Alchatek Blog

I was a Machinist Mate in the Navy and thus almost all of my training was mechanically focused. One class I had was Electrical Theory for Mechanics. The quick summation by the Senior Chief instructor for it was "Electricity is magic and when the smoke comes out the show is over." Being on a submarine it was deemed a good thing to keep water and electricity separate. My first time ever using polyurethane chemical grouts was on a group of sixteen conduits entering a below-grade mechanical room. While electricians may understand the "magic" of electricity they often fall short as waterproofers. Combined with the fact the numerous electrical cables coming through a conduit can be notoriously hard to waterproof and it is a recipe for leaks and electrical problems. In this post, I'll share step-by-step instructions, along with a couple of photos from a recent job one of our customers completed in a San Francisco condo complex.

Oakum soakem is a kindergarten-skill level procedure that makes waterproofing these types of penetrations easy. I refer to this as fingerpainting with chemical grouts.

1. For PVC and HDPE pipe roughing the surface will increase the mechanical bond and is recommended.
2. Wet the application area.
3. Soak oakum in either Spetec F400, GT500, or GT380 resin until saturated.
4. Pack soaked oakum into pipe joint to be sealed. If necessary, pack multiple layers. Ensure it is under compression.
5. Allow grout to cure.

Often this is all that needs to be done, but it can be followed up with injection to fill the conduit if required.

1. Stab injection needle through the cured grout and oakum plug.
2. Inject grout.

Photo: Contractor on a recent job in San Francisco, addressing multiple conduit leaks with electric injection pump, a pail of Spetec PUR F400, and Oakum.

Want more info on Alchemy-Spetec leak seal products and equipment?

Sealing Leaks in Concrete with Polyurethane

Water is RELENTLESS. Leaks appear in all kinds of structures, from underground parking garages to municipal treatment tanks to elevator shafts. Everything from fine hairline crack leaks to gushers can threaten the long-term integrity of the structure and surrounding property. Fortunately, pressure injection of polyurethane grout into the crack or behind the leaking wall (depending on the application) creates a durable and rugged positive side repair. A relentless solution to a relentless problem.

A wide variety of leak seal solutions are available to address almost any type of concrete leak. (Call the Alchemy-Spetec technical support team at 404-618-0436 for assistance in choosing a product for your specific project.)

Polyurethane Leak Seal Solutions - Crack and Joint Injection

Crack and joint injection products are generally used for smaller non-gushing leaks:

Spetc PUR GT380
Activates as Foam or Gel Depending on Amount of Water Added
Ideal for Manhole Rehabilitation

Spetec PUR GT500
Most Dry-Cycle Resistant Hydrophilic Grout
Ideal for Cracks with Intermittent Leaking

Spetec PUR GT350
MDI Based Grout
For Wet Dynamic Cracks & Joints

Spetec PUR F400
Flexible Hydrophobic Grout
Ideal for Dynamic Cracks & Joints

Spetec AG200
Acrylic Injection Resin
Used in Special Situations (Contact Alchemy-Spetec Support for More Info)

Polyurethane Leak Seal Solutions - Curtain Grouting

Curtain grouting products are generally used for gushing leaks or multiple smaller leaks in proximity:

Spetec PUR H100
Semi-Flexible
Ideal for Structures with Some Movement

Spetec PUR H200
2,050 psi Compressive Strength, Fastest Cure Time­­
Ideal for Soil Stabilization

Spetec PUR Highfoamer
50x Expansion
Cost Effective for Large Voids

Spetec Boom! Seal
Two-Component, High Expansion (35x), Hydro Insensitive
Used in Special Situations (Contact Alchemy-Spetec Support for More Info)

Want more information on polyurethane leak seal solutions?

Alchemy-Spetec's AP Fill 700 and AP Fill 720 are one-component polyurethanes used for filling voids in supporting soil surrounding a structure.  Situations in which these materials might be used for void fill include soil adjacent to retaining walls, basement walls, seawalls, and infrastructure boxes.  

