.

Key Benefits of SealBoss Epoxy Injection Ports include:

Versatile Design: Four durable port designs for varied conditions.
Comprehensive Compatibility: Supports manual, pneumatic, pump, cartridge, and high-pressure injection methods.
Specialized Solutions: Angled ports for corners and round base ports for shallow drill holes.
Reliable and Efficient: Seamlessly integrates with SealBoss systems for optimal performance.

Montana Department of Transportation
A Real-World Example: Montana DOT Bridge Crack Repair Restoration Project

The Montana Department of Transportation (DOT) has recently released an extensive work plan covering multiple bridge restoration initiatives, which involve the use of structural strength epoxy resin systems for crack injections.

A leading construction firm was tasked with the responsibility of executing these repairs. The project entails the injection of structural epoxy resin into specified cracks utilizing the SealBoss Epoxy Injection System.

The core elements of this repair strategy included:

SealBoss 4040 LV Structural Epoxy Resin: A low-viscosity, structural strength resin formulated for deep penetration into narrow cracks.
SealBoss 4500F Crack Seal and Port Setting Paste: Ensuring secure adhesion and setting of injection ports.
SealBoss Tri-Base Surface Mount Injection Ports: Facilitating precise injection of resin into targeted areas.
SealBoss PA3000 Epoxy Injection Pump: Delivering consistent and reliable performance throughout the project.

During this project, SealBoss regional manager Chris Conderre conducted a detailed on-site training session covering the operation and maintenance of the SealBoss PA3000 epoxy injection pump.

The training also emphasized the correct usage of accessories such as static mixers, Tri-Base Plastic Epoxy Injection Surface Mount Ports, and all connecting equipment required establishing a flawless union between the applicator and the substrate.

Conclusion

Reliable Bridge Crack Repair Solutions for the Future

Bridge crack repair using structural epoxy injection is a cost-effective and dependable approach that meets the needs of modern infrastructure maintenance, contractors and engineers.

By employing advanced equipment like the SealBoss PA3000 epoxy injection pump, along with high-quality materials such as the SealBoss 4040 low viscosity structural epoxy resin and the SealBoss 4500F crack seal and port setting paste, contractors can achieve exceptional repair results while minimizing downtime and costs.

Furthermore, proper training and education on the usage of these advanced tools and techniques are critical in achieving the desired outcomes.

As the demand for reliable and cost-effective bridge crack repair solutions continues to grow, it is essential for contractors and engineers to stay updated with the latest advancements in technology and materials. By adopting innovative methods like structural epoxy injection and utilizing state-of-the-art equipment, industry professionals can ensure the longevity and safety of bridges and other vital infrastructure components.

In summary, bridge crack repair using structural epoxy injection and advanced equipment like the SealBoss PA3000 epoxy injection pump offers numerous benefits. By adopting solid injection techniques and professional equipment, contractors and engineers can ensure the safety, reliability, and longevity of bridges and other critical infrastructure components, ultimately benefiting the communities they serve.

Structural Epoxy Injection System Products Used

By leveraging these innovative techniques and equipment, contractors can confidently tackle bridge crack repair projects, reinforcing the durability and safety of crucial transport infrastructure for years to come.

Related Links

SealBoss Surface Mount Epoxy Port Selection

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Epoxy Crack Injection Concrete Repair

Epoxy Crack Injection
Concrete Repair

Epoxy Concrete Crack Injection Systems

Epoxy Crack Injection Resin can mitigate problems of cracked concrete with larger and fine cracks. ACI specifies cracks widths that are acceptable in structures under defined conditions. ACI 224R-012 provides a guideline for crack widths for reinforced concrete under service loads for new construction. Crack widths deemed acceptable may range from 0.004 in. (0.1 mm) to 0.016 in. (0.41 mm), and even smaller widths for concrete in wet or aggressive environments. These crack dimensions would be considered fine and hairline cracks.

Pushing the Envelope – SealBoss Epoxy Systems
– Resins, Pastes, Injection Ports and Pumps –

Epoxy Crack Injection

Cracking does not always affect structural performance, but it can adversely affect the durability of structures.

Common causes of concrete cracking are post cure and drying shrinkage, thermal stress, chemical reaction caused by alkali-reactive silica & sulfates, freezing and thaw cycles due to water expansion, corrosion of steel rebar, settlement, load stresses, construction short comings such as design and construction errors.

The incorporation of steel reinforcement within structural concrete allows these elements to function under both compression and tension, frequently resulting in tension-induced fracturing of the concrete in certain regions.

Water is a major contributor to concrete corrosion in parking garages, bridges, industrial facilities and more. Water, chloride and carbon dioxide can migrate deep into the structure initiating corrosion of the reinforcement structure.

