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Leaking Crack Repair

Coached by a Top Industry Professional

In the world of construction and maintenance, “leaking crack repair” is a term that frequently emerges, particularly when addressing structures that contain water or are vulnerable to moisture and water intrusion. Addressing these cracks swiftly and efficiently is vital for the structure’s safety and durability.

Sealing the Future – Preserving the Past
Since 1988

Leaking Crack Repair

Sealing the Future – Preserving the Past
Since 1988

The Need for Crack Injection Training

A prominent general contractor, who usually subcontracts such tasks, expressed the need for immediate crack injection training on a specific jobsite. Their primary aim was to acquire the expertise for smaller projects, allowing them to handle leaking crack repair internally on certain timely projects. This proactive approach not only saves time but also ensures that minor issues can be addressed before they escalate.

A Case Study: Water Treatment Tank Crack Sealed

Scope: New Concrete Tank – Water Test Failure – Asses and Seal

The facilities in question comprised three holding cells, separated by two poured-in-place division walls. During a leak test on the outer two tanks, visible cracks were detected. These cracks, deemed non-structural for repair purposes, showed signs of dampness and minor leaks, emphasizing the need for immediate leaking crack repair. Pressure crack injection with a hydrophobic polyurethane expanding water stop foam utilizing an electric injection pump and mechanical injection packers was specified as the method of restoration.

The Repair Process

Materials Used: SealBoss 1570, SealBoss 15x
Additional Tools: SealBoss 13-60S packers, SealBoss 495 Injection Pump, Hammer Drill w/ 12” x ½” bit, PPE

For training purposes, a weeping crack was chosen for repair. This crack, though narrow, spanned about 10 feet in height and meandered across the wall. Given that the newly constructed wall was 14 inches thick, the repair strategy involved guiding the team to drill 5 to 7 inches out from the crack. The drilling was done at a 45-degree angle, aiming back towards the crack, employing the crack stitch method.

Depth of Intersection: The further the drill hole is from the crack, the deeper it will intersect the crack within the structure. This results in a more profound point of injection.

Considerations for Thicker Structures: A deeper injection point is often preferred in thicker structures. However, the length and reach of the drill bit play a crucial role in determining the optimal distance for the drill hole.

Avoiding Dead-End Drill Holes: A drill hole that misses the crack won’t 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.

In summary, while determining the spacing of drill holes, it is vital to balance the desired depth of injection with the capabilities of your drilling equipment to ensure effective grout injection.

To ensure precision, the placement was set parallel to the fissure. A 0.5-inch masonry bit, attached to a hammer drill, was used for the drilling process. Once the clean, crack-intersecting holes were established, SealBoss 13-60S heavy duty steel injection packers were installed.

The repair commenced from the bottom, progressing upwards. The SealBoss 495 injection pump, paired with the SealBoss 1570 NSF/ANSI/CAN 61 drinking water contact certified chemical grout, was used for the leaking crack repair. As the repair proceeded, water and material were observed exiting the substrate. This was a positive sign, indicating effective penetration and successful stopping of the water penetration and sealing of the crack.

Final Thoughts

Leaking crack repair is an essential aspect of maintaining the structural integrity of buildings and facilities. With the right knowledge, tools, and materials, such as those provided by SealBoss Corp., even the most challenging cracks can be effectively addressed. Whether you’re a contractor looking to expand your skill set or a facility manager aiming to maintain your structures, understanding the nuances of leaking crack repair is invaluable. Our SealBoss Water Stop Specialists are always ready to assist you.

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Efflorescence and Leaks

Efflorescence – Indicator of Water Problems in Structures

Efflorescence, at first glance, may seem like a simple aesthetic issue. It presents itself as a white or occasionally vibrant and colorful, chalky residue on walls, especially around cracks and joints. This substance can evolve, often resembling delicate, hair-like filaments. Yet, beyond its surface appearance, efflorescence strongly signals the presence of a water leak.

A crack with efflorescence built-up has to be considered a leaking crack.

What exactly is efflorescence?

Efflorescence is the result of a variety compounds that have been dissolved and transported by water. When this water reaches the surface of materials like concrete or masonry, it evaporates, leaving behind minerals, metals and inorganic compounds, such as calcium hydroxide which interacts with atmospheric carbon dioxide to form fine calcium carbonate crystals.

