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Dam Erosion and Sediment

Dam
Erosion and Sediment

Dam Erosion and Sedimentation Control
with Polyurethane Grout Injection Systems

Dam Erosion and Sedimentation Control with Polyurethane Grout Injection Systems

Introduction:

Dam erosion and sediment accumulation in dams present significant challenges, threatening their structural integrity and operational efficiency. Polyurethane grout emerges as an innovative, durable, and versatile solution to effectively address these critical issues. This article explores the advantages of polyurethane grout in managing erosion, sedimentation, and leak control, highlighting its essential role in ensuring the long-term safety and performance of dams.

Polyurethane Grout for Dam Erosion, Sediment, and Leak Control

Understanding Dam Erosion and Sediment Accumulation

Erosion occurs naturally as water infiltrates dams through cracks, joints, and fissures, gradually weakening concrete and soil structures. Additionally, incoming water carries sediment —soil, sand, gravel— which accumulates behind dams, significantly reducing reservoir capacity and placing increased structural stress on dam infrastructure.

Impacts of Erosion and Sedimentation

Structural Risks
Erosion compromises dam stability, potentially leading to structural failure. Sediment build-up exerts additional pressure on dam structures and impedes water flow.

Reduced Operational Efficiency
Sediment accumulation diminishes water storage capacity, adversely affecting flood control, hydroelectric power generation, irrigation, and drinking water supply.

Environmental Concerns and Safeguards

The environmental implications of dam leaks can be significant. Accumulated sediments disrupt downstream ecosystems and water quality, harming aquatic life and ecosystems by altering natural sediment flows and introducing contaminants. Leaks may carry contaminants into natural waterways. SealBoss Water Stop Systems featuring NSF-Certified Polyurethane Grouts can offer an environmentally safe solution for leak sealing, contributing to environmental sustainability.

Polyurethane Grout: A Robust Solution for Dam Erosion and Sedimentation

Polyurethane grout offers an effective, adaptable solution to combat erosion and sediment-related issues, significantly surpassing traditional methods. Its inherent flexibility allows it to accommodate the dam’s natural movements, maintaining a strong, watertight seal over time.

Benefits of Polyurethane Grout in Dam Applications

Versatility:
Suitable for concrete and earth dams, polyurethane grout is effective in crack injection, soil stabilization, permeation grouting, and sediment barrier formation.
Rapid Curing and Reduced Downtime:
Quick curing and hydro-active properties minimize operational interruptions, crucial for essential infrastructures such as hydroelectric power plants and water supply dams.
Economic Advantages:
Polyurethane grout’s long-term durability reduces maintenance costs, and rapid curing times help maintain continuous energy production, offering substantial cost savings.

Advanced Solutions from SealBoss for Dam Erosion and Sediment Control

SealBoss polyurethane grout injection systems deliver precise, reliable erosion control, leak sealing, and sediment management. Key applications include:

Polyurethane Soil Stabilization:
Injecting polyurethane resins stabilizes surrounding soils, mitigating erosion and preventing sediment influx.
Leak Sealing and Void Filling:
SealBoss products effectively address leaks and fill voids, reinforcing dam infrastructure and preventing further erosion and sediment-related damage.
Structural Reinforcement:
Polyurethane injection significantly enhances the structural integrity of dam walls and spillways, extending infrastructure lifespan and reliability.

Energy Efficiency and Environmental Protection

Leaks and erosion negatively impact dams’ energy generation potential. By sealing these vulnerabilities with polyurethane grout, dams maintain maximum energy output and protect against environmental harm, offering an environmentally safe, NSF-certified solution.

Best Practices for Effective Dam Maintenance

Dam owners and operators should adopt proactive strategies, including:

Comprehensive Inspection:
Regularly inspect and monitor for erosion and sediment issues.
Expert Consultation:
Engage specialists experienced in dam infrastructure.
Quality Materials:
Use high-quality polyurethane grout from reputable suppliers.
Professional Implementation:
Contract skilled professionals familiar with polyurethane grout applications.
Ongoing Monitoring:
Continuously assess effectiveness post-repair to ensure sustained performance.

Contact SealBoss for Expert Assistance

With decades of expertise in polyurethane grout technology, SealBoss offers specialized recommendations and connects you with experienced contractors skilled in dam repairs, including crack and joint sealing, curtain wall grouting, permeation and consolidation grouting, and injection waterproofing techniques.

Conclusion

Polyurethane grout injection systems present a comprehensive, durable, and economically viable solution to erosion, sediment accumulation, and leakage challenges in dams. Its versatility and effectiveness ensure long-term dam safety, structural integrity, operational efficiency, and environmental sustainability.

Call to Action

Enhance your dam’s safety and efficiency with SealBoss polyurethane grout solutions. Contact us at 714-662-4445 or via our Contact Form for tailored, expert-driven support in maintaining your dam’s integrity.