Water ingress, facilitated by fissures or compromised joints, often carries corrosive substances and chlorides that contribute to the degradation of concrete and the corrosion of steel reinforcements and rebar. Fortunately, epoxy concrete crack injection can address many of these concerns in structures exhibiting signs of such issues. Employing a proficient concrete repair team can frequently circumvent the need for a complete teardown.

SealBoss Epoxy Resins

SealBoss Epoxy Crack Injection resins for structural crack repairs conform to ASTM C881 specifications, with appropriate viscosities for the crack widths. The bond strength of epoxy to clean concrete is greater than the tensile strength of concrete itself.

Wider cracks may require a higher viscosity epoxy, small cracks a lower viscosity injection resin. Depending on the requirements, viscosities may range from approximately 150 to 600 cps at room temperature.

SealBoss Epoxy Crack Injection concrete repair can be performed with SealBoss Epoxy Cartridge Systems or SealBoss epoxy bulk resins using air guns, hand-actuated delivery systems, or dual-component injection electric or air-driven pumps.

Prior to repair, the structure must be carefully examined to establish that epoxy crack injection is indeed the correct method to regain the desired structural integrity. The cause of cracking must be determined. Cracks must be identified and the allowable crack width needs to be established. The width of cracks can be measured by using crack gauge cards. In some instances it may be recommended to measure the expansion and contraction cycles of a crack. To determine the depth and cause of cracking, core samples can be taken and examined by petrographic and chemical testing. In addition, nondestructive testing (NDT) ultrasonic pulse velocity can be used to measure the depth of cracks.

Once it has been established that epoxy concrete crack injection is the chosen method of repair, the SealBoss Epoxy Injection System can be utilized to restore the structural integrity of the concrete.

SealBoss ® Surface Mount Injection Ports

Surface-mounted injection ports are typically adequate for injecting most cracks. However, badly deteriorated concrete or higher injection pressures may require the use of drill-in or hammer-in plastic ports or even mechanical packers. Surface ports, aka plastic tubing ports, are glued on the surface over the open cracks using SealBoss epoxy paste adhesive. The injection ports are typically installed at a spacing that is equal to or slightly narrower than the depth of the crack. Hairline cracks require closer spacing than wider cracks.

Wire brushing and vacuuming the crack surface along the crack is often sufficient for surface preparation. In areas of badly deteriorated concrete, pressure washing, grinding, and V-grooving may be specified.

After the surface has been cleaned, surface ports are installed. Sealboss 4500 crack-sealer epoxy paste will be used as surface port adhesive and be applied on the face of the crack between and around the ports.

Once the injection ports are installed, Sealboss 4500 crack-sealer epoxy paste is applied on the face of the crack between and around the ports. To contain the epoxy resin in the crack until it hardens, it is a good practice to seal cracks on all sides of the substrate if possible.

Begin the Epoxy Crack Injection at the Point of the Structure

As soon as the epoxy appears at the next higher port, the current port is capped and the injection is continued from the next port. Multi port injection may be used in most epoxy injection environments. Typical injection pressures are between 50 to 100 psi (3 to 6 bars), with very fine cracks requiring pressures of over 200 psi (12 bars).

Epoxy resins are temperature sensitive. At higher temperatures resin viscosity decreases, but reaction time increases. For best performance during application, it is advised to keep the resin at room temperature or slightly above during injection.

After the injection resin has cured, the epoxy paste adhesive is removed from the surface of the concrete.

Quality assurance and control measures include visual observation of the injection process and product consumption, testing the injection equipment for mix ratio, taking core samples and testing repaired cracks using nondestructive testing methods.

Epoxy Crack Injection System – Epoxy Resins, Ports, Pumps

SealBoss epoxy injection system solution.
Ranging from epoxy resins and structural epoxy gels to injection ports and two component epoxy pumps.

SealBoss ® 4040 LV

SealBoss Highest Quality Epoxy Standard

Injection Epoxy Resin
Multi-Use Epoxy Resin

4040 low viscosity, 100% solids, hi-mod, 2-component, moisture-tolerant, low-viscosity, high strength, multi purpose, epoxy injection resin adhesive

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4050 SLV

Super Low Viscosity Epoxy Resin

4050 super low viscosity, 100% solids, hi-mod,
2-component, moisture-tolerant, low-viscosity, high strength, epoxy injection resin adhesive

– Commercial Bulk Packaging
– Cartridge System

SealBoss ® 4500 F

SealBoss Highest Quality Epoxy Standard

Fast Cure Epoxy Paste

Epoxy paste products for surface repairs, to prepare cracks for resin injection, and to bond SealBoss surface ports. 4500 NSF Drinking Water Approved Formula available.

