Alchatek Blog

Mechanical Packer diameter is relevant for two reasons, 1) this dictates the size of the drill hole required, and 2) the overall surface area of the rubber in the drill hole is a key contributor to the pressure tolerance of a mechanical packer. 

1. Size of drill hole considerations: Industry standards require 45-degree drilling to insert mechanical packers to a crack depth that is ½ the thickness of substrate.  For thin substrates, for example 6” thick slabs, drilling at a 45-degree angle with a 5/8” drill bit may cause spalling and damage to the surface above the drilled angle as the outward heave force from the passage of the drill is greater than the strength of the concrete at that location, resulting in concrete spall and cracking damage at that location.  For these applications, Alchemy-Spetec offers 5/16” (8mm) and 3/8” (10mm) diameter packers (see FIGURE 1).  

   The smaller cross section of drilling produces much less heave force against the face of the concrete and offers much better results when drilling into a thin concrete substrate. 

   Post-tension structures and/or structures with a significant amount of rebar also present an obstacle when drilling.  By reducing the size of the drill bit by 40-50%, the contractor also decreases the probability of drilling into rebar or post-tensioning accordingly.

2. The tradeoff for smaller diameter is a decrease in pressure tolerances.  Common ½” (13mm) or 5/8” (16mm) mechanical packers tolerate spikes in pressure greater than 4,000psi (see FIGURE 2).  At 4,000psi, packers and ports can present a significant job-site hazard as they can exit the drill hole at dangerous velocities.  While injecting at these pressures are never recommended, a ½” (13mm) or 5/8” (16mm) rubber base on the mechanical packer will prevent blow-out significantly better than the 5/16” (8mm) or 3/8” (10mm) counterpart.

Mechanical packers and ports are used on almost every leak seal chemical injection project. If a contractor is using chemical grout, then there is a high chance that they are also using mechanical packers. Considering that leak-seal injections are often performed in small cracks and joints, the mechanical packer portion of the project is often more significant than the chemical grout. Let’s begin with a brief overview of packer terminology as reference.

Several suppliers offer 2-3 standard mechanical packers and ports assuming that these are generic in design and commoditized. This assumption is incorrect. Not all mechanical ports are created equal, and we aim to define these functional differences in this brochure. Mechanical packers are most commonly defined by four key aspects; and these are Diameter, Length, Type, and Ball-Valve Location. Over the next few blog posts, we’ll examine the functional differences of these key aspects.

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The Alchemy-Spetec Gel Pump is a pneumatically-operated, high pressure, stainless steel, dual-component chemical injection machine designed primarily for low viscosity acrylic gels like Spetec AG100 and Spetec AG200.  A third component, or flushing agent, is pumped through an additional piston assembly that is operated at the mixing manifold.  

Advantages:

• Stainless steel design suitable for acrylic oxidizing agents
• Convenient pneumatic operation
• Portable machine able to be picked up
• Wheeled cart design for easy mobility
• Complete hose sets and applicator
• Single air drive runs both pistons to maintain true ratio
• Able to produce >2000psi of output pressure

Field of Application:

• Acrylic gels
• Low-viscosity, 1:1 chemical resins
• Combination grouting of microfine cements and polyacrylate gels

Click here to download the Gel Pump datasheet for more info.

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The Alchemy-Spetec Drill Pump is a high pressure, single-component chemical injection pump suitable for low to mid viscosity chemical injection grouts. It’s most commonly used for the application of polyurethane injection grouts. The drill-mounted design offers a convenient and portable solution for chemical injection applications.

The Drill Pump offers an unmatched ease of access to the piston assembly and ball/springs through just a few allen screws. The small reservoir and direct-feed design allows for small batch mixing and eliminates excessive losses due to mixing and priming. The portable design (20lbs with drill) provides a unique and high pressure solution that can easily be carried onto swing stages, scaffolding or scissor lifts.

Click here to download the Drill Pump datasheet for more info.