The result is the characteristic residue which is mostly greyish or white. However, it can sometimes appear colorful if the water causing the efflorescence contains minerals or compounds that produce colors when they crystallize. Copper salts often yield blue or green efflorescence. Similarly, iron salts can lead to yellow, brown, or reddish hues, while manganese can give rise to pink or purple shades.

The presence of these or other metal ions in the water can lead to colorful efflorescence. These ions may come from the soil, water supply, or even from the building materials themselves. Therefore, colorful efflorescence not only indicates a moisture issue but could also point to the presence of specific minerals or contaminants in the environment.-

While efflorescence itself might not be harmful, it is a beacon signaling a potential moisture problem. As water continues to seep into building materials, it does not just evaporate from the surface. The moisture can be absorbed deeper into the material, leading to a process known as wicking. Over time, this persistent moisture can compromise the structural integrity of the building materials.

For inspectors and concrete repair contractors alike, recognizing efflorescence is crucial. It is not just about identifying a water leak; it is about understanding the capillary forces at play and the distribution of water within the structure that will cause the damage. By educating their clients about efflorescence, inspectors can provide valuable insights into potential problems that already may exist, even when the structure appears to be dry on the outside.

In summary, efflorescence is an indicator for moisture problems in a structure, even when it appears to be dry at the time of inspection. It forms when water with dissolved salts evaporates from concrete or masonry surfaces, leaving a white, greyish or even colorful residue. It is a a clear signal of deeper moisture problems, past and present, that can have long-term implications for the structural health of a building.

When it comes to polymer crack injection and structural repairs, understanding and addressing the root causes of efflorescence is essential.

Efflorescence and Crack Injection Repair
A Case Study at International Airport's Reservoir

Introduction
We know that efflorescence is a clear indicator of moisture issues within a structure. Its presence can signify past leakage, even when the surface appears dry. Addressing efflorescence build-up and active leaks can be crucial for the longevity of concrete structures.

This short case study highlights a repair project at an International Airport, highlighting the solutions in association with efflorescence and crack injection repair.

Project Overview
The Reservoir spillway structure at the International Airport required significant restoration and rehabilitation. The contractor was tasked with chemical grouting as part of this extensive project. The objective was to clean up all compromised concrete, crack inject all areas of present and past water leakage, patch it, and re-caulk all cold joints.

Identifying the Problem

Visible water infiltration and signs of efflorescence on cracks and joints were the primary concerns. Efflorescence around cracks and joints indicates past leakage, even in the absence of active water seepage at the time of inspection, and needs to be addressed.

The source of water intrusion was identified as rain runoff, which led to the oversaturation of the built-up and back-filled sections adjacent to the spillway walls.

Proposed Solution
The engineer recommended injecting the affected cracks and joints with a moisture-activated hydrophobic foam. This foam was specifically designed to address areas showing signs of efflorescence and visible water infiltration.

Execution
Custom scaffolding was erected to facilitate the repair process. The contractor’s certified crew utilized the SealBoss P2002, a portable high-pressure injection system capable of overcoming the hydrostatic and physical resistance forces within the wall, displacing moisture, and injecting the SealBoss 1510 Water Stop and Leak Seal Foam at the appropriate pressure and volume. Given that the concrete wall was approximately 12 inches thick, the SealBoss 13-100AL Evolution Packers were strategically installed by drilling directly into the cracks.

This approach was chosen based on the concrete’s quality to minimize the risk of spalling due to injection pressures. Each packer was reinjected as deemed necessary to ensure a comprehensive and durable seal. In many instances, the injected material traveled through honeycombed concrete, reaching areas several feet away from the injection point.

Whenever this happened, the injection was paused until the material reached a state of cure to ensured that subsequent injections would follow a new path of lesser resistance within the crack structure’s capillaries.

Results
The injection crew successfully halted the water intrusion well within the specified time frame. This efficiency meant that the reservoir could return to its regular levels much quicker than initially anticipated.

Note
As water may find its way to areas beyond the initial injection repair, there might be a future necessity for spot treatments in previously dry regions.

Conclusion
Efflorescence around cracks and joints, is a clear indicator of leakage, even if dry durning inspection. It often is a telltale sign of deeper structural problems.

The Reservoir project at the International Airport serves as a testament to the importance of timely intervention and the use of advanced techniques like crack injection repair. By understanding and addressing the root causes of efflorescence and water intrusion, structures can be preserved and protected for the long term.

