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Dam Spillway Leak Sealed

Dam Spillway Leak Sealed

SealBoss 1510 Polyurethane Foam

SealBoss 1510 Leak Sealing Application

What is the Purpose of a Spillway in Dams?

A spillway serves a critical function in dam systems. Either incorporated into the dam’s structure or built adjacent to it, a spillway facilitates the controlled and secure discharge of surplus water downstream.

Introduction

Spillways play a critical role in safely managing excess water in dam systems. Over time, leaks can develop in cold joints and cracks, posing structural risks and operational challenges. Traditional repair methods often fall short—especially under high water pressure.

SealBoss 1510 Water Stop Foam offers a reliable solution. Its hydro-active, expanding polyurethane formula penetrates deep into leaking areas, sealing active water flow and forming a durable, watertight barrier. This article highlights a successful spillway leak repair using Water Stop Foam, demonstrating its effectiveness where other methods failed.

SB 1510 Polyurethane Foam in Dam and Spillway Leak Sealing

Dam Spillway Leak Sealed with Advanced Polyurethane Foam Injection

When it comes to critical infrastructure, few challenges are more pressing than water intrusion in dams. One of the most effective solutions available today is SealBoss 1510 Water Stop Foam, a high-performance, hydro-active polyurethane product. This case study and technical overview demonstrate how a dam spillway leak was sealed using SB 1510 polyurethane foam, offering a lasting and economical solution.

Why Polyurethane Foam for Dam and Spillway Leak Repairs?

Polyurethane foam is widely respected for its low viscosity and superior adhesive properties, making it ideal for sealing active water leaks in dam and spillway structures. Its hydro-reactive nature enables it to expand on contact with water, effectively filling cracks, joints, and voids — even under high-pressure flow.

When injected into a leaking dam or spillway, the foam penetrates deeply into fissures and gaps. It reacts quickly with water, expands, and cures into a solid, waterproof barrier. This process forms a robust seal that prevents further water ingress and strengthens the surrounding substrate.

How Dam Spillway Leaks Are Sealed Using SealBoss 1510

The leak remediation process begins with drilling holes along the affected cold joints or cracks in the dam spillway. Mechanical injection packers are then installed, allowing SealBoss 1510 to be injected precisely where needed. The foam expands rapidly within the concrete structure, bonding to the substrate and stopping the leak at its source.

After curing, the foam forms a permanent repair that is resilient, flexible, and capable of withstanding ongoing hydrostatic pressure—making it one of the best solutions when a dam spillway leak must be sealed quickly and reliably.

Case Study: Dam Spillway Leak Sealed After Multiple Failed Repairs

Background: Persistent Cold Joint Leak

SealBoss was contracted to repair a leaking cold joint in a dam spillway—one that had already failed four previous repair attempts. Prior caulking had eroded due to continuous water pressure, allowing active leakage through the “V” notched joint. With increasing water infiltration, the situation called for a proven, robust method to get the dam spillway leak sealed once and for all.

Step-by-Step: Leak Sealing with SB 1510 Water Stop Foam

  • Surface Prep and Joint Access
    Technicians began by removing loose and deteriorated caulking to fully expose the leaking joint. Drill holes were made adjacent to the joint, and active water flow confirmed correct placement.

  • Oakum Soakum Technique
    To immediately address the gushing leak, the team applied the Oakum Soakum method using SealBoss 1500 Seal Oakum saturated with SealBoss 1510 and accelerated with 15x Accelerator for fast reaction and curing. The oakum was placed directly into leaking crevices to form an initial water block.

  • Injection Packer Installation
    Next, 13-100 AL mechanical packers were installed in a staggered vertical pattern, based on SealBoss’s 1 – 2 – 3, 45 – Degree Injection Guidelines. Strategic spacing ensured coverage while avoiding rebar interference.

  • Polyurethane Injection
    Using the SealBoss P2002 injection pump, catalyzed SB 1510 foam was injected starting from the lowest packer. Controlled pauses allowed the resin to expand fully, minimizing waste while maximizing penetration.

Result: Dam Spillway Leak Sealed with Lasting Effect

All leaking joints were successfully sealed. The high-pressure, active leaks were stopped effectively, and the structure’s integrity was restored. This application proved once again that SealBoss 1510 polyurethane foam is a powerful tool in dam and spillway leak sealing.

Conclusion

If you’re facing persistent water intrusion, cracks, or joint failures in spillway structures, getting the dam spillway leak sealed properly is critical.

The SealBoss 1510 Water Stop Foam injection system provides a fast, durable, and cost-effective repair method—even under high-flow conditions.

This proven technology not only stops active leaks but also extends the life of dam infrastructure. As this case study demonstrates, polyurethane grout injection is the gold standard for dam and spillway maintenance.