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Sealing Tie Holes

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

Introduction

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

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

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

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

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

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

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

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

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

Sealing Tie Holes and Cracks

A Case Study in Effective Water Tank Repair

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

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

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

Encountering the Challenge

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

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

The Training and Repair Process

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

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

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

Preparation and Injection

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

Hands-On Learning and Independent Operation

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

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

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

Ensuring Long-Term Success

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

Conclusion

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

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

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

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Sealing Tie Holes - Water Stop System

SealBoss ® 1510

Concrete Leak Sealing

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

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

SealBoss ® 15X ACCELERATOR

Accelerator for SealBoss Single Component Injection Foams

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

P2002 Injection Pump Standard

Polyurethane Injection

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

13-100AL Evolution

ALUMINUM MECHANICAL PACKER

Dimensions
1/2″ X 4″
13 x 100mm

13-100AL Evolution

Standard Packer

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

Bestseller – a SealBoss Standard

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Crack Injection Guideline – 1 2 3 at 45 Degree

Crack Injection Guideline
1 - 2 - 3 at 45 Degree

Injecting Trust - One Crack at a Time

Introduction

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

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

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

Optimal Techniques and Considerations

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

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

Injection Packer Spacing

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

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

Injection Packer Placement

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

45 Degree Angle Drilling and Packer Placement

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

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

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

Optimizing Drill Hole Distance from the Crack

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

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

Determining the Required Minimum Length for a Drill Bit

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

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

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

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

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

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

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

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

General Injection Packer Preparation – Drill and Flush

Safety Gear

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

Cleaning

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

Spacing

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

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

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

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

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

Exceptions to the 45 Degree Injection Rule – Straight Drilling

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

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

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

Drill Dust

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

Rebar

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

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

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

Flushing / Cleaning Drill Holes Prior to Injection

Overview

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

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

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

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

Drill Hole Water Flushing Detail

Low Pressure Flush

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

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

Using a Dedicated Flushing Water Pump

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

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

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

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

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

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

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

Final Thoughts

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

Additional Injection Packer Installation Recommendations

Mechanical Packer Fundamentals

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

Mechanical Packers Installation

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

SealBoss Hammer-In Ports

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

Packer Connectors

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

Zerk Type Connector

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

Button Head / Slide Coupler

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

SealBoss Packers

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

Injection Products

Before You Start Injection

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

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

Injection Procedure

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

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

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

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

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

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

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

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

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

SealBoss Oakum Soakum Technique

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

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

Quality Injection Job

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

Packer Removal

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

SealBoss R70 Pump Flush for Clean-up

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

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

Inquiries, Comments, or Requests?

Podcast | “Leak Sealing Polyurethane Crack Injection | Concrete / Shotcrete”
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Water Treatment Plant Maintenance

Maximizing Performance and Longevity

Water Treatment Plant Maintenance
and Water Reclamation Facility Solutions

Introduction

Water Reclamation District Maintenance and Water Treatment Plant Maintenance in general are the backbone of modern infrastructure, ensuring clean and safe water for consumption, sanitation, and industrial use. Effective, ongoing maintenance of these facilities is critical to maintaining continuous, efficient operations.

At SealBoss, we understand the importance of maintaining water reclamation districts and water treatment plants. We provide comprehensive solutions to address common challenges, such as leak sealing, crack repair, and water stop systems. By leveraging advanced technologies and reliable products, we help ensure the long-term integrity and functionality of water infrastructure.

Products such as SealBoss 1510 Original Water Stop Foam play a pivotal role in resolving these challenges. This hydrophobic, water-activated grout is highly versatile, suitable for applications such as leak sealing, hairline crack injection, and void filling. When combined with the IP-495 Injection Pump and BP-13-115S Packers, SealBoss 1510 ensures precise, effective repairs for various crack injection scenarios. The resin’s NSF drinking water certification further highlights its suitability for water reclamation district and water treatment facilities.

This article highlights maintenance practices and tools, emphasizing innovative solutions designed specifically to address critical challenges, including sealing leaks, repairing cracks, and installing effective water stop systems.

The Importance of Water Reclamation District and Water Treatment Plant Maintenance

Good maintenance and is critical for several reasons. It ensures the safety of reclaimed as well as treated water, prevents costly downtime, and extends the lifespan of infrastructure components.

Regular maintenance reduces the risk of leaks, structural damage, and system failures, which can disrupt water supply and compromise safety standards.

SealBoss Offers Specialized Training for Water Reclamation and Treatment Plant Maintenance Applications

Proactive maintenance is essential for ensuring structural integrity and operational efficiency in water reclamation and water treatment facilities. SealBoss injection solutions, such as the SealBoss 1510 Original Water Stop Foam, BP-13-115S Packers, and the IP-495 Injection Pump, are designed to tackle common maintenance issues such as leaking cracks and structural degradation.