Curtain Injection In Pictures

Curtain Injection in Pictures

And Podcast

Curtain / Bladder Injection - Curtain Wall Grouting Method

Water intrusion is a persistent challenge for below-grade concrete structures, where traditional patching and surface sealers often fall short. The failures of these surface-applied remedies—such as patches, liquid sealers, and membrane applications—stem from their inability to address the root causes of leaks. These methods provide only temporary relief, leaving structures vulnerable to recurring hydrostatic pressure and ongoing water damage.

Curtain wall grouting, including advanced techniques like curtain and bladder injections, offers a reliable, long-term solution to these challenges. Unlike surface treatments, these methods work by creating a robust waterproof membrane and water barrier behind the structure. This approach not only seals cracks and cold joints from within but also fortifies the structure against future water intrusion.

By injecting specialized grouts through the structure to form a protective layer on the positive side, curtain injection ensures a comprehensive and lasting seal. Whether applied through stage grouting or other targeted injection methods, this professional approach delivers durable protection, minimizing service interruptions and maximizing cost-effectiveness in the long run.

Curtain / Bladder Injection is the Reliable Way to Waterproof Your Below Grade Concrete Structure Permanently

Why Patches and Liquid Sealers Often Don’t Stand the Test of Time

Experiencing the frustration of failing patches and paint applications on damp, actively leaking, below-grade structures is something many of us can relate to.

These are typically failed attempts to block hydrostatic water intrusion using surface-applied remedies that serve as temporary solutions at best.

Interior patches and membrane applications, while seemingly addressing the problem, often don’t tackle the root cause and rarely provide a lasting waterproofing resolution.

A Professional Approach to Curtain Injection:

Sealing Cracks Permanently and Establishing a Waterproof Membrane and Water Barrier behind the Structure

Water leakage via cold joints, cracks, and other irregularities in concrete can frequently only be effectively and permanently sealed using advanced injection techniques, such as curtain, bladder, and stage grouting injection methods.

The SealBoss Injection Product offers a professional solution to these issues, filling and sealing the cracks from the inside out. This product is injected through the structure, forming a membrane on the structure’s positive side, thus providing a more effective and lasting waterproofing solution.

The Art of Stage Grouting Technique

In complex grouting scenarios, the stage grouting technique is often the favored approach. This process entails a strategic series of injections carried out in a staged manner, utilizing lower volumes of product in each application.

Each stage of this meticulous process is allowed sufficient time to react, allowing the grout to solidify and establish a natural barrier before proceeding with the subsequent stage of grouting. This carefully phased and controlled deployment not only elevates the overall efficacy of the grouting operation but also ensures thorough and consistent coverage along the exterior of the wall.

Comparative Cost Analysis of Injection Grouting Sealing Methods

Understanding the financial impact of various sealing techniques is essential for making cost-effective decisions. Below is a comparison.

Crack Injection

Direct Costs: Moderate for materials and labor, product is injected directly into the cracks, joints, and voids. Low for equipment.
Indirect Costs: Minimal, as the method is fastest and causes little service interruption.

Curtain Grouting

Direct Costs: Higher for materials and labor, product is injected through the structure into the substrate behind, which results in higher material consumption. Packers are set in distinctive patterns. Moderate for equipment.
Indirect Costs: Higher, due to the lengthier process of preparation and product pumping, which can lead to more significant service disruptions.

Links

Curtain / Bladder Injection Products

Professional Polymers

Premium Packers

Powerful Pumps

SealBoss Injection Pump Systems

Mockups
Curtain Wall Grouting | Negative Side Injection Waterproofing

"The Mockup is Worth its Weight in Gold"
Technical Podcast for the Infrastructure Repair Industry

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Restoration Waterproofing

Restoration - Waterproofing

Restoration – Waterproofing with Injection Resins, Gels, and Foams

Restoration waterproofing projects represent a mix of various complex tasks, each with its unique set of challenges. The first crucial step is identifying the root source of the water infiltration, which at times can be a difficult process.

Diagnosis

A correct leak diagnosis might necessitate various steps, such as performing visual inspections of the inside and outside of the structure, examining the surrounding conditions, conducting flood tests, utilizing dye testing, creating mock-ups, and removing paints and finishes.

Waterproofing Restoration with SealBoss Water Stop Systems
– Resins, Foams, Gels, Packers and Pumps –

Setting Defined Objectives

Before starting a restoration waterproofing project, it is crucial to clarify the goals and expectations for every party involved.