– Commercial Bulk Packaging
– Cartridge System

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

SURFACE PORT

Epoxy Injection Port – Industry Standard Bestseller

Bestseller – a SealBoss Standard

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

1/2" EPOXY DRILL HOLE / HAMMER-IN PORT

‘BELOW’ SURFACE PORT

Epoxy Injection Drill Hole Mount Port

Durable plastic port designed to fit 1/2″ drill hole for higher injection pressures than regular surface ports. Suitable for epoxy injections. Caps included. For EP grouts.

1/2" EPOXY DRILL HOLE / HAMMER-IN PORT

PA3000 The Epoxy Pump Standard

High & Low Pressure
Epoxy Injection & Polyurethane Injection

Top of the Line – Professional Use
Pumps Epoxy & PU resin
Pneumatic
850 psi
2 Comp.
Ratio: 2:1 Standard, 1:1 custom

P3003-2C PUR & Epoxy Pump

High & Low Pressure
Epoxy & Polyurethane Injection Piston System

Versatile,
Pumps Epoxy & PU Resin
Electric Drill Operated
Dual Piston System
5000 psi
2 Comp.
Ratio: 2:1 standard, 1:1 custom

SealBoss ® Epoxy

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epoxy

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Epoxy Injection Preparation Tips

Introduction:

Epoxy injection is a highly effective, polymer delivery method through a pumping system for repairing cracks in concrete structures. This process involves sealing all accessible sides of a crack and bonding them with a high and strength, low-viscosity epoxy resin by pressure injection.

Proper preparation is crucial for successful epoxy injection. It begins with cleaning the crack thoroughly, surface sealing the crack, and installing surface mount Tri-Base ports along the crack at specific intervals with a fast setting, non-sag epoxy paste. Following these preparation steps ensures the epoxy resin can penetrate and bond the cracked concrete effectively, restoring its structural integrity in the process.

Epoxy Injection Preparation Tips – Installing Surface Mount Tri-Base Ports

Epoxy Injection is a typically a low pressure to medium pressure crack filling solution where all sides of the crack are sealed and structurally glued together with a high strength low viscosity Epoxy Resin.

To prep for injection, the crack must be cleaned with a wire brush and all dust removed. Any surface contaminants, such as oils or paints, must be removed for the epoxy paste-over to bond properly. If available, use clean compressed air to remove any dust and debris. For best results perform epoxy injection preparation when the crack and surface are dry. Any water seeping from the crack should be stopped prior to epoxy injection. For sealing water bearing cracks click here.

Once the surface is cleaned, the Surface Mount Epoxy Injection Ports are installed directly over the crack 6” – 8” (15-20 cm) apart. The finer the crack, the narrower the spacing should be.

Shown in this example are standard surface mounted Tri-Base ports, however corner ports and ½” drill in ports are available for specific applications.

Tri-Base Ports are mounted by placing epoxy on each of the three tabs on the base of the port. Once ports are placed, the non-sag paste is applied to both sides of the wall, sealing the crack.

When applying paste, the mixed material should be applied generously at roughly 1/8” (3-4 mm) thickness, and mounded up around each port to approximately 1/4″ (6-7 mm) thick or more using a putty knife or other suitable tool. The paste-over should be a minimum of 1 inch (3 cm) wide along the crack. If the paste is not applied thick enough it may crack and epoxy will escape during injection, preventing proper penetration and epoxy flow within the crack itself. Note: The length of time needed for the epoxy paste to fully cure varies with ambient and substrate temperature.

“ Once ports are placed, the non-sag paste is applied at roughly 1/8” thickness and mounded up around each port. If the paste is not applied thick enough it may crack open and epoxy will escape during injection. “

SealBoss Technical Support Team

After the surface paste has hardened, structural strength epoxy resin can be injected starting at the lowest port on the crack, for horizontal or lateral cracks start on one side and work your way over.

Because the crack has been sealed on both sides, the next port in line will need to have the cap removed to allow the displaced air to escape. Once the Epoxy resin can be seen escaping from that next port injection stops, the applicator is disconnected from the injected port and the port is capped.

The applicator is then connected to the next port and the process is repeated. Once the crack has been fully injected and the Epoxy resin has cured, ports and paste can be ground off for aesthetics.