Ready to get your dam spillway leak sealed?
Contact SealBoss today at 714-662-4445 or visit our website to connect with an expert and find the right solution for your project.

Contact Your SealBoss ® Technician

Concrete Leak Sealing

Concrete Leak Sealing

Guide to Concrete Leak Sealing:

Polyurethane Grout vs. Hydraulic Cement & Crystalline Waterproofing

When it comes to repairing and reinforcing concrete structures against leaks, not all solutions are created equal. Each method has unique strengths and is suited to specific conditions, making it essential to choose the right approach for long-lasting results. This guide provides a detailed comparison of three popular options—polyurethane grout, hydraulic cement, and crystalline waterproofing—highlighting their advantages, limitations, and ideal applications to help you make an informed decision.

A Product Comparison

Hydraulic Cement, Crystalline Waterproofing, and Polyurethane Grout

Hydraulic cement, crystalline waterproofing, and polyurethane grout are distinct material groups, each with its own merits and uses. The choice between them should be a strategic decision guided by the requirements of your project.

Understanding Hydraulic and Crystalline Systems

Hydraulic cement and crystalline waterproofing solutions are often utilized due to their cost-effective nature and straightforward application process. They find common use in below-grade concrete structures like parking garages, basement walls, and manholes, where their primary role is to coat surfaces or seal leaking cracks, preventing water infiltration.

Despite their utility in surface-level repairs for static structures, these products share a key limitation – their inability to form a flexible seal that penetrates the depth of the structure. This makes them somewhat akin to ‘band-aid’ fixes – temporary, surface-level solutions.

Their limitations become particularly evident in the face of structural movement, including thermal expansion and contraction of substrates. Such movements often lead to the re-emergence of leaks over time, creating a cycle of recurring repairs. These patchwork solutions, although effective in the short term, can prove to be a less sustainable choice in the long run.

Polyurethane Grout: A Dynamic Solution

For structures prone to any movement over time, including expansion and contraction of materials, polyurethane grout outshines its service applied counterparts. The long-term benefits of polyurethane grout injection often justify the investment.

Let’s consider an illustrative example: a substantial concrete structure, such as below grade wall or potable water tank, several feet thick and reinforced with rebar, that has developed a crack.

In cases where the leak is not too severe – keeping in mind that polyurethane grout injection is the preferred, and often only method for handling aggressive or gushing leaks – a surface patch solution like a hydraulic cement or crystalline system could be employed to halt a minor leak initially.

While this approach may provide temporary relief, it falls short in addressing the fundamental problem – the unending cycle of water infiltration, migration, and trapped moisture within the structural fissures and crevices. The unresolved water intrusion not only propagates moisture migration throughout the structure, but it may also expose the reinforcing bars (rebar) to corrosive effects. This corrosion can lead to expansion, creating additional stress on the concrete structure, potentially worsening the initial problem.

Here is where polyurethane grout shines – Full depth penetration concrete leak sealing

With a full-depth injection of polyurethane grout, you can not only disperse any water inside the structure and seal the entire volume of the crack, but also safeguard the rebar in the process, eliminating the threat of future corrosion. The penetrating and water dispersing ability, flexibility, and durability of polyurethane grout make it an ideal solution for preventing future leaks. Unlike surface patch solutions, it offers a comprehensive, long-term resolution to the issue.

The Role of Structural Movement in Permanent Leak Sealing

The effectiveness of hydraulic cement and crystalline waterproofing significantly diminishes when it comes to dealing with structural movement. This is particularly evident in dynamic below grade concrete structures like parking garages, which experience thermal cycles, vibration due to heavy traffic, and may additionally be situated on expansive soil. Moreover, its high elasticity makes it perfect for application in areas prone to constant vibrations or expansions, like bridges, highways, and large commercial buildings. The recurring nature of leaks due to movements necessitates a structure penetrating and permanent solution: A professional polyurethane grout injection concrete leak sealing system.

The Final Word:

Making an Informed Choice

Selecting the right materials for your concrete leak sealing repair needs is crucial. The long-term benefits of polyurethane grout often make it a superior choice, especially for structures prone to any movement. Unlike its counterparts, it can withstand significant structural movement over time without losing its sealing capabilities. 

As a trusted provider, we’re dedicated to guiding your decisions with reliable, professional, and detailed information tailored to your needs. Remember, making the best choice now will save you time and resources in the future.

Related Articles

Concrete Leak Sealing

Leak Sealing 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.

Concrete Leak Sealing

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

Flexible Polyurethane Injection Foam
Flexible Foam, Water-Activated chemical grout. 

Concrete Leak Sealing

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

Super Low Viscosity Polyurethane Injection Foam,
Water-Activated chemical grout. Drinking Water

Concrete Leak Sealing

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.