It goes without saying that the primary aim of such a venture typically revolves around halting water intrusion. There are many techniques and products that can be used for this, such as polyurethane injection foams, gels, and resins, as well as acrylate injection gels and even epoxy resins in some circumstances. These methodologies come with their individual costs, levels of site disruption, and project timetables. It is essential that all of these elements are thoroughly considered and presented to the end customer, facilitating an informed decision-making process.

Understanding Water Movement and Migration

It is indispensable to understand some key concepts related to water migration and movement around and within soil, structures, voids, joints, and cracks.

Water is Not Always Visible

The obvious appearance of a leak in a specific location does not definitively imply that other areas are devoid of water ingress. Water invariably seeks the path of least resistance, typically navigating towards any openings, fissures, and low spots. Upon remediation of these lower areas, the water may find its way to other compromised zones.

Leak Detection Techniques

The leak detection process is further complicated if the repairs are undertaken during a period of relative dryness. Under such circumstances, leak migration might not become evident until the advent of the next rain event. For more controlled testing, it may be advisable to deliberately flood the surrounding area, creating conditions that could induce a leak at the time of inspection and repair. Conducting flood testing before, during, or after the repair work can contribute significantly towards pinpointing any areas where the leak may have migrated. Executing waterproofing repairs amidst active leaking can effectively help identify and repair leak migration issues.

Restoration Waterproofing Products

Polymer injection foams, resins and gels serve as viable solutions in restoration waterproofing. Their superior qualities make them ideal for sealing leaks, even in wet environments. Polyurethane foams are adept at sealing large leakages, both in volume and speed, expanding upon contact with water to block infiltrations effectively. On the other hand, super low viscosity resins and gels ensure a long-lasting solution for smaller, more intricate leaks, seeping into hairline cracks and curing to provide a waterproof seal. Implementing curtain injection behind a structure can effectively generate a waterproof, membrane-like barrier, thus sealing wet and damp spots within concrete and masonry structures.

At times, epoxy resins may be required to restore structural integrity, even in wet or damp conditions. For an in-depth comparison between epoxy and polyurethane injection, please refer to the detailed information provided here.

In Conclusion

Remedial restoration waterproofing is often an iterative, exploratory process that might necessitate adjustments along the way. Setting realistic expectations, keeping open lines of communication among all involved parties, and maintaining a keen eye for detail are important to the efficient and successful execution of a waterproofing process.

A well-executed waterproofing restoration can add years to the lifespan of a structure, safeguarding it against potential damage and preserving its aesthetic and functional value.

Restoration – Waterproofing Systems

Popular Water Stop & Leak Sealing Injection Links

SealBoss ® 1510

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam Grout

Our #1 Selling Polyurethane Injection Foam
Water Cut-Off Injection Grout
1510 PU Foam & Oakum Pipe Plug Kit

SealBoss ® 1570

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

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

SealBoss ® 1570 LV

Leak Sealing Foam Grout
Water Stop Foam Grout
Hydrophobic Injection Foam

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

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 foaming to high foaming depending application.

SealBoss ® 1403 SLV

Leak Sealing Injection Resin
Super Low Viscosity PUR Injection Resin

Two Component Flexible Resin
The solution for wet and dry surfaces and moving cracks. Extremely low viscosity for superior penetration in hairline crack injection.

SealBoss ® FLEXGEL

Leak Sealing Injection Gel
Hydrophilic Injection Foam Gel
Hydrophilic Gel

Versatile Hydrophilic Polyurethane Foam-Gel
Water activated single component hydrophilic Polyurethane grout.

SealBoss ® 2400

Leak Stop
Leak Sealing
Acrylate Gel
Acrylic Gel

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

Restoration - Waterproofing

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Water Stop

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Irrigation District Canal Sealing

Injection Technologies for Irrigation District Canal Sealing

Introduction:

Irrigation canals are the lifelines of agriculture, channeling water across vast landscapes to nourish crops and sustain farming operations. Yet, the integrity of these canals is under constant threat from leaks and seepage, challenges that not only compromise water efficiency but also the very foundation of our agricultural infrastructure. In response to these challenges, innovative solutions such as polyurethane grout injection and grout-impregnated oakum applications have emerged as effective methods for canal sealing and repair.