Epoxy does not Flow as Expected – Troubleshooter

Injected crack is not continuous or the area being injected is saturated
Crack is blocked by debris or cured epoxy paste
Surface mount port does not align with the crack
Epoxy has cured in injection nozzle, port or crack
Epoxy resin viscosity too high

Epoxy injection is an efficient and economical method of repairing cracks in structural concrete walls, slabs, columns and piers. If applied in compliance with all recommendations and specifications, high strength epoxy is capable of restoring concrete structures to their strength prior to crack development.

If at any time during your epoxy injection preparation and any other repairs you encounter issues that can’t be resolved, please call us here at SealBoss for support – 714-662-4445. Your technical representative will gladly be of assistance.

At SealBoss, we offer full system solutions for Structural Epoxy Injection Repairs including Electric and Pneumatic Pumps, various Ports, Epoxy Resins, Paste and Cartridge System.

SealBoss ® EPOXY

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Epoxy Prep

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Plastic Surface Mount Injection Ports | Epoxy Injection Ports

Plastic Surface Mount Injection Ports
Epoxy Injection Ports

SealBoss ® Surface Port Advantages

Four Durable Plastic Port Designs to Suit Jobsite Conditions
Epoxy Pressure Crack Injection
Cartridge Injection with Low Pressure Zerk Type System
Rough | Uneven Surface Epoxy Crack Injection
Corner Crack Injection
High Pressure Epoxy Injection

Why should I use SealBoss Plastic Surface Mount Injection Ports?
– More Choices

Our quality surface mount epoxy injection ports are expertly designed to meet a wide array of jobsite application challenges. They are meticulously engineered to integrate flawlessly with the entire range of SealBoss epoxy injection systems. This comprehensive compatibility includes:

Handheld manual gun injection: Ensuring ease of use and precision for smaller applications
Pneumatic gun injection: Facilitating efficient and consistent application pressures and flow
Epoxy pump injection: Offering robust performance for large-scale and demanding applications
Cartridge injection: Providing a convenient and quick solution for smaller or more detailed repair tasks
High-pressure zerk coupler connected epoxy injection: Catering to high-pressure scenarios requiring utmost reliability and strength.

These ports are the epitome of versatility and reliability, ensuring that no matter the system or application requirement, our solution seamlessly aligns with your project needs, enhancing efficiency and effectiveness.

Challenging Application?
– We have You Covered

SealBoss surface ports are designed to cover typical application conditions including smooth, rough and uneven concrete surfaces, corner injection and high pressure epoxy injection.

In addition to the standard Tri-Base port, we offer 90 degree base angled ports designed for corner crack injection and 1/2 inch (13mm) round base plastic ports for shallow drill hole recessed port injection.

Using High Epoxy Injection Pressures?

– Go BIG

Our plastic surface port with zerk fitting can be equipped with either a regular high pressure or a low pressure injection zerk fitting to suit your needs for epoxy pump or epoxy cartridge injection. Equipped with a large base, this port provides a massive adhesion contact surface when glued to the concrete substrate, providing superior stability for higher injection pressures where needed.

1/4 EPOXY PORT | TRIBASE PORT
SURFACE PORT

1/4 EPOXY CORNER PORT
NOZZLE

1/2" EPOXY DRILL HOLE
HAMMER-IN PORT

BIG PLASTIC SURFACE PORT
WITH ZERK

Most epoxy crack injection is performed with the use of surface mounted injection ports. The port is glued to the concrete surface with SealBoss 4500 epoxy paste adhesive. Our nozzle type injection ports have a perforated base to increase the surface for the adhesive to hold on to the port and provide a secure connection between port and substrate.

Our zerk type surface port with extra large base plate takes surface port injection to another level. Now you can use high pressure zerk coupler equipped injection equipment with a surface mounted port for better connection security and higher injection pressures.

Please don't hesitate to contact us here at SealBoss for more information about our extensive packer selection. Your representative will be happy to assist.

We provide on-site support and training in eight Southern States for all SealBoss System Solutions.

Technical Sales Team

Surface Injection Ports

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EP Ports

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Epoxy Injection in Cold Weather

Cold Weather
Epoxy Injection Training

Epoxy Injection in Cold Weather

Inclement weather can often pose challenges in the concrete repair and waterproofing industry where applications often rely on the reactive cure of chemical grouts, such as polyurethane foams, gels and epoxy resins.

This cold Thursday morning was no exception to the rule. During a mock-up epoxy injection training an impending cold front was on its way toward Oregon and Washington states, resulting in unusually cold temperatures. However, when a crew needs to receive proper technical training on Sealboss Systems, the show must go on.

We Provide Training in All Conditions

A week prior to the training we wanted to make sure that we were prepared so that everybody in attendance could get the most out of the experience. We proactively sent an email to the contractor requesting that they provide the ancillary items necessary to make the training as efficient and effective as possible.

