If you’re reading this, you’ve likely encountered the headaches of dealing with cracks and leaks in your projects, whether you’re a homeowner or a professional installer. Luckily, advances in structural repair have led us to develop a revolutionary technique: crack injection. While crack injection solves the basis of problems caused by cracks and leaks on its own, it is essential for the applicator to have a comprehensive understanding of the technologies behind the material used. Arguably the most important step, ensuring a successful and enduring crack injection by selecting the correct materials with the appropriate properties is essential in determining the longevity of your project and its intended performance. Specializing in construction products and equipment for structural, water stop, leak sealing, floor repair, soil stabilization, filling, lifting, and geotech applications, SealBoss caters to both commercial and residential sectors.

Choosing Your SealBoss Crack Injection Products

Hydrophilic and Hydrophobic Product Groups

SealBoss offers a breadth of quality hydrophilic and hydrophobic products with varying degrees of physical characteristics, such as viscosity, expansion rate, reaction time, flexibility, density, and hardness. Hydrophilic products tend to mix with water, whereas hydrophobic products repel water. SealBoss 1510/1570/1570LV/1500 Water Stop Foam Grouts are hydro-active, hydrophobic products whose properties intersect. Water or moisture initiates the reaction, while the cured product resists moisture and remains at a constant volume. The cured material is not affected by water or dryness and does not shrink or swell because water is not a component of the foam structure. These products are not affected by the freeze/thaw and wet/dry cycles. SealBoss 1640 Foam and SealBoss 1403 PUR Resin are hydrophobic products that do not require water to react.

SealBoss FlexGel and SealBoss 2400 Acrylate (Acrylic) Gel are hydrophilic products. Water initiates the reaction, and since the product is capable of absorbing and incorporating water post-cure, it swells and forms a flexible, waterproofing gel/foam. Products like these are recommended for applications in permanently moist environments, curtain/bladder injection, and capillary injection.

Viscosity

Viscosity is the measure of a substance's resistance to motion under an applied force. In other words: the state of being thick, sticky, or semifluid in consistency due to internal friction. The lower the viscosity, the thinner the substance will be, and vice versa. A basic understanding of viscosity is required to make the best decisions about different products you may use. SealBoss 1510/1570/1500 Water Stop Foams and Flexgel are of low viscosity and are good for penetrating concrete cracks and joints. Super low-viscosity products are available to seal hairline cracks, capillary fissures, and tight cold joints such as SealBoss 1570LV Water Stop Foam, SealBoss 1403 PUR Resin, and SealBoss 2400 Acrylate (Acrylic) Gel.

Accelerator Adjustable Hydro Active Expansion and Reaction Time

A product's water stop and penetration properties are determined by the reaction time and expansion rate. Faster reaction times and expansion benefit water cutoff properties, while slower reaction times enhance product penetration and performance in the substrate.

By adding precisely measured amounts of SealBoss accelerator, the reaction times and expansion rates of the SealBoss 1510, 1570, and 1570LV Water Stop Foams can be adjusted based on your project needs. The gel times of SealBoss’s 1403 PUR Resin and 2400 Acrylate (Acrylic) Gel are also adjustable.

When in contact with water, water-reactive polyurethane grouts will expand by the resulting CO2 gas. A compression seal is created when the foam expands, which supports the sealing properties of the injection grout. The quick expansion helps to cut-off high-volume active water leaks and benefits curtain/bladder grouting. The properties of the cured product are determined by the expansion rate, such as material consumption, cell structure, and density. SealBoss’s best-selling, industry-standard SealBoss 1510 Water Stop Foam can rapidly expand between 5 to 50 times (50X) of free-rise product volume when catalyzed accordingly. Considering this, it is important to understand that expanding foams can create significant amounts of pressure.

Flexibility and Density

Semi-flexible standard products with high expansion rates and higher compressive strengths, such as SealBoss 1510 Water Stop Foam or SealBoss 1500 2-Component Water Stop Foam, are best used for injections in joints, cracks, and some curtain/bladder wall grouting that do not experience much movement. Structures exposed to thermal expansion and contraction or dynamic loading resulting in increased movement may require a more flexible formulation grout, such as SealBoss 1570/1570LV Waterstop Foam, SealBoss 1403 PUR Resin, or SealBoss Flexgel. Additionally, as a final seal injection in critical foam injection areas, we recommend SealBoss 1403 PUR Resin.

A successful leak-seal injection needs good product density, complete penetration, and adequate product consumption. For good material travel, proper penetration, and density, injection pressures must be high enough. Always monitor injection pressures and material flow closely; when done correctly, the high-density injection material will form a compression seal and provide a long-lasting application.