By combining advanced technologies with comprehensive training, SealBoss supports facility teams in preventing system failure, reducing downtime, and extending the operational life of critical water treatment installations.

Key Challenges

Water treatment plants and water reclamation districts often face a range of ongoing maintenance challenges that necessitate regular maintenance:

Structural Cracks and Leaks: Over time, concrete structures in water treatment plants can develop cracks due to pressure, chemical exposure, and natural wear and tear. These cracks can lead to leaks, compromising the efficiency and safety of the plant.
Corrosion and Chemical Damage: Continuous exposure to chemicals and water can corrode metal components and degrade concrete, necessitating timely repairs.
Equipment Wear and Tear: Pumps, filters, and other equipment experience mechanical wear over time, leading to reduced efficiency and potential failures.
Environmental Factors: Fluctuations in temperature, seismic activity, and other environmental factors can impact the integrity of water treatment plant structures.

SealBoss Solutions for Water Reclamation District and Water Treatment Plant Maintenance

SealBoss provides comprehensive solutions tailored to the unique challenges of water containment maintenance. Our products and systems are designed to address cracks, leaks, and structural integrity issues effectively.

Pictures: Repairing Thickener Leaks at Water Reclamation District Facility

SealBoss 1510 Original Water Stop Foam

SealBoss 1510 Water Stop Foam is our most versatile and our best-selling chemical injection grout for stopping water leaks in most crack injection situations.

It is a hydrophobic water-activated, hydro-active water cut-off grout and foam seal grout based on an MDI polyurethane.

Mixed with 15x Accelerator, the resin is 100% solvent-free and 100% solids.

Product Highlights:

Hydrophobic, water-activated, hydro-active grout
Based on MDI polyurethane
Mixed with 15x Accelerator
100% solvent-free and solids-based

Applications include:

Crack Injection Foam: Seals cracks in concrete effectively.
Water Stop Foam: Ideal for stopping active water leaks.
Leak Sealing Foam: Provides durable and reliable leak sealing.
Concrete Repair Foam: Restores structural integrity.
Void Fill Foam / Filling Voids under Concrete Slabs: Stabilizes and fills voids under concrete.
Curtain / Bladder Injection Grout: Creates water-tight barriers.
Soil Stabilization Grout: Reinforces and stabilizes soil structures.
Hydrophobic Moisture Inert Structure: Offers resistance to water ingress.
Hairline Crack Seal Foam: Perfect for sealing fine, hairline cracks.
NSF Drinking Water Contact Foam: Safe for applications involving potable water.

Key benefits include:

Durability: SealBoss 1510 forms a permanent seal, preventing water ingress.
Versatility: Suitable for hairline cracks, larger voids, and various other applications.
Ease of Application: Efficient and controlled injection, minimizing downtime.

Pictures: SealBoss System Polyurethane Foam Grout Injection

System Solutions for Water Reclamation District and Water Treatment Plant Maintenance

SealBoss System Solutions: Injection Pumps & Packers

SealBoss InjectionPump System

SealBoss Injection Pumps, particularly the IP-495 Injection Pump, is a cornerstone of effective crack injection and leak sealing operations.

Engineered for reliability and precision, the IP-495 offers high-pressure performance necessary to handle a variety of polyurethane and epoxy injection applications. Its lightweight, portable design ensures ease of use in demanding environments like water treatment plants. The pump’s ability to deliver controlled and consistent material flow makes it an essential tool for achieving successful repairs with SealBoss products, such as the 1510 Water Stop Foam. By streamlining the injection process, the IP-495 significantly reduces downtime and enhances the efficiency of maintenance operations.

SealBoss Injection Packer System – Placement and Spacing

Proper packer placement is a cornerstone of effective crack injection. The spacing and positioning of SealBoss BP-13-115S Packers depend on the width and depth of the crack, ensuring even distribution of the injection material. SealBoss provides training and guidelines to help operators achieve optimal results, as demonstrated during the Clark County training session.

Total System Solutions

SealBoss’s Total System Solutions encompass a range of products and accessories designed to work seamlessly together. From injection pumps to packers and hydrophobic foams, our systems ensure reliable and efficient repairs. These solutions are available through a nationwide distribution network, making it easy for water treatment plants to access the tools they need for maintenance.

Video: Fine Crack Water Leak Sealing Repair with SealBoss PU Injection Systems

Best Practices for Water Reclamation District and Water Treatment Plant Maintenance

Effective maintenance requires a proactive and systematic approach. Here are some best practices to consider:

Regular Inspections: Routine inspections are essential for identifying potential issues before they escalate. Inspectors should check for visible cracks, leaks, and signs of wear and tear in concrete and metal components.
Proper Training: Training personnel in the use of advanced maintenance tools and techniques is crucial. The training session demonstrated the value of hands-on experience with SealBoss products.
Scheduled Repairs: Addressing minor issues promptly can prevent costly repairs and downtime. Products like SealBoss 1510 enable quick and effective crack repairs, minimizing disruptions.