One of the items requested was a focused source of heat in the way of a heat gun. We were very pleased to see that they were prepared with two heat guns which enabled them to speed up the setting process for the crack seal paste. When chemistry is at play, temperature is a very important factor. In almost all cases, heat will speed up reactions between different chemicals.

In cold weather it is critical to precondition the epoxy resins to room temperature prior to use. Epoxy resins may not react below 35-45°F, but will begin to cure again once the temperature rises. A heat gun can be used to warm up the concrete surface prior to installing surface mounted ports and to increase the temperature of the installed epoxy adhesive to approximately 100°F or 40°C to initiate the exothermic reaction and speed up the cure time. Take care to avoid heating the surface or epoxy to over 130°F or 55°C .

While there are many things out of everyone’s control such as the weather, those things that are in our grasp ought to be executed to the best of everyone’s ability thanks to the preparedness from all members involved with this session, the team was able to benefit from and learn the basics as it relates to structural epoxy injection all the way from port setting to clean out of the pump.

Please inquire about training opportunities with your local SealBoss representative.

We are standing by to do what we can to make sure your teams have the requisite knowledge to be successful when it comes to using SealBoss Systems.

Specified – Epoxy Resin and Polyurethane Grout

- Specified -
Epoxy Resin and Polyurethane Grout

Repairs at Water Treatment Plant
Sealing Active Leaks in Filter Gallery and Associated Basins Sealed

Overview

At a Texas Water Treatment Plant, active leaks in the filter gallery and associated basins were expertly sealed using specified polyurethane grout and epoxy resin. This article delves into the methods and products used to achieve this.

Active Water Leak Repair
Specified Product: Polyurethane Grout

The engineering team recommended using Hydrophobic Injection Foam Grout, administered through high-pressure injection equipment, to address all pipe penetrations in the filter gallery and specifically identified cracks with active leaks.

For the Water Stop Injection phase, the SealBoss 1510 Water Stop Foam NSF/ANSI 61 was selected and endorsed as the ideal solution for sealing the cracks effectively.

Structural Strength Repair
Specified Product: Epoxy Resin

Per the guidelines and specifications set by the engineering firm, the holding basins were emptied, and cracks were treated using a low-viscosity Structural Epoxy, applied at reduced pressures.

For reinforcing the structure, the combination of SealBoss 4040 and the 4500F non-sag adhesive paste was chosen and recommended.

Training and Expertise

SealBoss dispatched a technical expert on-site to guide the contractor in utilizing both injection techniques. The training encompassed the use of the approved SealBoss Injection Systems. This included the SealBoss P2002 high-pressure, single-component injection pump, equipped with mechanical injection packers, and the SealBoss PA 3000 low-pressure system, which operates at a 2:1 ratio and features surface-mounted injection ports.

SB P2002 Pump – Injection Kit

SB PA3000 Pump System

Repair Method

Water Stop and Leak Sealing with Polyurethane Grout

The SealBoss P2002 injection pump was employed for the Water Stop injection, paired with SealBoss 1/2 inch aluminum and 5/8 inch stainless steel Injection Packers for effective grout delivery.

In the filter gallery section, packers were strategically positioned approximately 12 inches apart and 4 inches away from the pipe sleeve/annulus, encircling the pipe. For the designated cracks set to be filled with the SealBoss 1510 Hydrophobic Foam Grout, injection packers were spaced between 8 to 12 inches apart, adhering to the 1, 2, 3, 45 Degree Injection Guidelines.

Injection continued on the cracks until the emergence of the SealBoss 1510 water stop foam was clearly observed on the crack’s surface, indicating a successful fill.

Epoxy & Polyurethane Repairs

Pipe Penetration Injection

Structural Repair with Epoxy Resin System

Before initiating the injection process, the water basins were drained and dried in preparation.

The SealBoss PA3000, our professional, heavyduty pneumatic two-component epoxy pump, was utilized for the low-pressure Epoxy Injection phase. This pump was set-up to a 2:1 pumping ratio, aligning with the SealBoss 4040 LV Structural Epoxy’s 2:1 mixture ratio.

Cracks were meticulously traced, and surface-mounted ports were affixed 6 to 8 inches apart, positioned directly above the crack. These ports were securely anchored using the SealBoss 4500F Quick Seal Epoxy surface adhesive.

After the 4500F adhesive set, the 4040 LV epoxy was methodically injected into the ports. The process began from the lowest port and progressed upwards, leaving the subsequent vertical port open to ensure and verify seamless port-to-port flow.