Rigid, High Strength, SlabLifter & Void Fill Foam
Two component polyurethane foam with structural qualities to stabilize, lift and cut-off water. Fast reactive formula to gain strength within minutes. 

– Commercial Bulk Packaging
– Cartridge System

Related Chemical Grouts

SUPER LOW VISCOSITY
Poly Acrylate Chemcial Grout Gel
Hydrophilic poly-acrylate gel / acryclic gel for soil stabilization, curtain-injection, infusion bladder injection into structures and to seal degrading masonry grout.

Contact Your SealBoss ® Technician

Chemical Grouting

Chemical Grouting

Understanding Chemical Grouting

Chemical grouting is a cutting-edge technique that has been gaining traction in various industries over the past decades, primarily for its prowess in addressing a myriad of structural, environmental, and geotechnical challenges. Often, these challenges are intertwined with issues of water migration or infiltration.

The Power of Polyurethane Chemical Grout

At the heart of this process are polyurethane chemical grouts, a potent polymer material that springs to life upon contact with water. This interaction activates the grout’s hydro-active properties, prompting it to expand and solidify. The result? A robust, watertight barrier and seal for concrete structures that can also be used to fortify loose, granular soils in geotechnical applications. Given its versatility, it’s no wonder that these grouts are the go-to solution for a diverse set of building structure and soil related repair scenarios.

Acrylate Gel Chemical Grouts: The Ultra Low Viscosity Solution

Then there’s the acrylate gel chemical grout, known for its exceptionally low viscosity. This characteristic allows it to seep into the tiniest of cracks and loose soils with remarkable efficiency. Once settled, it transforms into a flexible and resilient gel, making it a prime choice for some challenging water sealing and soil stabilization scenarios demanding the super low viscosity properties of the injection grout.

Your Quick Guide to Chemical Grouting

Chemical grouting is an innovative process employed across various industrial sectors to rectify or prevent a wide array of structural, environmental, and geotechnical issues, often – but not always – correlated with water migration or water infiltration.

Navigating the world of chemical grouting can be daunting, given the plethora of grouting agents on the market. However, a few stand out for their unparalleled efficacy and adaptability:

  • Water-Activated, Hydro-Active Polyurethane Chemical Grouts: These are your best bet for creating strong barriers or solidifying soils.

  • High-Strength Two-Component Water-Blown Polyurethanes: Known for their strength, they’re a reliable choice for demanding applications.

  • Super Low Viscosity Acrylate Gels: Ideal for situations requiring a fine touch, these gels are both effective and adaptable.

In essence, each of these grouting agents brings a unique set of benefits to the table, making them indispensable tools in the realm of chemical grouting.

Types of Chemical Grouting Polymers

In broad terms, there are Two Categories of polyurethane grouts:

  • Flexible polyurethane grouts: These grouts are often used to fill voids and cracks in the soil or structure, creating an impermeable, flexible seal that can withstand slight movements without cracking.

  • Rigid polyurethane grouts:Typically used for soil stabilization and lifting concrete slabs, these grouts solidify into a strong, durable material capable of bearing significant loads.

Applications of Polyurethane Chemical Grout

With its diverse properties, polyurethane chemical grout finds applications in a wide range of scenarios. Here are some of its most common applications:

Sealing and Waterproofing

Polyurethane chemical grout serves as an excellent waterproofing agent. It creates an impermeable barrier that prevents water infiltration, making it an ideal solution for:

  • Tunnel and Dam Sealing: Polyurethane grout is often used to seal leaks in tunnels and dams. 

  • Below Grade and Foundation Waterproofing: Polyurethane injection grout is used to effectively seal basements and foundations. The products are used for crack injection and curtain and stage grouting techniques to seal structures permanently.

Ground and Soil Stabilization

The grout is injected into the soil, where it expands, displacing loose soil and filling voids. It then solidifies, creating a stable, durable mass that strengthens the overall structure.

  • Seawall Repair: Polyurethane grouting is an effective solution for filling voids and stabilizing soil behind seawalls, reducing the risk of further washouts and damage to structures.

  • Permeation and Consolidation Grouting: It is also used to solidify loose, unconsolidated soils around structures and on slopes, thus preventing soil movement and erosion.

Concrete Lifting and Leveling

Rigid polyurethane grout can be used to lift and level concrete slabs, making it a popular choice for:

  • Roadway and Sidewalk Repair: The grout can be injected beneath the concrete to lift and realign sagging or uneven roadways and sidewalks. 

  • Building Foundation Leveling: Polyurethane grouting is also employed to level building foundations that have settled or shifted over time.

Applications of Acrylate Gel Chemical Grout

Acrylate gel grouts are widely utilized due to their exceptional flexibility and permeation characteristics. Here are some typical applications:

  • Curtain Grouting: Acrylate gel grouts can be used to create an impermeable barrier or “curtain” around tunnels, basements, or other structures, preventing water ingress. Acrylate gel grouts are ideal for sealing fine cracks in concrete and other structures, thanks to their super low viscosity and flexibility.