Environmental Monitoring

Monitoring environmental factors such as temperature, humidity, and chemical exposure helps identify potential risks to the plant’s infrastructure.

Record-Keeping

Maintaining detailed records of inspections, repairs, and maintenance activities ensures accountability and helps in planning future maintenance schedules.

SealBoss’s Commitment to Excellence

At SealBoss, we go beyond providing products — we offer solutions designed to meet the rigorous demands of water reclamation and water treatment environments. Whether you’re sealing a hairline crack or stabilizing a larger structural issue, our systems are engineered for performance, longevity, and ease of use.

Why Choose SealBoss?

Proven Track Record – Over three decades of repairs in water treatment plants and water reclamation facilities.
Comprehensive Solutions –From crack injection to complete solutions.
Expert Support – Our team offers training and technical support to ensure successful implementation of our products.
Nationwide Distribution – SealBoss products are readily available through a nationwide network, making it easy to access the tools you need for maintenance.

The Future of Water Reclamation District and Water Treatment Plant Maintenance

As water treatment and water reclamation plants face increasing demands and aging infrastructure, the need for effective maintenance solutions will continue to grow.

SealBoss is at the forefront of innovation, providing products and systems that address the evolving challenges of the industry. By investing in regular maintenance and leveraging advanced tools like the SealBoss 1510 Water Stop Foam, water treatment plants can ensure their longevity and efficiency.

Conclusion

Ongoing maintenance is essential for keeping water treatment and reclamation systems safe, efficient, and compliant.

Even the newest structures require attention — and SealBoss is here to help.

With proven products, expert support, and nationwide access, we empower facilities to address problems early and build lasting reliability. Contact SealBoss today to learn how we can support your water treatment plant maintenance needs.

Together, we can protect your infrastructure — one repair at a time.

Concrete Wall Repair Epoxy System

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Injection

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Watertight Pipe Penetration Sealing

Guidelines for Pipe Penetration Waterproofing

Introduction

Waterproofing pipe penetrations is a critical task in maintaining the integrity of a structure housing utility systems. Ensuring that pipes and conduits passing through walls or floors do not allow water ingress is essential for preventing damage and maintaining safety, especially in environments with high moisture or any water exposure. This guide provides a comprehensive overview of the steps and techniques necessary for effective pipe penetration waterproofing and sealing.

It covers the basics of installing new or replacing failed water stops around existing pipe penetrations, utilizing a range of products and techniques to seal these areas effectively. Whether you are dealing with active leaks, dormant leaks, or the unwanted migration of pollutants or gases such as exhaust fumes, unsealed pipe penetrations and conduits require an understanding of the best sealing procedures for your specific situation, this guide, along with the expert assistance of SealBoss technicians, offers the knowledge and solutions needed to address these challenges confidently.

How to Replace failed Water Stop around existing Pipe Penetrations

Step 1: Clean the area – Begin by eliminating any old grout or deteriorated concrete from around the pipe penetrations. Ideally, remove material to a depth of at least 1″ and a width of 1/2″ all around the pipe’s circumference. In this demonstration, an air chisel was utilized adhering to the safety protocols outlined by the natural gas plant.

Step 2: Clear the debris – After the removal of old grout or concrete, it’s essential to thoroughly clean the area. Employ a brush, air blower, or vacuum cleaner to eliminate any remaining dust or loose particles.

Step 3: Initiate the repair process – Once the area is clean, you’re ready to proceed with the installation of the repair products. Your pipeline is now prepped for the restoration process to commence.

Utilizing Multiple Products and Techniques for Pipe Penetration Sealing

Using SealBoss Seal Oakum for pipe penetration waterproofing by following the “Oakum Soakum” technique with SealBoss Water Stop Foam 1510 / 1570 and Oakum.

Oakum Saturation with Foam Grout

Oakum Soakum Installation

The process starts by unwinding and snipping an adequate length of Oakum rope to encircle the part of the pipe where it breaches the wall. The installer will initially manipulate and expand the Oakum, augmenting its surface area for better adherence with the catalyzed resin.

Next, using a zip-top bag or a bucket, dispense a sufficient quantity of SealBoss 1510/1570 resin to comprehensively saturate the Oakum strand. Following this, add the desired 15x catalyst concentration of 5% – 20%, contingent on the intensity of the leak.

The catalyst ratio dictates the reaction time and expansion rate. For dormant leaks, we recommend a catalyst percentage of 5% to 10%, and for active leaks, a proportion of 10% to 20% is suggested. Our technical representatives are available for any queries related to catalyst ratios.