Benefits of One-Component Void Fill Foams

• Their slow reaction time allows for the material to travel farther from the injection point, fill more voids, and permeate more soil before curing.
• They're ideal for encapsulating underground debris (decaying organics, roots, buried construction waste).
• On small jobs, they can be installed with a very small, portable pump that can be lifted and transported by hand. 

Differences Between AP Fill 700 and AP Fill 720

• AP Fill 700 features very low viscosity, making it ideal for permeating fine soil with small voids.
• AP Fill 720 is extremely rugged and durable when cured, while still retaining some flexibility. Its high expansion rate makes it ideal for filling larger voids.

Want more information on Alchemy-Spetec geotech products?

A contractor in Atlanta was recently called in to seal off a rain-induced ceiling leak in a new construction high-rise penthouse suite. Sealing off the water intrusion from the roof above was not an option, due to the rooftop swimming pool directly above the penthouse. So, they had to get into the ceiling from the interior of the suite and repair the leak from the underside.

Powerful Polymers

The crew on this job injected Spetec PUR F400, a water-reactive, hydrophobic, flexible, single component polyurethane resin. This product is ideal for sealing off active leaks in cracks.

Painless Procedures

Leaking concrete structures can be permanently repaired with concrete crack injection & curtain wall procedures using water-activated polyurethane foam. Pressure injection of these liquid polyurethane resins forces the material into leaking cracks or behind leaking walls depending on the application. After the polyurethane injection is complete, the polyurethane resin rapidly reacts with water to form a watertight seal.

Rapid Results

In this case, the leak was shut down in less than two minutes. This all went down literally right before the new tenant was scheduled to begin moving in. (No pressure there!)

Want more information on polyurethane leak seal repair?

What Causes Leaks in Concrete?

Imperfect Construction
Concrete construction is by no means a perfect science. New construction often requires Leak Seal treatment follow-up work. If the initial construction isn’t properly sealed at the time of construction, leaks are bound to appear sooner rather than later.

Weather and Wear
Concrete naturally decays over time. Exposure to extremely hot temperatures and extremely cold temperatures can take their toll over time. Even structures located in mild climates will begin to decay purely due to the aging process.

Unstable Soil
Unstable soil can undermine the integrity of concrete structures and cause cracks to appear. Loose soil has four main causes: soil erosion, poor compaction, freeze/thaw cycles, and biological decay. If soil is the main culprit, additional stabilization and slab lifting treatments may be required in order to prevent further cracks from appearing.

What is Curtain Grouting?

Curtain grouting is the process of injecting water-reactive resin behind the leaking wall in a grid pattern (from the negative side). The water on the other side mixes with the grout and cures to a solid mass covering the surface of the wall on the other side (positive side). In addition, you don’t have water pressure dislodging external “patches” over time, as can be the case with other methods.

Curtain grouting is often required when there are gushing leaks, multiple leaks in proximity, cracks cannot be identified, the walls are made of material that does not respond well to crack injection (such as masonry, stone, and CMU), or previous leak seal methods have failed.

The most well-known Alchemy-Spetec product for this application is Spetec PUR H100, a one-component, closed-cell, hydrophobic, water-reactive, solvent, and phthalate-free, low viscosity resin. If there are large voids involved, Spetec PUR HighFoamer (a similar product with a higher expansion rate) may be a more cost-effective option.

Want more information on curtain grouting?

Unstable soil can be defined as soil that will not stay in place on its own, and therefore requires extra support. It should be noted that unstable soil can threaten the stability, security, and safety of infrastructure and can damage, degrade, and even destroy a number of structures, such as buildings, bridges, and roads. There are a variety of factors that can cause unstable soil including erosion, poor compaction, freeze/thaw cycles, and decomposition.

The Causes of Unstable Soil

Erosion
Poor drainage, improperly placed downspouts, leaking drain pipes, and broken water lines are common culprits.

Poor Compaction
When backfilling on a job site, the contractor is supposed to compact the backfill by driving over it with heavy equipment. However, this isn’t always done properly for one reason or another.