Pre-Repair Inspection

Water Bearing Cracks

Products Used

Hydrophobic, High-Pressure Injection System

Injection Grout: SealBoss 1510 NSF/ANSI w/ 15x Accelerator

Injection Packers: 1/2” Aluminum Packers & 5/8” Steel Packers
High Pressure Pump: P2002 Single Component Injection Pump
Cleaning Material: SealBoss R70 Pump Flush
Xylene, rags, bucket
Tools: 18” x 1/2″ drill bit & 18” 5/8” drill bit, 3/8” Crescent Wrench
Dead Blow Hammer, Hammer Drill, Access 110v Power, Vacuum, various tools
Structural Epoxy, Low Pressure Injection System

Injection Resin: SealBoss 4040 LV Structural Epoxy

Surface Anchoring Paste: SealBoss 4500F Quick Seal Paste
Injection Ports: Surface Mount Tri-base Ports
Low Pressure Pump: PA3000 2:1 Dual Component Injection Pump
Cleaning Material: SealBoss R70 Pump Flush
Xylene, rags, bucket
Tools: Air Compressor, Angle Grinder with Diamond Wheel, various tools

If you have any questions on Specified Epoxy Resins and Polyurethane Grouts, please contact our team of qualified SealBoss representatives.

Schedule an on site consultation & full injection systems training.

Call us at 714-662-4445.

SealBoss Epoxy & PUR Systems

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Specified

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Vehicular Barrier Wall – Bumper Wall Repair

Vehicular Barrier Wall / Bumper Wall Repair

Epoxy Dispensing Systems

An Overview to Vehicular Barrier – Bumper Wall Crack Repair in Parking Garages Using the SealBoss P3003 Epoxy Injection Pump and SealBoss Surface Mounted Tri-Base Epoxy Injection Port System

Maintaining the integrity and safety of parking structures is paramount, specifically the vehicular barriers or bumper walls. These walls play a significant role in preventing accidents, thereby ensuring the protection of property and human lives.

Over time, due to various factors such as stress, wear and tear, or movement of reinforcing lateral cables causing additional forces, these barriers often develop structural and shrinkage cracks. This is where the technology of epoxy injection comes to the rescue.

The Damage: Cracked Vehicular Barriers

Cracks can be a source of structural weakness in parking garage bumper walls. They may compromise the strength and stability of the barrier, leading to potential safety hazards. Additionally, moisture seeping through these cracks can cause the steel reinforcement to corrode and the concrete to spall, igniting a vicious cycle of accelerating deterioration.

The Answer: Epoxy Injection

Epoxy injection presents itself as a proven, cost-effective method to repair cracks in structures. The technique involves the injection of a low-viscosity epoxy into the cracks. The injected epoxy fills the void and, once cured, can restore the structural integrity and strength of the concrete structure, warding off further damage.

The Tools: Epoxy Dispensing System

Proven reliability and cost-effectiveness, the SealBoss P3003 Epoxy Injection Pump and SealBoss Surface Mount Tri-Base Ports exemplify a professional solution for epoxy pressure dispensing.

Scope: Inject Structural Cracks on Exterior Vehicular Barrier Wall

Professional Epoxy Dispensing System:
SealBoss P3003 Epoxy Injection Pump & SealBoss Surface Mounted Tri-Base Ports

A successful epoxy injection process relies heavily on the right equipment. The SealBoss P3003 Epoxy Injection Pump and SealBoss Surface Mounted Tri-Base Ports are precisely designed to manage such repairs. Specifically, the P3003 pump is custom-designed with a 2:1 ratio feature in mind, or, if needed, a 1:1 ratio conversion, vital for most structural epoxies, providing optimal curing and strength characteristics.

Procedure: Repairing Cracks with Epoxy Injection

The epoxy injection process kicks off by preparing the crack for repair. Any loose concrete or debris within the crack is removed, the paint is grinded off, and the surface is cleaned thoroughly. For fine shrinkage cracks, the contractor chases the cracks out to allow for proper material travel during injection.

Connectors: SealBoss Tri-Base Ports

The SealBoss Surface Mounted Tri-Base Ports are strategically installed along the crack. Acting as a connector between the injection machine or dispenser, they are placed directly over the crack, and a non-sag, fast setting epoxy paste is built up around the port to ensure a proper seal that can hold pressure.

1/4 EPOXY PORT | TRIBASE PORT
SURFACE MOUNTED PORT

SURFACE PORT

Epoxy Injection Port – Industry Standard Bestseller

Durable plastic design surface mounted port. Tri-Base design with perforation holes for best possible adhesion. .