After thoroughly soaking the Oakum, swiftly wrap it around the pipe, manipulating the fibers to fill as much of the pipe penetration annulus as possible. This forms a gasket-like sleeve around the pipe. Spray the soaked Oakum with water to facilitate the foam’s catalyzation. Within moments, you’ll observe the foam starting to form and expand.

Upon the foam’s complete curing, consider the repair concluded successfully.

In areas of constant hydrostatic pressures it is often recommended to inject the circumferential void throughout the thickness of the wall using SealBoss 1510 or 1570 Water Stop Foam.
With the use of a SealBoss Grout Injection Needle and a low cost HP1500 Ultra Light Hand Gun or a HP 100 Hand Pump, the foam grout can be conveniently placed and injected into the void. Depending on the conditions at the jobsite, the injection can be performed following the ‘Oakum Soakum Procedure’, by penetrating the initial repair with the injection needle and inject SealBoss Water Stop Foam behind it.
For small jobs and pipe diameters, and for low cost applications where hand pump and injection needles are not feasible, SealBoss Can-Seal Foam can be used as a lower grade alternative.

Upon completion of the leak-sealing application, carefully remove any surplus cured foam protruding from the annulus to ensure a clean working area for the subsequent application of grout or mortar around the pipe penetration.

SealBoss SwellCaulk is a premium, single-component hydroactive sealant, specifically designed to expand upon contact with water, thereby creating a secure, watertight seal. This product is especially effective for repairing pipe and cable penetrations. For optimal results with SwellCaulk, apply a bead of an appropriate size around the pipe, extending it beyond the chipped area and up to two inches deep into the circumferential void. Upon exposure to moisture, this hydrophilic material initiates its expansion process, thereby effectively forming a watertight seal around the pipe.

Pipe Penetration Sealing Products

Which Pipe Sealing Procedure is Right for You?
Call Your SealBoss Technician

Should you have any inquiries regarding pipe penetration sealing, crack injection water stop methodologies, or any other injection-related procedures, do not hesitate to reach out to our team of proficient SealBoss representatives. We are more than happy to assist you.

In order to assist you in understanding our systems more effectively, we provide on-site visits along with practical, hands-on training sessions involving our injection systems.

Call us at 714-662-4445.

SealBoss Leak Sealing

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Leak-sealing

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Cold Joint Injection

Leaking Cold Joints Sealed

Cold Joints in Concrete Structures and the Polyurethane Polymer Solution

Introduction

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

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

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

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

What are Cold Joints?

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

Cold joints typically occur due to:

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

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

Cold Joint Injection: The Polyurethane Polymer Foam Solution

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

Why Use Polyurethane for Cold Joint Injection?

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

Benefits of polyurethane cold joint injection include:

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

Step-by-Step Cold Joint Injection Process

The cold joint injection procedure typically involves the following steps:

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

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

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

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

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

Advantages of SealBoss Cold Joint Injection Systems

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

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

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

Cold Joint Injection: An Investment in Longevity

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

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

Contact SealBoss for Expert Cold Joint Solutions

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

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

Considering a Solution for Sealing Cold Joints During Construction?

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

Materials and Tools Used

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

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Polymer Pump for Acrylate Gel Injection

Introducing the New and Enhanced SealBoss® IP2C Generation 2 Gel Injection Pump

A true pioneer in next-generation acrylate gel injection technology, the SealBoss® IP2C Gen 2 is crafted with meticulous attention to detail and a relentless commitment to innovation, longevity, and functionality. This professional polymer pump sets unprecedented standards in quality, performance, design, and ease of ownership, making it a leader in its class.

The SealBoss® IP2C Gen 2 is the epitome of modern engineering excellence, featuring a robust stainless steel pump body for unmatched durability, precision, and exceptional corrosion resistance. Equipped with a dedicated water flush pump, it is specifically designed for use with acrylate gel injection products, ensuring efficient and seamless operation.

This state-of-the-art polymer pump is more than just a tool—it is a cornerstone of efficient construction and repair work, providing the reliability and performance that professionals trust.

Optimal Compatibility and Use

The SealBoss® IP2C Gen 2 polymer pump is designed to work seamlessly with quality acrylate injection resins and a variety of buttonhead packers, which enhances its compatibility and utility across numerous applications.

We recommend pairing this polymer pump with our SealBoss Super Flexible Acrylate Gels and SealBoss Buttonhead Injection Packers to achieve the best results and performance.

Environmentally Friendly Cleaning with Water when used with Acrylate Injection Gels

Maintaining this polymer pump is straightforward and efficient. For short breaks in the injection process, the mixing head can be flushed using water via the dedicated flush pump, which includes a separate suction tube and flush pressure line. Users can easily switch the applicator handle to flush mode for this purpose.

