Alchatek Blog

The Maze of Repair-Related Regulations

For municipal managers overseeing stormwater and wastewater systems, the regulatory landscape can often feel like a complex maze. When it comes to repairs on manholes and lift stations, the stakes are even higher. Regulatory compliance is not just a matter of adhering to best practices; it's a legal requirement that carries significant consequences for non-compliance. This blog post aims to guide you through the labyrinth of permits and compliance requirements, offering tips for staying ahead of regulatory changes and outlining the benefits of compliant repair practices.

Navigating Permits and Compliance During Repair Projects

Understanding the Regulatory Framework

Before embarking on any repair project, it's crucial to have a thorough understanding of the regulatory framework that governs stormwater and wastewater systems. This includes federal, state, and local regulations, as well as industry standards. Ignorance is not an excuse in the eyes of the law, and failure to comply can result in hefty fines, legal action, and damage to your municipality's reputation.

Obtaining Necessary Permits

Permit acquisition is often the first step in any repair project. Whether it's a minor leak seal or a major overhaul, permits are usually required to ensure that the work meets established safety and environmental standards. Make sure to apply for these permits well in advance of your planned repair dates, as the approval process can be time-consuming.

Compliance Checks and Balances

Once you've obtained the necessary permits, the next step is to ensure that the repair work itself adheres to all regulatory requirements. This often involves:

• Pre-repair inspections to assess the scope and impact of the work.
• Mid-repair checks to ensure that the work is proceeding as per the approved plans.
• Post-repair audits to confirm that the repairs meet all compliance standards.

Record-Keeping

Maintaining detailed records is not just good practice; it's often a regulatory requirement. Documentation should include:

• The initial assessment and scope of the repair.
• All permits and approvals.
• Details of the repair process, including materials used and personnel involved.
• Final inspection reports and compliance certifications.

Tips for Staying Ahead of Regulatory Changes

Regular Training and Updates

Regulations are not static; they evolve over time. Regular training sessions can help your team stay updated on the latest changes and how they impact your operations.

Consult Regulatory Agencies

Don't hesitate to consult with regulatory agencies for guidance. They can provide valuable insights into compliance requirements and may even offer resources to help you meet them.

Leverage Technology

Modern technology can be a valuable ally in maintaining compliance. Software solutions are available that can track permit statuses, alert you to upcoming regulatory changes, and even automate some aspects of the compliance process.

Peer Networking

Networking with peers in other municipalities can provide additional perspectives on how to navigate the complex world of regulatory compliance. Industry conferences, webinars, and online forums are excellent platforms for such interactions.

The Benefits of Compliant Repair Practices

Adhering to regulatory compliance during repairs is not just a legal necessity; it offers several tangible benefits:

Risk Mitigation

Compliance reduces the risk of legal repercussions, including fines and lawsuits, that can be both financially and reputationally damaging.

Operational Efficiency

A well-planned, compliant repair process is often more efficient, minimizing downtime and ensuring that repairs are durable and effective.

Public Trust

Compliance with regulations not only protects the municipality from legal consequences but also builds public trust. When residents see that their local government is committed to following the law and protecting public safety, it enhances the municipality's credibility.

Environmental Stewardship

Many regulations are designed to protect the environment. By adhering to these rules, municipalities contribute to broader environmental conservation efforts, aligning with public sentiment and ethical responsibilities.

In summary, navigating the maze of repair-related regulations may be challenging, but the benefits of doing so are manifold. By understanding the regulatory landscape, obtaining necessary permits, and maintaining rigorous compliance checks, municipal managers can ensure that their repair projects are not only successful but also legally sound. Staying ahead of regulatory changes through training, consultation, and technology can further streamline this process, making compliance an integrated part of your operational strategy.

For information on municipal leak seal products...

The High Stakes of Unpredictability

Extreme weather events are becoming increasingly unpredictable, posing significant risks to municipal stormwater and wastewater systems. For municipal managers in charge of these systems, the unpredictability translates into a heightened risk of expensive emergency repairs, especially concerning manholes and lift stations. This blog post aims to shed light on how preventative maintenance, particularly with the use of polyurethane grout, can save municipalities from the financial burden of emergency repairs.