Freeze/Thaw
Processes of freezing and thawing essentially accelerate erosion processes. Cold weather freezes moisture trapped in tiny cracks. When this water freezes, it expands, subsequently pushing on the rocks and breaking them into smaller pieces. As processes of freezing and thawing continue, rock and sediment are continually broken down.

Biological Decay
Construction trash pits, buried trees, and other biodegradable materials all break down. Sometimes structures are built over these areas.

Stabilize Soil with Polyurethane

Loose soil can be consolidated, voids can be filled, and water migration halted by permeating the soil with one of the AP series products of ultra-low viscosity polyurethane resins. Once the bearing capacity of the soil has been increased with this process, then the structure can be lifted if necessary.  Learn more about Soil Stabilization Products here.

Want more information on polyurethane soil stabilization?

Crack Injection Explained

Crack injection has many advantages over other methods.  For example, if you’re sealing a leak in a water tank, you can inject from the outside of the tank. So the tank can remain in service while you repair it. Having to dry a crack, like you do with epoxy resin, is not needed as this material reacts with water. The material also remains flexible at all times.

Crack injections can be applied in both vertical cracks and in horizontal cracks. With vertical cracks, it is imperative to start at the bottom of the crack and work your way up the crack until it is filled. This forces the material up and through the crack and will simultaneously push the water up and out as well. With horizontal cracks, injection can be started at either the left or right end.

Read more from Charlie Lerman's article Crack Injection Explained.

Curtain Wall Grouting Explained

Curtain wall injection is the process of drilling holes through a structure in a diamond pattern, then injecting the grout into soil on the other side. This procedure creates a curtain wall made of a resin/soil mixture that prevents water from getting back into the structure. It is often required if there are multiple cracks or leaks in a wall. Filling each individual crack may cause you to waste time following the water from crack to crack. Curtain wall grouting allows you to stop multiple leaks at one time and protects the structure on a long term basis.

This procedure was first performed in 1960 on a sewer manhole with a multiple leak problem. As described above, chemical grout was injected through to the outside of the manhole. This created a “positive side seal” (on the side the water was coming from), blocking water from penetrating the joints of the structure.

Read more from Charlie Lerman's article Curtain Wall Grouting Explained.

Want more info on crack injection and curtain wall grouting products?

Looking for polyurethane concrete repair product Tech Data Sheets, Safety Data Sheets, Application Procedures, Case Studies, Environmental Safety Info, or Specifications?  All of these documents are available on one convenient page at Alchemy-Spetec's Comprehensive Download Resource Center.

Technical Data Sheets for Polyurethane Concrete Repair Products

Technical Data Sheets are available for the following product categories:

• Leak Seal
• Soil Stabilization
• Slab Lifting
• Water Stop
• Structural Repair

Safety Data Sheets for Polyurethane Concrete Repair Products

Safety Data Sheets are available for the following product categories:

• Sealing Leaks
• Stabilizing Soil
• Lifting Slabs
• Structural Repair
• Accessories

Procedures for Polyurethane Concrete Repair Applications

Procedures are available for the following applications:

• Standard Application for Injecting Cracks and Joints
• Railroad Ballast Rock Repair and Stabilization
• Manhole Infiltration Control
• Concrete Pipe and Corrugated Metal Pipe Joint Repair
• Targeting Pipe Leaks with Point Grouting

Case Studies for Polyurethane Concrete Repair Projects

The following Case Studies are available:

• Contractor Successfully Completes Unique & Challenging Driveway Lift
• Deep Soil Stabilization with Polyurethane
• Protecting a Building Foundation Next to an Excavation Site
• Stabilizing a Foundation to Save a Valuable Two Story House
• Protecting Drinking Water from Potential Flood Contamination
• Leaks in Wastewater Treatment Plant Sealed to Prevent Environmental Contamination
• Sealing Leaks in a Church Wall to Stop Costly Flooding of Elevator Pit
• Leak Seal at Water Treatment Plant
• Leveling Sunken Slabs in a Pole Barn
• Massive Underground Leak in Aquifer Shut Down
• Sealing Hairline Concrete Cracks with Acrylic Injection Resin
• Seawall Repair at Base of Bridge
• Slab Lift for Chinese Railway
• Slab Lift at Seed Sorting Plant
• Soil Stabilization at Busy Intersection