After completing your injection tasks, it is crucial to perform a thorough cleaning of the entire polymer pump system. Simply place the suction hoses into a tank filled with flushing agent and operate the pump at a lower pressure setting. This cleaning regimen ensures that every component of the polymer pump is free from contaminants and ready for its next use, maintaining the system in optimal condition.

Comprehensive Package and Features

This comprehensive system includes a triple set of 15-foot high-pressure hoses coupled with an equally robust set of suction hoses, ensuring extensive reach and flexibility in various working environments. Each polymer pump component operates independently—two dedicated product component pumps and an independent water pump—culminating in a high-performance mixing head housed within the heavy-duty applicator. This setup ensures precise mixing and application, with a disposable plastic element static mixer that epitomizes ease of use and efficiency.

To prevent any possibility of cross-contamination between components, the polymer pump is equipped with sophisticated built-in check valves. An integrated high-pressure flush pump allows for straightforward cleaning of the mixing chamber through a separate flush line, ensuring that the system remains pristine even when work is momentarily paused.

Advantages of Using SealBoss® IP2C Gen 2 Polymer Pump

Enhanced Durability and Corrosion Resistance
The stainless steel pump units construction ensures longevity and resistance to corrosion.
High-Performance Mixing and Application
The independent pumping system and state-of-the-art mixing head deliver precise and consistent applications every time.
Ease of Maintenance
With integrated flushing systems and easy-to-follow procedures, maintaining this polymer pump is hassle-free.
Versatility
Suitable for a wide range of environments and applications, from simple repairs to complex construction projects.
Cost-Effectiveness
Minimize waste and maximize efficiency with precise application and reduced need for frequent repairs or replacements.

In Conclusion

The SealBoss® IP2C Gen 2 Gel Injection Polymer Pump is more than just a piece of equipment; it is a vital ally in the construction and repair industries, designed to meet the highest standards and tackle the toughest challenges. Whether you’re sealing foundations, repairing concrete, or handling intricate waterproofing projects, this polymer pump promises performance that professionals can depend on. Embrace the future of construction and repair with SealBoss® IP2C Gen 2, the ultimate polymer pump for your acrylate gel injection needs.

SealBoss 2400 Gel Injection System

Links to Leak Sealing with SealBoss Acrylate/Acrylic Super Low Injection System

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Sealing Pipe Penetration Water Leaks at Multi Family Apartment Complex

Sealing
Pipe Penetration
Water Leaks

Multi Family Apartment Complex

Introduction

Water intrusion through pipe penetrations in apartment complexes can lead to significant structural damage, safety concerns, and costly repairs if not addressed promptly.

At a newly constructed apartment complex, persistent water leaks from a courtyard into an underground parking structure posed a serious challenge.

The leaking water caused concrete staining, erosion, and fire-stop material damage, jeopardizing the integrity of the building.

To tackle these issues, a certified SealBoss installer implemented a comprehensive and effective solution to seal the pipe penetration leaks.

Using advanced chemical injection grouting techniques and specialized SealBoss products, the contractor successfully resolved the problem, ensuring a watertight seal around the pipe penetrations and restoring the structure’s integrity.

This article details the step-by-step process and products used to address these complex leaks, offering insights into effective pipe penetration sealing solutions for multi-family apartment projects.

Multi Family Apartment Pipe Penetration Leak Stop

A certified SealBoss installer was engaged to resolve water intrusion issues at a new apartment complex, where water from a courtyard was leaking into the underground parking structure. This water was causing staining and erosion of the concrete floor and soaking into the fire-stop material. Upon investigation, it was found that rainwater and the courtyard’s irrigation system were the sources of the leaks.

The contractor employed a three-step approach to inject SealBoss 1510 Water Stop Foam into and around the affected pipe penetrations, successfully sealing the most problematic leak points.

Horizontal Blanket Injection: This technique filled the voids between the geofoam and poured concrete, creating a barrier around each pipe penetration. The contractor drilled strategically through the concrete deck and into the geofoam, placing injection packers to form an effective seal.
Area Draining and Packer Installation: After draining the area, injection packers were placed for a targeted injection of hydrophobic foam, addressing the initial leak sites.
Penetration Sleeves Sealing: A few days later, new leaks were detected around the pipe sleeves. For larger metal sleeves, the contractor drilled at a 45-degree angle toward the sleeve and injected SealBoss 1510 Water Stop Foam until a positive refusal around the sleeve was achieved. To contain the expanding material, SealBoss CanSeal Foam was used as a temporary backing and also to fill the voids between the concrete and ribbed steel sheeting.

SealBoss ® CanSeal Utility Foam is a specially formulated closed cell sealing foam — engineered to fully expand inside the applicator ‘gun barrel’. When the foam exits the tip of the gun it is already fully expanded, enabling you apply exactly as much foam as you need without the messy and undesired “mushrooming” experience you may have with most of the other ‘over the counter’ foam products.