The Cost of Negligence: Emergency Repairs

When a stormwater or wastewater system fails, especially during an extreme weather event, the immediate need for repair can be both urgent and costly. Emergency leak seal repairs on manholes and lift stations can cost up to three times the price of preventative maintenance. These emergency situations often require immediate action, specialized labor, and sometimes even system shutdowns, all of which contribute to inflated costs.

The Power of Prevention: Polyurethane Grout

One of the most effective ways to prevent the need for such expensive emergency repairs is using polyurethane grout in preventative maintenance. Polyurethane grout offers a cost-effective, durable solution for sealing leaks and stabilizing structures. It provides a long-lasting seal that can withstand the pressures and conditions often exacerbated by extreme weather events.

Why Polyurethane Grout?

• Durability: Polyurethane grout is highly resistant to wear and tear, making it a long-lasting solution.
• Flexibility: Unlike traditional materials, polyurethane grout can expand and contract, making it ideal for fluctuating weather conditions.
• Cost-Effectiveness: While the upfront cost may be a consideration, the long-term savings in avoided emergency repairs make it a wise investment.

Implementing a Preventative Maintenance Plan

Preventative maintenance is not just about fixing problems as they arise; it's about anticipating issues and addressing them before they escalate into emergencies. Here's how to implement a preventative maintenance plan effectively:

Conduct Regular Inspections

Regular inspections of manholes and lift stations are crucial. Utilize modern technologies like CCTV cameras and sensor systems to monitor the condition of these structures continually.

Prioritize Areas for Maintenance

Not all areas will require immediate attention. Use the data collected during inspections to prioritize areas that are most at risk.

Schedule Preventative Maintenance

Once you've identified the priority areas, schedule preventative maintenance activities. This is where polyurethane grout comes into play. Use it to seal minor leaks and reinforce structures that show signs of wear and tear.

Train Your Team

Ensure that your maintenance team is well-trained in using polyurethane grout and other preventative maintenance technologies. Their skill level can significantly impact the effectiveness of your maintenance activities.

Monitor and Adjust

After implementing your preventative maintenance plan, continue to monitor its effectiveness. Adjust as necessary, and don't hesitate to update your plan to accommodate new technologies or methods.

The Financial Logic: Cost-Benefit Analysis

When weighing the costs and benefits of a preventative maintenance plan, the numbers speak for themselves. The initial investment in polyurethane grout and other preventative measures pales in comparison to the potential costs of emergency repairs. Factor in the additional benefits of avoiding system downtime, and the case for preventative maintenance becomes even more compelling.

The Long-Term Benefits of Preventative Maintenance

Preventative maintenance, especially when utilizing polyurethane grout, offers municipalities a viable path to avoid the financial and operational pitfalls associated with emergency repairs. It's not just about cost-saving; it's about operational efficiency, system reliability, and ultimately, public safety. By adopting a proactive approach to maintenance, municipal managers can effectively mitigate the risks posed by the increasing unpredictability of extreme weather events. In doing so, they not only protect their communities but also ensure the longevity and reliability of critical infrastructure.

For more information on sealing leaks with polyurethane grout...

The Environmental Stakes of Wastewater Management

Wastewater management is not just a logistical challenge; it's an environmental imperative. The stakes are high, and the consequences of mismanagement can be devastating. From contaminating water bodies to harming aquatic life, the environmental impact of poorly managed wastewater systems is far-reaching. As stewards of public infrastructure, municipal managers have a responsibility to not only ensure the effective treatment of wastewater but also to minimize its environmental footprint.

Eco-Friendly Technologies and Practices

Fortunately, advances in technology and best practices offer a path to more sustainable wastewater management. Here are some of the leading eco-friendly technologies and practices that can make a significant difference:

Membrane Bioreactors (MBRs)

MBRs combine conventional activated sludge treatment with membrane filtration. This technology offers higher-quality effluent and reduces the need for chemical use in wastewater treatment.

Anaerobic Digestion

Anaerobic digestion breaks down organic matter in the absence of oxygen, producing biogas that can be used for energy. This process reduces the volume of sludge and its associated disposal costs.

Phytoremediation

Using plants to remove or neutralize pollutants in water is an eco-friendly and cost-effective method. Wetlands, for example, can be engineered to treat wastewater naturally.

Energy-Efficient Pumps

Switching to energy-efficient pumps can significantly reduce the energy consumption of wastewater treatment plants, thereby lowering their carbon footprint.