  • Soil Stabilization and Permeation: Similar to polyurethane grouts, acrylate gels can be used to solidify loose soils, enhancing stability.

Applications of Epoxy Chemical Grout

  • Epoxy resins are renowned for their exceptional compressive and tensile strength properties, making them a go-to choice for structural repairs. For a more comprehensive understanding of the benefits of epoxy products and to explore a selection from the SealBoss Epoxy System Product Line, please follow this link.

Leading Chemical Grout Products

There are several exceptional polyurethane grouting and acrylate gel products available on the market today, each offering unique features to address specific needs. From the robust line of SealBoss Corp., find below a selection of some standout products:

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.

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

Flexible Polyurethane Injection Foam

Flexible Foam, Water-Activated chemical grout. 

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

Super Low Viscosity Polyurethane Injection Foam,
Water-Activated chemical grout. Drinking Water

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.

Rigid, High Strength, SlabLifter & Void Fill Foam

Two component polyurethane foam with structural qualities to stabilize, lift and cut-off water. Fast reactive formula to gain strength within minutes. 

– Commercial Bulk Packaging
– Cartridge System

SUPER LOW VISCOSITY
Poly Acrylate Chemcial Grout Gel

Hydrophilic poly-acrylate gel / acryclic gel for soil stabilization, curtain-injection, infusion bladder injection into structures and to seal degrading masonry grout.

STRUCTURAL REPAIR INJECTION
Epoxy Systems

Super low viscosity and low viscosity, 100% solids, hi-mod, 2-component, moisture-tolerant,high strength, multi purpose, epoxy injection resin adhesives.

Contact Your SealBoss ® Technician

How to Permanently Waterproof Tilt-Up Panel Joints with Polyurethane Grout

How to Permanently Waterproof Tilt-Up Panel Joints with Polyurethane Grout

How to
Permanently Waterproof
Tilt-Up Panel Joints
with Polyurethane Grout

How to Permanently Waterproof Tilt-Up Panel Joints with Polyurethane Grout

Failing and leaking tilt-up construction joints can be sealed to full depth with single component SealBoss 1570 NSF Certified Water Stop Foam and the Oakum-Soakum Method

Tilt-up Construction Joints are Typically Caulked

Over time, caulks often fail, break open, and allow water to flow into the structure. Caulk failure can be evident as shrinkage of the bead of sealant, delamination (caulk no longer sticks to surface), cracking of the bead, powdering or dusting of the surface of the caulking.

How to Create a New Full-Depth Joint Seal

While caulking creates a small 1/4″ to 1/2″ bond surface with the concrete panel, 1570 Polyurethane Leak Sealing Resin soaked SealBoss Seal-Oakum fibre provides a full-depth bond and seal against leaks permanently. The ‘Oakum Soakum Technique’ is a proven methodology for polyurethane chemical grout installation — creating a permanent seal that remains unaffected by wet, dry, and even in constant water submerged environments.

How to Prepare the Joint

Prior to any remedial repair, the existing, failed caulk has to be removed, and the joint needs to be free of any debris. The joint then needs to be wetted for the water activated grout to react, expand, and cure.

How to Install the Flexible Permanent Seal

To create a permanent seal with the Oakum-Soakum Technique, oakum fibres are first soaked in hydro-active 1570 polyurethane resin (catalyzed with SealBoss 15X Accelerator), and then pushed deep into the clean and pre-wetted joints to form a flexible and uniform seal during expansion.

How to Protect and Finish the Seal for Cosmetic Appearance

After the foam has cured, any surplus of the foam/oakum seal is cut back and finished with an even bead of caulk to provide UV resistance and achieve a matching surface appearance to the other caulked joints.

Learn More

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

Contact Your SealBoss ® Technician

Chemical Grouting – SealBoss 1510

Chemical Grouting SealBoss 1510

SealBoss ® 1510
Chemical Grouting Polyurethane

The Versatile
Low Foamer / High Foamer
Chemical Injection Grout

  • Accelarator Adjusted Low/Hi Foam Grout
  • PUR Injection Foam
  • Leak Sealing Hydro-Active Foam
  • Wall Sealing Chemical Injection Grout
  • Soil Permeation Grout
  • Soil Consolidation Grout
  • NSF Water Contact Certified

SB 1510 Chemical Grout
Single Component - Accelerator Controlled

SB 1510 Chemical Grout is a ‘Low Foamer Grout – Low Expansion Rate ‘ and ‘High Foamer Grout – High Expansion Rate’, accelerator adjusted, all-in-one, polyurethane injection grout with a large spectrum of applications.

Contact Your SealBoss ® Technician

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