Small Pipe and Pipe Penetration Leak Sealing Kits

SealBoss SealPipe Kit

For smaller pipe penetrations with poly sleeves, a Grout Injection Needle was utilized to inject foam into tighter spaces. Open-cell backer rod was inserted into the sleeve to contain the resin as the needle was withdrawn, allowing SealBoss 1510 Water Stop Foam to expand upward, effectively sealing the poly sleeve and stopping the leak.

This comprehensive approach enabled the contractor to stop the leaks successfully. Following the repair, the building owner was advised to re-evaluate the courtyard’s irrigation system to prevent future water intrusion into the underground parking area.

Chemical Grouting Products Used

Grouting Pump Used

SealBoss P2002 – Electric Injection Pump

Call Your SealBoss ® Pipe Penetration Leak Sealing Specialist

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

Pipe Penetration Leak Sealing

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Pipe Seal

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Below Grade Waterproofing

Below Grade Waterproofing: Innovative Solutions for Complex Challenges

In the field of construction and building maintenance, below-grade waterproofing poses distinct challenges, particularly when addressing sensitive areas where direct access to the source of leakage is limited, and traditional crack injection methods for waterproofing are not feasible.

A recent case involving a below grade mechanical room with water intrusion issues highlights the innovative approaches and solutions available in today’s construction industry.

Polyurethane Polymer Gel and Foam Injection are effective methods to seal areas that are not easily accessible. With direct and indirect chemical grout delivery methods available, a wide array of below grade waterproofing problems can be resolved.

In this specific case grout injection lances were the delivery method of choice to combine waterproofing techniques such as soil permeation and consolidation grouting and curtain injection grouting to seal a subterranean mechanical room of a hospital.

Below Grade Waterproofing
Using Injection Lances and Polymer Gel

The Challenge: Water Intrusion in a Below Grade Mechanical Room

A mechanical room located below grade was experiencing water intrusion through shrinkage cracks and cold joints. The complexity of the situation was heightened by the fact that the problem could not be addressed from the negative side (inside the mechanical room) due to the placement of conduit and utility pipes. This scenario is not uncommon in below grade waterproofing projects, where access and space constraints often limit traditional repair methods.

Seeking Expert Solutions

In response to this challenge, the engineer overseeing the project reached out to SealBoss, a renowned name in the field of waterproofing and chemical grout injection solutions. SealBoss proposed a soil permeation and consolidation grouting and curtain injection grouting solution using SealBoss FlexGel hydrophilic polyurethane polymer leak sealing foam gel, a method well suited for this complex below grade waterproofing scenario.

The Process – Soil Permeation Injection and Consolidation Grouting with Injection Lances

Once the proposal was approved by all parties involved, the injection process began. The first step involved drilling cores to confirm the layout of below grade structures. During this phase, an unexpected utility bay was discovered, necessitating a modification in the layout of injection points to accommodate these below grade structures.

Installation and Injection Techniques

The installation process involved driving ½” soil injection lances into the core holes and installing female couplers to work with the custom applicator built by the contractor.

SealBoss Grout Injection Lances for soil permeation and consolidation grouting and curtain injection grouting.

This step was crucial for ensuring that the SealBoss FlexGel would be injected precisely where needed. Before the injection of FlexGel, each hole was initially flooded with water using a SealBoss IP495 Pump, specifically dedicated for water injection. This flooding was essential to suspend the strata below and prepare it for the FlexGel injection.

FlexGel Injection: Creating a Waterproof Barrier

Each hole received an initial injection of 3 gallons of water, followed by 1 gallon of FlexGel neat out of a separate dedicated SealBoss IP495 polymer injection pump. A final injection of up to 1 gallon of water through the designated water pump was then administered. During the FlexGel injection, the lance was lifted to create a vertical curtain, effectively wrapping around the found utility bay. Additional material was pumped below the elevation of the bay on either side to flood the cavity between the utility bay and the exterior of the mechanical room, creating a comprehensive waterproof barrier.

Results and Follow-Up

The initial injections were completed within a few hours, but additional cores had to be made to proceed further. A week after the installation, the area experienced heavy rains for three days. The hospital maintenance staff reported that the leak had subsided, marking a successful application of below grade waterproofing using the Curtain/Blanket Injection method with FlexGel.

Conclusion: Below Grade Waterproofing Success

This case study exemplifies the effectiveness of innovative below grade waterproofing techniques in addressing complex water intrusion issues. The use of FlexGel Hydrophilic gel in a Curtain/Blanket Injection method proved to be an efficient solution for a challenging situation, highlighting the importance of choosing the right approach and materials in below grade waterproofing projects. As the construction industry continues to evolve, solutions like these offer hope and reassurance for tackling even the most daunting waterproofing challenges.