Real-Time Monitoring Systems

Advanced sensors and control systems can optimize the treatment process, reducing the need for chemicals and energy.

Steps for Implementing a Green Wastewater Management Strategy

Implementing an eco-friendly wastewater management strategy requires a comprehensive approach. Here are some steps to guide municipal managers:

Conduct an Environmental Audit

The first step is to assess the current environmental impact of your wastewater treatment facilities. This audit will identify areas for improvement and help prioritize actions.

Set Clear Objectives

Define what you aim to achieve with your green wastewater management strategy. Whether it's reducing energy consumption by a certain percentage or lowering chemical use, clear objectives will guide your efforts.

Choose Appropriate Technologies

Based on your audit and objectives, select the technologies that best fit your needs. Consider factors like cost, scalability, and ease of integration with existing systems.

Train Staff

Successful implementation requires a well-trained staff. Make sure your team understands the new technologies and practices, and how they contribute to environmental sustainability.

Monitor and Adjust

Once implemented, continuously monitor the performance of your new systems. Use real-time data to make necessary adjustments and optimize efficiency.

Engage the Community

Transparency is key. Keep the community informed about your efforts to make wastewater management more eco-friendly. Public support can be a significant asset in securing future investments in green technologies.

The Importance of Using NSF-Approved Products in Repairs

When it comes to repairs involving contact with drinking water, it's crucial to determine if your project requires products that meet NSF/ANSI 61-5 standards. The National Sanitation Foundation (NSF) develops public health standards and certification programs that protect the world's food, water, consumer products, and environment. NSF ensures that adequate testing is conducted for all products used in or around drinking water from source to tap.

Each product must undergo rigorous testing to receive NSF approval. The manufacturer's plant and quality assurance practices must also pass a thorough inspection. This rigorous certification process is invaluable to all parties involved, ensuring that products meet the highest standards for safety and quality.

Moreover, compliance with NSF standards ensures that you are also in compliance with the Safe Water Drinking Act (SDWA). The SDWA gives the EPA the authority to impose criminal and civil penalties on industries that are not in compliance. In 2014, enforcement efforts netted $163 million in penalties and fines, 155 combined years of incarceration for sentenced defendants, and $16 million in court-ordered project clean-ups.

For municipal managers, using NSF-approved products in repairs is not just a best practice; it's a legal necessity. It ensures that you are not the source or cause of drinking water contamination, either in the short or long term.

The Long-Term Benefits of Eco-Friendly Practices

Adopting eco-friendly practices in wastewater management is not just good for the environment; it's also good for the community and the municipal budget. Reduced energy consumption lowers operational costs, while cleaner effluent means healthier ecosystems and, potentially, fewer regulatory hurdles. Moreover, sustainable practices can enhance a municipality's reputation, making it more attractive for both residents and businesses.

In the long run, the benefits far outweigh the initial costs and challenges of transitioning to a green wastewater management strategy. It's an investment in the future—a future where both people and the planet can thrive. Municipal managers have the opportunity, and indeed the responsibility, to lead the way in adopting sustainable, eco-friendly practices. By doing so, they safeguard not just their immediate community, but also contribute to global environmental conservation efforts.

For more information on sealing leaks in wastewater systems...

The Critical Role of Wastewater Management in Public Health

Wastewater management stands as a cornerstone of public health. It's not just about pipes and pumps; it's about protecting communities from diseases and environmental hazards. When wastewater systems fail, the consequences are immediate and severe. One of the most alarming issues is Sanitary Sewer Overflows (SSOs), which can lead to backups into people's homes, including toilets and basements. These incidents are not just unpleasant; they are unhealthy and can result in significant costs for the city, as municipalities often bear the financial burden of repairs.

The Consequences of System Failures: SSOs and Backups

When SSOs occur, untreated sewage can overflow into rivers, contaminating water sources and posing a severe environmental risk. The immediate impact on residents is equally concerning. Imagine the horror of sewage backing up into your home. It's not just a foul-smelling inconvenience; it's a health hazard that exposes residents to harmful bacteria and other pathogens.

The EPA Steps In: What Happens When You're Sued

If your municipality's wastewater system is causing pollution due to SSOs or other failures, you can expect intervention from the Environmental Protection Agency (EPA). The EPA has the authority to sue municipalities for failing to manage wastewater effectively, and they often win these cases. Once that happens, the EPA will mandate a repair deadline. While this may sound daunting, it's worth noting that the EPA also provides funding assistance to help municipalities comply with these mandates.