Choosing Your SealBoss Packers

The gateway to a successful injection relies on the mechanical packers and injection ports selected for the job. Packers act as the connecting pieces between the structural element and the injection device, designed to connect your injection equipment safely and securely to the substrate. SealBoss offers packers varying in material type, diameter, length, and ball and valve location. Made from materials like steel, brass, aluminum, zinc, and various metal alloys and plastics, SealBoss packers are designed with differences in functionality for a variety of products, substrates, and objectives in mind.

Steel

Steel packers offer the most strength and resistance to the oxidizing components found in acrylate/acrylic gels. SealBoss steel packers deliver superior performance in high-pressure injection applications, designed to endure considerable force. This makes them ideal for demanding crack injection scenarios where high injection pressures are needed and reliability is paramount.

Brass, Aluminum, Zinc

Brass, aluminum, and zinc packers have similar functionality to steel packers and offer a more economical alternative. These packers have less strength than steel packers since they are composed of softer materials. In some designs, the shaft can be broken off by a hammer after injection, leaving a flush surface. In some cases, this is an advantage if the removal of the packer prior to patching is not specified.

Plastic

The most economical packers, plastic packers come in many varieties. Some permit low resistance, high-volume product flow, and super-quick installation.

Button Head/Button Top

Button head packers offer high volume flow with minimal leakage due to the button head coupler on the top.

Hammer-In

Hammer-in packers, sometimes called bang-in packers, are inserted into a drill hole with the tap of a hammer. The plastic body of the packer creates a compression seal and sets very quickly. Due to the lower friction fit, injection pressures are limited with this packer type.

Diameter, Length, Valves

Diameter

As a rule, a larger mechanical packer diameter permits higher injection pressures. 5/8” (16mm), ½” (13mm), 3/8” (10mm), and 1/4” (6mm) are the most common diameters for man-made structures. Larger diameters are mostly utilized in rock and other natural structures. Exercise caution, as packers and ports may exit the drill hole at high velocities under pressure. To minimize this probability, ensure your installation is correct by utilizing packers of the right dimensions. In general, larger packers prevent blow-out better than smaller packers. Choose a packer that will equal the diameter of the drill hole.

Length

To create an adequate seal in the substrate and to prevent spalling of the substrate during installation and injection, the shaft of the mechanical packer must be recessed into the drill hole deep enough.

For a weaker substrate and deteriorated concrete, longer packers between 4” and 6” (10-15cm) are recommended. The drill hole itself acts as a channel through which the product will travel. Extended shaft length can be advantageous when the contractor is attempting to bridge a gap in the substrate. In such cases, SealBoss offers special-length packers to carry the material to a specific point within the substrate.

Low and High-Pressure Valves

Most packers include a ball valve to prevent material backflow on disconnecting the pressure line. In standard high-pressure valves, the ball is pressure loaded with a small spring. Low-pressure valves omit the spring to permit lower injection pressures.

Top Mounted Valves

Zerk valves and button-head (button-top) valves are examples of top-mounted valves. For the most secure connection opt for a button-head valve which will minimize leakage. Some top-mounted zerks are supplied separately to observe port-to-port travel of injection grout during the injection process. Once the material is leaking from the next packer(s), the contractor immediately installs the valve at that time.

Bottom Mounted Valves

Bottom or stem-installed valves allow for the removal of the top portion of the packer early after injection while keeping the drill holes sealed for patching of the hole with the remainder of the packer in the substrate. As a rule, packers should not be removed before the injected product has fully cured.

Surface Ports

Typically used for epoxy injection, surface ports are glued to the surface or inside of a drill hole. Many surface ports have an open/valve-free design to work with quick release connectors with a multiple port injection option, supplied with caps to prevent epoxy backflow. There are also surface ports with zerk fittings for a super secure fit at higher injection pressures. SealBoss also offers corner ports for placement in 90 degree construction corners.

Choosing Your SealBoss Pump

Determining the right pump is dependent on several factors, such as job size, product components and properties, injection volume and pressures, and injection frequency. For injection grouts and gels, single and two-component high-pressure pumps are utilized. SealBoss gel pumps also include a separate water pump flush.

At Sunshine Supply, we have several of the latest pumps offered by SealBoss. Below is a comparison.

Conclusively, selecting the right products ensures successful repairs and long-lasting results. By considering all aspects and functions of the products you choose, as well as the characteristics of the material itself, you can make informed decisions that will maximize the effectiveness of your repairs. Prioritize high-quality products from reputable manufacturers - like SealBoss, who offer superior performance, durability, and technical support. With careful consideration and the right products, you can confidently undertake projects that restore the integrity of your structures with optimal results.