Polyurethane grouts, oakum, and injection lance technologies represent significant advancements in the sealing and maintenance of irrigation district canals, addressing both traditional challenges and modern needs.

Polyurethane grout, with its expansive properties, offers a dynamic solution by filling cracks and voids with a durable foam that cures into a watertight seal, reinforcing the structural integrity of canals and minimizing water loss.

Oakum, a fibrous material impregnated with grout, provides a versatile and environmentally friendly option for sealing irregular or wide cracks, combining the resilience of natural fibers with the sealing power of modern grout.

The injection lance technique, used in both curtain and probe grouting, allows for precise application of materials, targeting specific seepage paths and ensuring a comprehensive barrier against water loss. Together, these methods enhance the efficiency of water delivery systems, safeguard the structural stability of irrigation canals, and contribute to the sustainability of agricultural practices by conserving water and reducing maintenance costs.

Polymer Grout Systems for Irrigation District Canal Sealing

The Challenge of Leaking Canals

The network of irrigation canals that crisscross agricultural regions is vast and complex. Managed by various entities, including the Bureau of Reclamation, this infrastructure spans thousands of miles and is crucial for the delivery of water to farmlands. However, the aging of these canals, combined with natural and mechanical damages, presents a continuous battle against leaks and seepage. Such issues not only lead to water loss but also pose significant risks to the structural integrity of canals, potentially resulting in erosion, sinkholes, and even catastrophic breaches that can have far-reaching impacts on agriculture and nearby communities.

Advanced Solutions for Irrigation District Canal Sealing

Polyurethane Grout Injection

Polyurethane grout injection stands out as a modern solution for addressing irrigation canal leaks. This method involves injecting a liquid polymer, which expands upon contact with moisture, into cracks and voids, thereby creating a durable, watertight seal. The rapid curing time of polyurethane grout minimizes downtime in water delivery, and its flexibility allows the structure to accommodate future movements, significantly reducing the likelihood of recurrent leaks.

Using NSF Drinking Water Contact Certified Polyurethanes

NSF-approved polyurethane grouts are essential in irrigation canal sealing because they meet stringent safety standards by the National Sanitation Foundation (NSF) and the American National Standards Institute (ANSI). This certification ensures these materials are safe for use in environments in contact with potable water, preventing contamination. SealBoss NSF/ANSI/CAN 61 Certified Products undergo rigorous testing to ensure they do not leach harmful contaminants, making them a reliable choice for maintaining the purity of water systems and complying with regulatory requirements for public health and environmental protection.

Addressing Seepage with Curtain and Probe Grouting

In addition to direct crack sealing, addressing pervasive seepage is critical for maintaining the functionality and integrity of irrigation canals. Techniques such as curtain and probe grouting play a crucial role in this context. Curtain grouting involves creating a grout barrier along the canals wall to block water pathways into the soil, while probe grouting with injection lances targets specific seepage paths, allowing for precise application and minimal environmental disturbance.

Steel Injection Lances, tailored for specialty grouting applications, facilitate the delivery of various polymer solutions directly into the soil. Their primary function is to inject these polymers deep into the soil to enhance its properties. By doing so, they significantly increase the soil’s strength, decrease its permeability, and improve its overall stability, making them indispensable tools for polymer leak sealing and soil stabilization efforts.

Sealing Joints in Concrete Canals

Concrete-lined canals face the challenge of leaking panel joints. SealBoss 1510 Water Stop Foam, used in conjunction with SealBoss Oakum, provides an effective solution for sealing these joints. The combination of these materials forms a water-impermeable barrier, ensuring the longevity and functionality of lined canal systems.

Grout-Impregnated Oakum

Grout-impregnated oakum represents a blend of traditional and modern repair techniques. Utilizing SealBoss Oakum—a fibrous material derived from old hemp ropes—saturated with specially formulated grout, this method can effectively be used to seal wider cracks and seals cracks and joints in irrigation canals. The natural flexibility of oakum, combined with the strength of the grout, offers a resilient barrier against water seepage, making it especially suitable to seal irregular and wide cracks, as well as leaking joints.

Soil Cavity Filling and Sealing

The stability and functionality of irrigation canals are compromised not only by the effects of soil erosion and washouts but also by the presence of wildlife, which presents unique and significant challenges.