A Cost-Efficient Approach to Mitigating Infiltration in Sanitary/Stormwater Systems

So, how can municipal managers effectively address these challenges without breaking the bank? One promising solution lies in the use of flexible polyurethane grout for targeted leak repairs. This approach promises a robust return on investment and can be broken down into three key steps:

Assessment: Inspect Lift Stations and Manholes

The first step in any repair process is a thorough assessment. Municipal managers must inspect lift stations and manholes to identify the system's weak points. Modern technologies, such as remote sensors and CCTV cameras, can assist in this process, providing real-time data on system integrity.

Identification: Locate and Prioritize Significant Leaks

Once the assessment phase is complete, the next step is to identify and prioritize leaks that require immediate attention. Not all leaks are created equal. Some may be minor and pose less immediate risk, while others could be catastrophic if not addressed promptly. Prioritizing these leaks ensures that the most critical issues are resolved first, thereby reducing the risk of SSOs and backups.

Targeted Repair: Utilize Flexible Polyurethane Grout

After identifying the most significant leaks, the final step is the repair process. Here, flexible polyurethane grout comes into play. Unlike traditional repair methods that often require extensive excavation and are labor-intensive, polyurethane grout offers a more efficient solution. It provides a precise, point repair approach that seals leaks effectively, ensuring a longer-lasting fix.

The Strategic Importance of Flexible Polyurethane Grout

For municipal managers overseeing stormwater and wastewater systems, embracing flexible polyurethane grout for leak repair is a strategic move. It's not just about ensuring infrastructure longevity; it's about safeguarding public health and achieving economic efficiency.

When you consider the potential costs of EPA intervention, including legal fees and mandated repairs, the return on investment for proactive maintenance becomes abundantly clear. Add to this the public health risks and environmental damage that come with system failures, and the case for a proactive, efficient approach to wastewater management is compelling.

The Time for Action is Now

If your municipality is under an EPA mandate, or if you're looking to avoid one, now is the time to act. Proactive management of wastewater systems is not just a regulatory requirement; it's a public health imperative. By adopting a cost-efficient approach that utilizes modern technologies like flexible polyurethane grout, municipalities can not only comply with regulations but also protect their communities and the environment.

Remember, wastewater management is not just an engineering challenge; it's a community responsibility. By taking timely, effective actions, municipal managers can fulfill this responsibility and ensure the well-being of their residents for years to come.

For more information on polyurethane leak seal grout...

All cracks that aren’t actively leaking at the time you are sealing them need to be flushed out with water. Flushing them gives you several advantages:

1. Lets you know whether your drill holes have intersected the crack.
2. Flushes dirt and debris out the surface of the crack so your resin has a cleaner internal surface to bond to.
3. Reveals how far you can expect the resin to travel so you know if your drilled holes are close enough together.
4. The water will help open up tight cracks that the thicker resin may not otherwise have been able to penetrate.
5. Ensures that the resin has sufficient moisture to react with.

Start at the lowest point in the crack and flush clean water through your injection ports. It is best to have at least two pumps onsite. One for pumping water and one for pumping resin. Use the same type of high-pressure pump that you use for resin. You can use a smaller pump if you like, as long as it is capable of generating between 2,800 and 3,500 p.s.i.

BE CAREFUL when flushing tight cracks! The low viscosity of water coupled with the high pressure of the pump can shear the concrete. The water can push into tight cracks and capillaries and all at once split your concrete. You can also shear concrete with resin, but it is more likely to happen with water because you are testing your crack and trying to open it up.

Always start every port with the lowest pump pressure and slowly turn it up as necessary. Also, slowly crack the valve open when you are first injecting water or resin. This is a critical moment in the process. If you forget to turn the pump pressure down after each port, you risk blasting high pressure into the port all at once which can result in shearing of the concrete or blowing out the port.

Keep injecting water as long as it is flowing through the port and moving further and further along the crack. Monitor the water coming out of the crack. Notice if it is clean or cloudy. Keep injecting until it comes out clean.

If the project is big enough, you can have one technician injecting water and another injecting resin right behind. Personally, I like to do both steps myself. That way I know what to expect when injecting the resin. In any case, keep the water pump nearby. Many times you will have to pop another hole in the wall here and there to completely seal the crack with resin.