Dispenser: SealBoss P3003 Epoxy Pump

Having completed the preparation phase, the SealBoss P3003 Epoxy Injection Pump is effectively engaged as the device for dispensing the epoxy. This allows for the precise injection of the epoxy resin into the existing cracks through the strategically placed ports. The process starts at the lowest port on a vertical crack or the first port on a horizontal crack. Epoxy is injected until it begins to appear at the next port, signifying that the section of the crack between the ports has been filled. The injection process then proceeds to the next port, repeating the process until the entire crack has been repaired.

Once the epoxy has cured, the ports and the surface seal are removed. The result is a structurally sound bumper wall, restored to its original strength and durability.

P3003-2C PUR & Epoxy Pump

Versatile,
Pumps Epoxy & PU Resin
Electric Drill Operated
Dual Piston System
5000 psi
2 Comp.
Ratio: 2:1 standard, 1:1 custom

Conclusion

The fusion of the SealBoss P3003 Injection Pump with the SealBoss Surface Mounted Tri-Base Port connection system, complemented by superior-quality epoxy polymer resin, forms an efficient solution for concrete injection tasks.

Designed to address a wide variety of concrete repairs, its capabilities extend well beyond fixing vehicular barriers in parking garages, providing a robust system for an extensive range of concrete structures.

It is always advisable to engage professionals experienced with epoxy injection techniques to ensure the most effective and optimal results for these critical repairs.

Additional SealBoss Surface Ports and Epoxy Pumps

1/4 EPOXY CORNER PORT

Epoxy Injection Corner Port

Durable plastic design corner surface port suitable for epoxy injections. Corner base design with perforation holes for best possible adhesion.

1/2" EPOXY DRILL HOLE / HAMMER-IN PORT

Epoxy Injection Drill Hole Mount Port

Durable plastic port designed to fit 1/2″ drill hole for higher injection pressures than regular surface ports.

PA3000 The Epoxy Pump Standard

Top of the Line – Professional Use
Pumps Epoxy & PU resin
Pneumatic
850 psi
2 Comp.
Ratio: 2:1 Standard, 1:1 custom

PA5000 Epoxy Pump

Top of the Line – Professional Use
Pumps Epoxy & PU resin
Pneumatic
1000 psi
2 Comp.
Ratio: 2:1 Standard, 1:1 custom

SealBoss Epoxy Injection System

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Foundation Crack Epoxy Injection – Transmission Towers

Foundation Crack Epoxy Injection - Transmission Towers

Epoxy Injection System Kits and Specialized Training

Our expert Technical Team is adept at offering training in the field of foundation crack repairs, specifically using the epoxy injection method with SealBoss 4040 Epoxy Resin, 4500F Epoxy Paste Adhesive, SB Surface Mount Plastic Ports, and the convenient, easily-operated SealBoss P3003 Epoxy Injection Pump. All these elements are provided at a reasonable cost to contractors through the Pro P3003 Epoxy Injection Starter Kit, offering affordability without compromising the quality.

Structural Pylon Footing Repair

Highly specialized contracting companies with a unique skill set are charged with constructing and installing transmission towers for power lines across California’s inland regions where renewable energy sources are developed at a rapid pace. With wind turbines and solar farms increasingly dotting the hilltops in California, the enhancement of renewable energy necessitates a robust infrastructure consisting of sturdy electricity transmission towers and well-distributed power lines.

Yet, the challenging weather conditions, which can include sandstorms, frosty snowstorms, and extreme temperature fluctuations, pose a significant threat to the structural integrity of the concrete supports that uphold this infrastructure.

Restoring Structural Integrity – Foundation Crack Epoxy Injection for Infrastructure Repairs

To counter these challenges, specially trained repair crews are commissioned to restore the structural integrity of concrete foundations and footings for the electricity transmission pylons that support overhead power lines spanning across California’s Central Valley.

The design of the pylon footings can take cylindrical or rectangular shapes, and cracking can manifest horizontally or vertically. Regardless of the orientation or size of these cracks, SealBoss Epoxy systems are proficiently designed to repair, mend and restore the concrete to its predetermined integrity.

Presenting the SealBoss Structural Infrastructure Repair Systems

Among several options, the compact Sealboss P3003 Electric Epoxy Pump Pro-Kit is a popular choice. This system encompasses high-strength, low-viscosity 4040 epoxy resin, quick-setting odourless SealBoss 4500 paste adhesive, surface mount ports with perforated tri-base legs, and the impressively portable, lightweight P3003 epoxy injection machine.

The P3003 epoxy injection system comes standard with a 2:1 ratio by volume setup, with the option for a 1:1 ratio conversion. The system also incorporates the capability to pump SealBoss Polyurethane Water Stop Foams and Leak-Seal Resins. Additional Epoxy pumps, including the large job professional PA 3000 pneumatic epoxy injection machine, are also available for selection.