Animals like gophers, muskrats, and beavers can create tunnels and burrows in canal berms, potentially leading to significant water loss and instability. Sealing these wildlife burrows with quick expanding SealBoss polyurethane foam grout not only prevents water leakage but also deters animals from re-establishing their burrows, thereby protecting the canal and adjacent agricultural lands from unintended water damage.

The Importance of Professional Expertise

While some maintenance tasks pertaining irrigation district canal sealing can be handled through do-it-yourself approaches, the complexity of canal repair often necessitates professional expertise. Companies like SealBoss offer comprehensive guidance and technical support tailored to the unique challenges of canal maintenance. Their referrals to experienced contractors ensure that repair projects are executed effectively, safeguarding this critical infrastructure against the myriad challenges it faces.

Conclusion

The sustainability of our agricultural system relies heavily on the integrity of irrigation canals. Through the application of advanced sealing techniques and materials, combined with professional expertise, we can ensure the efficient delivery of water to farmlands, preserving the foundation of agricultural productivity and environmental stewardship for future generations.

Related Links

Structural Irrigation Canal Concrete Repairs

Structural Epoxy Repair System

Related Article

Seawall Repair

Irrigation Canal Sealing Systems

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Cold Joint Injection

Leaking Cold Joints Sealed

Cold Joints in Concrete Structures and the Polyurethane Polymer Solution

Introduction

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

What are Cold Joints?

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

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

Injection Process

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

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

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

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

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

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

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

Considering a Solution for Sealing Cold Joints During Construction?

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

Materials and Tools Used

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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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Tunnel Water Stop Injection Leak Repair

Tunnel
Water Stop
Injection
Leak Repair

Leak Sealing
Systems

Tunnel Water Stop Injection Leak Repair with Polymer Grout Injection

Introduction:

Tackling water leakage in tunnels, this piece outlines the challenges and solutions associated with different tunnel types, such as utility, vehicle, subway, rail, and pedestrian tunnels. It proposes the use of Polymer Injection Grouts, specifically acrylate gels and polyurethane resins, for effective leakage sealing and structural consolidation.

The article discusses the properties and applications of acrylate gels, guiding through the steps of leak repair including diagnosis and material selection. Additionally, it highlights SealBoss’s products tailored for addressing underground water ingress and emphasizes the importance of proper training and equipment for repair personnel.

Tunnels, serving diverse purposes and varying in structure, are crucial infrastructures. Below is an overview of the tunnel types most susceptible to water leakage and the associated risks:

Utility Tunnels: Hosting vital systems like electrical wires, water pipes, and gas lines, water leaks in these tunnels can cause pipe corrosion and electrical faults, endangering safety and disrupting services.

Vehicle Tunnels: Susceptible to water leakage from tunnel walls and the road, accumulated water can create dangerous driving conditions, resulting in accidents and traffic congestion.

Subway Tunnels: Positioned beneath city areas, they are at risk of water leaks from surrounding soil and existing utilities, leading to service disruptions, delays, and increased maintenance costs.

Rail Tunnels: Highly sensitive to water intrusion due to their electrical systems and the high-speed trains, water leakage can damage the track bed, potentially causing uneven rails and, in severe cases, derailments.

Pedestrian Tunnels: Vulnerable to water leaks, they can become slippery, posing fall risks, and the dampness can foster mold and bacteria growth.

How to stop leaks of high hydrostatic pressures with Injection Grouts

Water ingress can cause immediate damages as well as lead to increased project costs and may lead to many other issues down the line.

Water leaks through cracks, joints and voids can be repaired with cost effective and highly successful injection systems, utilizing chemical grouts such as multi component acrylate gels and single component polyurethane resins.

Appropriately engineered resin injection systems do not not only seal leaks in the structure itself, but can transform loose sands behind the structure to a confined consistency similar to sandstone, and consolidate gravel to a bonded conglomerate.

Example: SealBoss Acrylates Used to Seal Leaks in Tunnel

What are Acrylate Gels?

Acrylate Gels, also known as Acrylic Gels, are very flexible, super low viscosity — similar to water — hydrophilic gels designed for non-structural injections of cracks, joints, voids, and used for grid, curtain, bladder injection and as sealant in the injection tube system.

Due to their extremely low viscosity and low surface tension, polyacrylate gels offer superior penetration properties. Acrylates are gel time adjustable to meet jobsite conditions such as temperature and injection distance.

Acrylic gels are used to waterproof leaks and create a compression seal due to their hydrophilic swelling behavior when in contact with water.