5 Steps of Crack Injection - Overview
5 Steps of Crack Injection - 1. Drilling Holes
5 Steps of Crack Injection – 1. Drilling Holes (Continued)
5 Steps of Crack Injection – 2. Flushing Holes
5 Steps of Crack Injection – 3. Installing Ports
5 Steps of Crack Injection – 4. Flushing Cracks
5 Steps of Crack Injection – 5. Injecting Resin

Want in-depth info on crack injection procedures and products?

Here it is. My favorite topic. Why? Because it is my pet peeve. It separates the technicians who care from those who are only going through the motions. Quite frankly, it can be the difference between a successful outcome and dismal failure - or at the very least an expensive callback.

When you drill holes you create concrete dust. The hammer drill bit literally chews up the concrete. Most of it comes out of the hole and falls on the floor. However, a lot of dust is left behind inside the hole. If it is not properly flushed out then it will mix with your polyurethane injection resin and make a thick paste. This thick paste can be forced into the crack and prevent the clean resin from reaching deep into the crack where it is needed. Most of the time you won’t even realize you have a problem. But there it is nonetheless. Waiting for the right conditions to allow water to seep back through the crack you thought you fixed.

How do you avoid this? Simple - flush the hole out from the back using a very cheap flexible hose that attaches to your flush pump (you did bring a separate flush pump didn’t you?). Start at the highest hole and work your way down until clean water is flowing out of each hole.

Spraying water on the face of the holes may make it look clean, but it is not effective. There is still dust deep in the hole. Filling a water bottle up and squeezing it so that water shoots part way up the hole is not good enough. You have to have the water exit your hose at the back of the hole. This is the only way.

Are there exceptions? Of course, there are. If you pull the drill bit out of the hole and water gushes out behind it in a steady stream you can skip this step. Otherwise, make sure you bring a flush hose with you. It has to be small enough to fit inside your drill hole. We make it easy for you. We make one and sell it for cheap (so don’t blame us if you get to your job site and don’t have one).

This is so basic it is silly. However, I have seen experienced technicians do the water bottle trick and try to explain that it is sufficient. I’m happy to report that those guys are working for your competitors now. Just make sure your guys don’t get lulled into laziness and skip what just might be the most important of these five basic steps:

1. Drill the hole
2. Flush the hole
3. Install the ports
4. Flush the crack
5. Inject the resin

Next up, we install the ports!

5 Steps of Crack Injection - Overview
5 Steps of Crack Injection - 1. Drilling Holes
5 Steps of Crack Injection – 1. Drilling Holes (Continued)
5 Steps of Crack Injection – 2. Flushing Holes
5 Steps of Crack Injection – 3. Installing Ports
5 Steps of Crack Injection – 4. Flushing Cracks
5 Steps of Crack Injection – 5. Injecting Resin

Want in-depth info on crack injection procedures and products?

Let’s face it, most of the structures you drill through will be full of rebar. Rebar is the steel reinforcement that gives the structure its strength. Concrete protects the rebar by shielding it from moisture, and the high pH of concrete keeps the rebar from rusting. However, once a crack forms it allows more water and environmental gasses to reach the area surrounding the rebar. Carbonation of the concrete can now occur which causes the pH to drop and the corrosion process to begin. The rust expands and takes up 15 times the volume of the un-corroded steel which causes tensile forces to work against the concrete eventually resulting in additional cracking and spalling. Hopefully, you will be called in to fix the leaks before much of this damage occurs.

Once you are on the job site, this slow process of decay does not really affect you (unless the concrete is spalling off as you drill). Your issue with the rebar is that it will stop your drill bit from penetrating the crack. The cracks will often follow the rebar, especially if there is not adequate coverage of concrete over the rebar. Shallow rebar is a huge contributing factor to cracks in concrete.

At this point, all you care about are two things. First, how do you know if you have hit rebar? Second, if you have hit it, what do you do next?

After drilling many thousands of holes, as I have over my career, I pretty much know when I have hit rebar. Here are a few things to look for:

1. The forward progress of drilling has stopped.
2. The sound of the drilling changes.
3. The quantity of drilling dust is reduced.
4. If you are not sure, put your hand out to catch some of the drilling dust coming out of the drill hole. Observe it for metal shavings.