Epoxy Injection Procedure Outline

Identify and Assess Cracks:
Inspect the concrete foundation for visible cracks and micro fissures. Assess the size, orientation (horizontal or vertical), and depth of each crack.
Prepare the Epoxy Materials:
Condition the SealBoss 4040 Epoxy Resin and the odorless SealBoss 4500 Epoxy Paste adhesive to the appropriate temperatures, especially in cold conditions to ensure a faster set time.
Apply Paste Adhesive:
Apply the SealBoss 4500 Epoxy Paste over the cracks to serve as a surface seal. This paste also acts as an adhesive for the SealBoss Tri-Base surface mount plastic ports.
Install Injection Ports:
Position and install the SB Surface Mount Plastic Ports along the length of the cracks, ensuring secure fastening. These ports should come equipped with caps to prevent epoxy resin back-flow.
Inject the Epoxy Resin:
Once the adhesive paste is set, begin the injection process. Using the SealBoss P3003 Epoxy Injection Pump, inject the low-viscosity SealBoss 4040 Epoxy Resin into the cracks at the lowest speeds, just enough to move the epoxy resin into the crack and allow for continuous flow and deep penetration of the material.
Use SealBoss 4050 SLV for Micro-cracks:
For extreme micro-cracks, consider using SealBoss 4050 SLV super low viscosity epoxy to ensure deep penetration into these smaller cracks.
Monitor the Injection:
Watch for the epoxy material to appear in the next port, indicating sufficient filling of the current crack and time to cap the port and move onto the next.
Curing:
Allow enough time for the epoxy resin to cure fully within the cracks, restoring and reinforcing the structural integrity of the concrete foundation.
Finish the Surface:
After the material has fully cured, grind off the ports and smooth down the surface to achieve the desired look and finish.

These procedures should be done carefully and patiently, keeping in mind that the main goal is to ensure a completely sealed and controlled environment for the epoxy to set up properly.

Foundation Crack Epoxy Injection | Transmission Towers – Procedures

To manage the structural integrity, hairline cracks and micro fissures in the concrete foundations are injected with low viscosity SealBoss 4040 epoxy resin. The odourless SealBoss 4500 epoxy paste serves as a surface seal and adhesive for SealBoss Tri-Base surface mount plastic ports equipped with caps to prevent epoxy resin back-flow. For operations in cold conditions, it is advised to precondition the epoxy products to warmer temperatures to facilitate a quicker setting time. When the environment is cold and time permits, mounting the surface port and applying the crack paste a day prior to injection can ensure an appropriate seal around the cracks and good port adhesion to the concrete substrate.

Once the ports are securely fastened and the paste adhesive has set, injection can commence. By using the lowest speeds on the P3003 epoxy pump, sufficient to push epoxy resin into the crack, it allows for continuous flow and deep penetration of the material through the crack.

In situations where SealBoss 4040 epoxy resin, a low viscosity 2:1 material is used for most crack dimensions, SealBoss 4050 SLV super low viscosity can penetrate even deeper, reaching into the farthest corners of extreme micro-cracks.

Once the material is visible in the subsequent port, it serves as a signal to halt the application, cap the port, and proceed to the next one. The primary principle of epoxy injection is to maintain a completely sealed and controlled environment to allow the epoxy to set up and restore the structural integrity of the concrete.

After the epoxy has fully cured, contractors can remove the ports and smooth down the surface to achieve the desired aesthetic look.

Request the Best – Comprehensive System Solutions and Tailored Training from SealBoss

SealBoss specializes in providing comprehensive system solutions designed to restore and preserve the structural integrity of infrastructures. Our solutions are engineered to protect structures from environmental damage including water intrusion, corrosion, and damage from seasonal frost expansion.

Our complete Pro-Kit systems are user-friendly and designed for quick deployment, capable of getting a crew operational in just a few hours.

SealBoss’s on-site training is also available to ensure your project is executed correctly and achieves success. Our commitment to delivering superior-quality service, coupled with our product innovation and industry expertise, makes us a trusted partner in the infrastructure repair and maintenance sector.

Relevant Epoxy Injection Links

SealBoss Structural Repair Epoxy

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Two Component Epoxy Applicator | Anti Return Valve System

How to Use
SealBoss Two Component Epoxy Applicator

This SealBoss® Epoxy Injection Pump Two Component Applicator Gun is equipped with two high pressure quality shut-off ball valves and two anti return valves to prevent material backflow. The applicator system is designed for use with Plastic Static Mixers of various dimensions.