Acrylate injection equipment can easily be cleaned with water.

SealBoss provides a wide range of products to control water ingress into underground mining works, tunnels and many other commercial structures with leakage issues. We supply materials for waterproofing, consolidation, sealing, crack and joint repair, bonding and cavity filling.

Tunnel Water Stop Injection Leak Repair

How to Start Acrylate Injection Leak Sealing Injection Repairs

The principal steps to solve a problem are:

Diagnosis of the problem
Specification of injection methods
The correct choice of resin, pumps, packers and accessories
Training of installation personnel, a well trained and experienced team is paramount

Will I need more than One Product?

That depends on the conditions of the jobsite. Polyurethane and Acrylate injection systems offer a variety of solutions to problems found in geotechnical applications, in tunneling, waterproofing underground works and civil engineering in general. While there is no single resin that will suit all conditions, the correct resin must be used to achieve the best results possible and to meet the requirements of the specification.

If there are any questions about the various chemical grouts available, please do not hesitate to contact us, we are here to assist in any way we can. Always remember to work safely by wearing eye protection and gloves when handling any type of chemical systems.

Which products are shown in the videos?

Products used for Tunnel Water Stop & Leak Sealing Injection

Related Article

Flooded Tunnel Repair

Call Your SealBoss Technician

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

SealBoss Leak Sealing Systems

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How to Seal Shrinkage Cracks

Shrinkage Cracks Sealed at Wastewater Treatment Plant

Introduction:

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

Understanding Shrinkage Cracks in Concrete

What are Shrinkage Cracks?

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

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

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

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

Effective Sealing of Shrinkage Cracks at a Wastewater Treatment Plant

Scope

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

Procedure

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

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

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

Employed Products:

SealBoss 1510 superior penetration through hairline cracks

SealBoss ® 1510 NSF Approved Water Stop Foam

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

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

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

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

Related Super Low Viscosity SealBoss Chemical Injection Grouts:

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

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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.

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Utility Vault Leak Sealing Repair

Injection Technology for Utility Vault Repair and Maintenance

Introduction:

Utility vaults, integral components of modern infrastructure, house essential services like electrical and telecommunications equipment. Despite their robust construction, they are prone to leaks, especially at precast joints and pipe penetrations. Neglecting these leaks can lead to operational, safety, and financial challenges. This comprehensive guide delves into the intricacies of utility vault leak sealing repair, emphasizing the application of polyurethane grout for long-lasting solutions.

Advantages of Polymer Grout Injection for Utility Vault Leak Sealing Repair

Polyurethane grouts stand out for their material longevity and flexibility after curing, accommodating structural shifts and reducing the likelihood of cracks. Economically, it requires fewer reapplications and offers reduced labor costs, making it a cost-effective choice in the long run. Environmentally, SealBoss’s NSF-certified polyurethane grouts meet stringent public health and safety standards, ensuring minimal impact on the environment.

Acrylate / acrylic gel injection resins offer extreme penetration properties and super low viscosity and are used for permeation and curtain injection while providing a sealing membrane in blow grade structures between the concrete and surrounding soil.

Utility Vault Leak Sealing Repair

Ensuring Structural Integrity and Operational Efficiency

The Consequences of Ignoring Leaks

Unaddressed leaks in utility vaults can lead to equipment corrosion, failure, or increased maintenance needs, affecting the reliability of utility services. Moreover, water in electrical vaults creates a hazardous environment, increasing the risk of electrical short circuits and posing a safety threat to maintenance staff.

The Solution: Polymer Grout

Polyurethane grout, with various physical properties and reaction profiles, including hydrophobic and hydrophilic formulations, offer highly specialized solutions and a professional approach to sealing leaks in utility vaults permanently. On large and damp concrete walls of damp acrylate / acrylic gel injection may be the application method of choice.

Polymer grout injection most often outperforms traditional methods like cementitious grouting by accommodating structural movements, active high velocity water flow, and preventing leak reoccurrence.

Sealing General Leaks and Leaking Cracks

Leaks can occur due to a variety of reasons including poor construction, soil movement, and aging materials. Cracks in the walls or floor of the vault can develop over time, leading to water ingress.

Crack Injection Method

Crack injection is a precise technique used to address leaking cracks. This method involves injecting a sealing material, typically a polyurethane (or sometimes epoxy resin), into the cracks to create a waterproof barrier.