Given enough time and effort, you can drill through rebar. However, I wouldn’t recommend this as a general practice. It takes a lot of time, weakens the structure you are trying to protect, and...have you bought a drill bit lately? Steel is expensive! Try this instead:

1. Move further away from the crack and try again (adjust your drilling angle).
2. Move closer to the crack and try again (adjust your drilling angle).
3. Move parallel to the crack and try again.
4. Move to the other side of the crack and try again.

As a last resort, drill straight into the crack. This is not the ideal situation, but if you can drill deep enough to get an injection port installed, then you might be able to successfully seal the leak. 

Now that the surface of your concrete looks like Swiss cheese, it is time to go get that bag of fast-set hydraulic cement you brought along for just this purpose. Try to patch it up before you begin injection because some of those abandoned holes are libel to have hit pay dirt. If you don’t seal them up then you will have foam or resin leaking out of the holes.

Hitting rebar is not fun and can be frustrating. The key is to expect it and try to think three-dimensionally. See if you can visualize what is going on behind the concrete. This is one of the keys to becoming a really good injection technician.

5 Steps of Crack Injection - Overview
5 Steps of Crack Injection - 1. Drilling Holes
5 Steps of Crack Injection – 1. Drilling Holes (Continued)
5 Steps of Crack Injection – 2. Flushing Holes
5 Steps of Crack Injection – 3. Installing Ports
5 Steps of Crack Injection – 4. Flushing Cracks
5 Steps of Crack Injection – 5. Injecting Resin

For more information...

Inflow and Infiltration (I&I)

Inflow and infiltration (I&I) refer to the entry of groundwater and rainfall-derived water into wastewater and stormwater collection systems through defects such as cracked pipes, deteriorated manholes, faulty connections, and other openings. This excess water can overload the capacity of wastewater treatment plants and collection systems.

Inflow refers to water that enters the sewer system from direct connections such as roof drains, yard and area drains, foundation drains, surface runoff, or street wash waters. Infiltration refers to groundwater that enters the sewer system from the surrounding soil through defective pipes, pipe joints, connections, or manhole walls. Infiltration is the focus of polyurethane grouting.

Managing I&I is important for preventing sewer overflows, reducing treatment costs, and minimizing energy consumption.

Understanding the Risks: What are Sanitary Sewer Overflows (SSOs)?

Sanitary sewer overflows (SSOs) are a prevalent concern, posing significant public health threats. EPA data indicates an alarming 23,000 to 75,000 SSO incidents annually in the U.S. These overflows, laden with raw sewage, are carriers of bacteria, viruses, and other harmful entities, potentially leading to conditions ranging from mild stomach discomforts to severe diseases like cholera and hepatitis.

The Financial Implications and Opportunities

Tackling these issues often requires a significant financial commitment. The EPA's Clean Water State Revolving Fund (CWSRF) has allocated hundreds of billions of dollars for diverse water infrastructure projects. Established in 1987, this initiative offers states the autonomy to address their unique water quality challenges.

A Cost-Efficient Approach to Mitigating Infiltration in Sanitary/Stormwater Systems

Here's an efficient plan employing flexible polyurethane grout that promises a robust return on investment:

1. Assessment: Start with inspecting lift stations and manholes.
2. Identification: Locate and prioritize significant leaks.
3. Targeted Repair: Utilize flexible polyurethane grout for precise point repairs.

A single crew can often mitigate leaks in two standard 8' deep manholes a day. This swift mitigation can lead to substantial savings. For instance, addressing leaks in just a single day can easily amount to around $30,000 in annual savings, based on local water treatment costs. In mere months, the cost of the repair is already recouped.

For municipal managers overseeing stormwater and wastewater systems, embracing flexible polyurethane grout for leak repair is a strategic move. It's not just about ensuring infrastructure longevity, but also safeguarding public health and achieving economic efficiency.

For more information...

I remember my first day on the job back in June of 1985. We were working nights in the subway tunnels of Atlanta, sealing leaks in the ceiling. The crew handed me a 30-pound hammer drill and told me to drill holes in the ceiling at a 45-degree angle. Sure, what the heck is a 45-degree angle? I put on a lot of muscle that summer drilling overhead and hauling 50-pound pails of resin all over the Southeastern U.S.