Environmental Safety Info on Polyurethane Concrete Repair Products

NSF Certificates are available for the following products that have been approved for contact with drinking water:

• AP Lift 430
• AP Lift 475
• AP Soil 600
• AP Fill 700
• AP Fill 720
• Spetec PUR F400
• Spetec PUR GT500
• Spetec PUR HighFoamer
• Spetec PUR H100
• Spetec PUR H200
• Spetec AG200

Engineering Specifications for Concrete Repair with Polyurethane

The following Engineering Specifications are available:

• Injection Grouting – Hydrophilic
• Injection Grouting – Hydrophilic & Hydrophobic
• Slab Lifting with AP Lift 430
• Permeation Grouting

Want more info on polyurethane concrete repair products?

A homeowner called Home Energy Professionals in Tennessee with an interesting driveway problem. There was an 8-inch drop at the point where the driveway met the edge of the garage floor. That was enough to prevent the resident from getting their car into the garage at all. The homebuilders did not extend a nearby gutter downspout far enough away from the driveway. Rainwater caused erosion under the slabs, causing them to sink over time. What made this case unique was the fact that the final slab (closest to the garage) in this 20-foot-wide driveway was only two feet long. Slabs with such narrow dimensions are notoriously difficult to lift evenly. Due to the unusual nature of this job, they called in Alchemy-Spetec’s Colt Hullander (Director of Technical Services – Geotech Division) as a consultant.

Powerful Polymers

The Home Energy Professionals crew used AP Lift 430, a two-component, high strength, high density, hydro-insensitive structural polyurethane foam. They chose AP Lift 430 because it’s one of the most consistently reliable lifting foams in the industry. This high-density foam is extremely strong, providing concrete slabs and structures with reliable and lasting support.

Painless Procedures

The crew drilled their first injection hole about 3 feet from one edge of the slab, right in the middle of the 2-foot length (about 1 foot in from both edges). They lifted this end of the slab for about 2 inches and then stopped. Lifting any further at this point would likely have cracked the slab. Next, they drilled another hole about 6 feet in from the edge and repeated the process. When they reached the end of the 20 feet, they started again – redrilling that first hole and lifting another 2 inches. With this gradual injection process, they carefully raised the slab 8 inches and leveled it off with the garage floor. They then moved on to lift the other, conventionally sized slabs in the rest of the driveway.

Rapid Results

This challenging slab lift job was completed in just 3 hours. Fifteen minutes after the injections were completed, the homeowner was able to drive their car across the newly leveled driveway and into the garage. The crew at Home Energy Professionals had another successful job in the books!

Want more information on lifting slabs?

A general contracting company working on an excavation job for a new sea turtle habitat at Loggerhead Marinelife Center in Juno Beach, Florida needed specialists to protect the foundation of the adjacent building from potential destabilization. Underground Services of America was called in to create a polyurethane grout wall for this very purpose.

Powerful Polymer

The crew used AP Soil 600, a single component, moisture activated, hydrophobic, extra-low viscosity, polyurethane soil grout. This is the premier product for stabilizing soil via permeation grouting. It's also NSF-approved for contact with drinking water. Using an environmentally safe repair material in a marine habitat is extremely important.

Painless Procedure

Underground Services of America professionals drove injection rods into the ground next to the building foundation in a staggered pattern (see photo). The rods were 18 inches apart from each other to ensure consistent, thorough permeation of the soil with the high-strength grout. They injected at a rate of one gallon per foot. A total of 500 gallons was used to form the grout wall. The project was completed in just two days.

Rapid Result

The resin was cured within 24 hours of completion. The job was finished on a Friday. On the following Monday, the GC began excavation on the future sea turtle habitat without any fear of damaging the adjacent foundation.

Want more information on soil stabilization products and procedures?