For the Comprehensive SealBoss Crack Injection Guideline click here.

Steps for Crack Injection:

Identifying and Cleaning the Crack: The first step is to thoroughly inspect the utility vault and identify all the cracks. These cracks need to be cleaned to remove any debris or contaminants.
Installing Injection Ports: Small injection ports are then installed along the crack at regular intervals. These ports will serve as entry points for the injection material.
Injecting the Resin: The selected resin is then injected into the ports, starting from the lowest port and moving upwards. The resin fills the crack completely, creating a waterproof barrier.
Curing and Finishing: Once the injection is complete, the resin is allowed to cure. After curing, the injection ports are removed, and the surface is finished as required.

Sealing Damp Walls with Curtain Injection Technique

Damp wall and water seepage with very fine cracks or no visible cracks. This issue is typically due to water seeping through the walls, which can be a result of groundwater pressure, capillary action and porous substrate.

Curtain injection is an effective method for addressing general leaks and damp walls. It involves creating a waterproof barrier behind or around the leaking area. Curtain injection is performed with SealBoss polyurethane grouts or SealBoss 2400 acrylate/acrylic gel resin.

Read more on the Curtain Injection Technique – click here.

Steps for Curtain Injection

Assessment of the Leaking Area: A thorough assessment is conducted to determine the extent and source of the leaks or dampness.
Drilling Injection Holes in Grid Pattern: Holes are drilled into the wall or ceiling at strategic locations to cover the area affected by the leaks or dampness.
Injecting the Grout: A low-viscosity polyurethane grout is injected into these holes. The grout travels through the voids and cracks behind the wall or ceiling, forming a curtain-like barrier.
Creating the Waterproof Barrier: The grout permeates and creates a curtain or bladder, sealing off the water paths and creating a waterproof barrier.
Curing and Inspection: After the injection, the grout is given time to cure. A final inspection is conducted to ensure the effectiveness of the barrier. Curtain injection can often be tested by flooding the area behind the structure.

The Water Migration Problem of Precast Joints and Pipe Penetrations

Precast joints in utility vaults, formed at the junctions between concrete sections, are susceptible to leaks due to cracks, soil shifts or temperature fluctuation caused movement.

Similarly, pipe and conduit penetrations, where utility lines enter the vault, can become leak points. The original sealing around these areas can degrade over time, allowing water to infiltrate the vault.

Repairing Precast Joint Leaks

For precast joint leaks, products like SealBoss 1510 and SealBoss 1570, combined with SealBoss Oakum, offer effective solutions. SealBoss 1570 is a highly flexible polyurethane grout that adapts to movements between concrete sections, while SealBoss Oakum, a special oil-free dry jute rope, helps to seal large and irregular defects when used in combination with the grout.

Installation Guideline

Clean and moisten surfaces before applying Oakum
Saturate SealBoss Oakum with SealBoss Polyurethane Resin
Pack the Oakum into the precast joint and, if necessary, inject additional resin for a complete seal.
Allow the material to cure overnight

Addressing Pipe Penetration Leaks

For pipe penetration leaks, a combination of SealBoss Polyurethane grout and SealBoss Oakum can create a durable seal. Soaking SealBoss Oakum in the grout and then packing it around the pipe forms a tightly sealed gasket.

Installation Guideline

Soak SealBoss Oakum in SealBoss Polyurethane Grout and water
Pack the soaked Oakum around the pipe
Use a SealBoss Injection Needle to fill any remaining gaps with chemical grout

This method offers longevity, with the potential to last up to five decades.

Selecting a Qualified Contractor

The effectiveness of the repair largely depends on the skill of the contractor. It is crucial to choose a contractor experienced in applying polymer grout. Look for contractors who have received training from the material manufacturer and have a proven track record in polymer water stop injection and leak sealing projects.

Evaluating Proposals

When reviewing proposals, focus on the detailed scope of work, proposed materials, cost breakdown, project timeline, and references. This due diligence ensures that your investment in utility vault leak sealing is well-placed.

Conclusion

Utility vault leak sealing repair, particularly with polymer grouts and resins, is an essential aspect of maintaining infrastructure integrity. Choosing the right contractor and using quality products like those offered by SealBoss can ensure the longevity and effectiveness of the repairs. By addressing these leaks proactively, you can mitigate operational challenges, ensure safety, and avoid negative economic impacts.

Related Links

Structural Utility Vault Repairs