Drilling holes into concrete seems like a straightforward process. However, it must be done correctly or everything you do afterward is a waste of time. Often, contractors put their least experienced technician on that job because it is manual labor and can be taught quickly. But knowing a few of the basics can help a newbie drill like an expert.

First, you have to understand that the beginning of the hole is where the injection port makes its seal against up to 3,000 pounds per square inch of injection pressure. It is important that the hole stay round, especially when using hammer in type ports. That means you have to keep the drill bit in a straight line.

Why a 45-degree angle? This is the best way to intersect the crack halfway through the structure (which is your goal). For example: On a 10” thick wall, come off the crack 5”, drill at a 45-degree angle and you should hit your target. Just start with your drill bit straight into the wall, give the trigger a few bumps to make an indention in the concrete with the bit, and rotate your drill so that the angle is halfway between your starting position and the wall.

How far apart should you space your holes? It depends on the width of the crack. Tighter cracks need tighter spacing because the resin won’t travel as far. Wider cracks can have wider spacing because the resin will travel with ease. A rule of thumb is to drill your holes no farther apart than the thickness of the concrete. Drill, flush, and pump a test hole with water to get an idea of how far the resin will travel.

Be sure to pull the drill bit out every four or five inches of penetration to clean out the drilling dust. Otherwise, you are likely to bind up your drill bit, which is not fun to try to remove.

Sometimes you will have to drill straight into the crack. I always try to angle drill first, but with extremely tight cracks you may have to compromise and drill straight in. Go as deep as you can, but make sure you don’t go all the way through.

Another tip: If you stagger your holes from one side of the crack to another, be sure not to intersect a hole you already drilled. This causes all kinds of problems.

We will talk about flushing drilling dust out of your holes later, but I can’t repeat it enough. If you want a successful injection job you have to flush the drilling dust out of the holes from the back. Otherwise, the dust will form a paste that gets forced into the crack and blocks your resin from getting where it needs to be. Splashing water on the front of the hole doesn’t really help. Be sure to get a small hose to the back of the hole and flush it with clean water.

In the next article, we'll take a look at what to do when you inevitably hit the injection contractor's nemesis...rebar!

5 Steps of Crack Injection - Overview
5 Steps of Crack Injection - 1. Drilling Holes
5 Steps of Crack Injection – 1. Drilling Holes (Continued)
5 Steps of Crack Injection – 2. Flushing Holes
5 Steps of Crack Injection – 3. Installing Ports
5 Steps of Crack Injection – 4. Flushing Cracks
5 Steps of Crack Injection – 5. Injecting Resin

Want in-depth info on crack injection procedures and products?

A general contractor working on new luxury apartment construction in Queens, NY reached out to a local leak seal specialist after discovering hairline cracks in the base joint of a fire protection storage tank. (A fire protection storage tank stores water for use in fire suppression systems.)

Powerful Polymer

Cracks in concrete come in all widths and sizes. Some of the most difficult ones to inject are the hairline cracks. The thinnest flexible polyurethane grouts on the market are between 100cps - 200cps which makes it difficult if not impossible to get them to penetrate a hairline crack. Spetec AG200 is an acrylic-based grout and it is 18cps, or about 5-10 times thinner than the thinnest flexible polyurethane. Clearly, a thinner grout will penetrate cracks much more effectively. Spetec AG200 is almost as thin as water, but when it polymerizes it forms a flexible hydrophilic gel. This gel features 500% elongation, which may sound like overkill to some, but 500% movement in a hairline crack is not much. The ultra-low viscosity and field adjustable set time make Spetec AG200 ideal for thin and hairline cracks.

Painless Procedure

The crew followed the standard crack injection procedure:

1. Identify crack locations.
2. Estimate the amount of material needed.
3. Prepare the surface of the crack.
4. Drill injection holes at a 45-degree angle.
5. Flush out injection holes with water to remove any debris.
6. Insert injection ports on both sides of the crack.
7. Inject water into each port.
8. Start injection of material.
9. Always grout twice.
10. Add water again.

Spetec AG200 was successfully injected into cracks and the base joint of the firefighting water reserve tank.

Rapid Result

The defects in the tank were easily penetrated by Spetec AG200 and the job was a success. This allowed the general contractor to get back on schedule with the building construction.

Want more information on leak seal products and equipment?