Related Links

Below Grade Waterproofing - Water Stop System

SealBoss ® FLEXGEL

Leak Sealing Injection Gel
Hydrophilic Injection Foam Gel
Hydrophilic Gel

Versatile Hydrophilic Polyurethane Foam-Gel
Water activated single component hydrophilic Polyurethane grout. Reacts to a foam with 1 to 3 parts of water added and to a very flexible gel with 4 to 15 parts of water added (by volume). Drinking Water Contact meets NSF/ANSI 61 Section 5 requirements.

IP495 Pump

Polyurethane Injection Pump

Larger Projects, Extended Injection
Electric Motor
Piston System
2500 psi – 1 Comp.

Grout Injection Lances

STAINLESS STEEL

Dimensions
12″
36″
60″

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Leak Sealing Methods

Leak Repair Overview

Leak Sealing Methods

Introduction

This article provides an overview of various methods for sealing leaks in concrete structures, emphasizing the importance of choosing the right technique based on factors like leak severity, material compatibility, and environmental considerations.

It highlights the most common methods: crack/joint injection and curtain grouting, which are essential for maintaining the structural integrity of concrete structures including tunnels, dams, commercial buildings, and foundations in general. The article also explores other leak sealing methods and options like epoxy resin injection and swellable waterstop caulking and water activated, expanding polymer strip tapes, discussing their applications and effectiveness.

Key considerations for method selection are outlined, including the size and location of the leak, material compatibility, effectiveness, environmental impact, cost-efficiency, regulatory compliance, and long-term sustainability.

The conclusion underscores the necessity of a comprehensive understanding of these factors for making informed decisions that ensure the safety and longevity of concrete structures.

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Ensuring Integrity in Concrete Structures

Water leaks in concrete structures can pose significant challenges, necessitating a thorough exploration of leak sealing methods. The integrity of structures like tunnels, dams, and foundations depends on the effectiveness of these methods. This article delves into the various techniques available, their applications, and the factors influencing their selection.

Crack/Joint Injection and Curtain Grouting

Crack/joint injection and curtain grouting stand out as the most prevalent techniques for addressing active water leaks in concrete structures. These leak sealing methods are the first line of defense against water intrusion, providing immediate solutions to maintain structural integrity.

Crack/Joint Injection – A Focused Approach to Leak Sealing

Crack/joint injection is a precise method that involves injecting polyurethane grout into specific cracks or joints where water is actively leaking. This technique is renowned for its effectiveness in sealing everything from minor seepage to significant leaks across various concrete structures, including walls, foundations, and commercial parking structures.

Curtain Grouting – Creating Barriers Against Water Intrusion

For larger leaks or when the precise leak location is elusive, curtain grouting is the method of choice. This leak sealing method involves injecting grout in a pattern that forms a waterproof barrier, particularly behind tunnel linings, offering a robust solution to water ingress.

Epoxy Resin Injection – Strengthening and Sealing Combined

While epoxy injection is primarily used for structural repairs, it also serves as an effective barrier against water intrusion. However, its use as a water stop is limited in areas with very active leaks.

Epoxy resins, synthetic polymers known for their strong adhesive properties, are particularly useful for sealing leaks in a variety of structures. Their ability to bond with concrete, some metals, and wood makes them a versatile option in the leak sealing methods arsenal.

Swellable Waterstops – Expanding the Fight Against Leaks

Swellable waterstops are hydrophilic materials that expand upon contact with water, effectively sealing off leaks. These are commonly implemented in construction joints and are highly effective in segmented concrete tunnels and structures.

Key Considerations for Leak Sealing Method Selection

The choice of a leak sealing method is influenced by several factors

Severity and Location of the Leak
The size and accessibility of the leak are key in determining whether crack/joint injection or other methods like curtain grouting are appropriate
Material Compatibility
The compatibility between the sealing material and the structure, such as concrete linings in tunnels, is crucial. Polyurethane grouts are compatible with concrete, while epoxy resins are better suited for metal surfaces
Effectiveness
The method’s ability to seal the leak and prevent future occurrences is the foremost consideration
Environmental Considerations
In environmentally sensitive areas, such as near water bodies, the selection of eco-friendly sealing materials is imperative
Cost-Efficiency
Long-term costs, including maintenance and potential resealing, should be considered alongside the initial cost
Regulations – Compliance
It is essential to select a method that adheres to local regulations to avoid any legal issues
Long-Term Sustainability
The method should provide a durable solution to minimize the need for frequent repairs

Conclusion

Leak sealing methods extend beyond crack/joint injection and curtain grouting. A comprehensive understanding of material compatibility, leak severity, and environmental impact is essential in selecting the appropriate method. By considering these factors and the outlined criteria, stakeholders can make informed decisions that offer long-term benefits, ensuring the safety and longevity of concrete structures.

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