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The Dynamic Cone Penetrometer allows you to perform continuous dynamic penetrometric tests. The fact that it is exceptionally small means you can use it on sites that are inaccessible to normal machines. A hydraulic extractor is used to extract rods, casing tubes and samplers. The penetrometer is controlled via a pedal-operated distributor. The hydraulic connections on the various components use quick connectors. Its reliability is proven by hundreds of units operational around the world.

The penetrometer is equipped with a 66 pound (30 kg) hammer with a 7.87 inch (200 mm) stroke, operated by a hydraulic motor. It is driven by a motor-pump unit (the motor can be either electric or a gasoline engine).

The Dynamic Cone Penetrometer can be used not only for dynamic tests, but also for soil sampling with limited disturbance, which guarantees improved ability to interpret the penetrometric data.

Click here to download Dynamic Cone Penetrometer datasheet for more info!

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Hydroactive chemical grouts, by definition, require hydrogen molecules from water to initiate the polymerization reaction.  Typically, an ISO component is catalyzed by an amine, but this solution will remain unreacted until it comes in contact with hydrogen.  All of the contractors out there familiar with chemical grouts are familiar with the ‘skin’ on the top of a catalyzed batch.  This is simply the top layer of the catalyzed batch showing signs of initiation just through contact with moisture in the air.  For injection into active leaks, these products are a slam dunk.  But what happens when you get to the job, and there is no leak where there was one just a few days ago? 

Most manufacturers will provide the generic answer of ‘just introduce water.’  And in layman’s terms, this is accurate.  But what is the CORRECT way to introduce water?  Twin streaming through an F-Valve Assembly is perhaps the most proven technique to ensure adequate and thorough activation of hydroactive grouts.  An F-assembly is an applicator apparatus designed specifically for twin streaming multi components.  This can easily be achieved through the use of two pumps, one designated for water and another designated for chemical grout.  This will also prevent the leaking resin phenomenon sometimes observed following mechanical packer removal. 

Alchemy-Spetec supplies F-assemblies and the following hydroactive grouts: Spetec PUR H100, Spetec PUR F400, Spetec PUR F1000, Spetec PUR H40, AP Fill 700, and AP Soil 600.  For application recommendations and guidance, call an Alchemy-Spetec consultant now at 404-618-0438.  Don't rely on suppliers who simply promise a universally easy application process.  Lean on the suppliers who teach you how to navigate the unique challenges that each job site inevitably presents. 

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When you set out to work on a leak seal injection project, it's important to be prepared. 

Let's imagine you have a big polyurethane grout injection job today. Great, let’s go!

Everything starts going into the truck and you’re off. You get to the job, start pulling material, equipment, tools and a lot of other stuff out of the truck - then someone asks, “Where is the______? And where is the _______? And what happened to the _______?"

Suddenly it’s time to find the nearest hardware store, so you can get what you need, so you can get your job started and finished and cleaned up after you’re done. When you're not prepared, one trip to the hardware store is usually only the beginning. Sometimes multiple trips are necessary to get the project done.

The Boy Scouts always talk about the importance of being prepared. Here is a little help. Make a checklist to be sure you have what you need, so you can get to the job…..get started……..and get it done (without holding up work because someone needs to go to the hardware store).

Here is a suggested starter list. Add to it whatever else you think you may need:

Before you pack up for a job, it's critical to make a checklist of what you need. Check it twice (like Santa does) to make sure you have everything squared away up front. 

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Continuing on from the previous overview of Mechanical Packers and Ports, let's take a closer look at all of the required mechanical ports and accessories you could possibly need for your next chemical injection project.

The product line is comprised almost entirely of the most versatile steel mechanical packers compatible with practically all of the chemical injection grouts supplied on the market. These steel packers are offered in bottom-zerk and top-zerk style, allowing for customization and familiarity on site for all contractor preferences of technique and clean-up. All top-zerk configurations are interchangeable with button head clutch-couplings that prohibit excessive leakage which is ideal for finished or pristine spaces, or overhead applications. Alchemy-Spetec also supplies the required couplers that connect the anti-return valve to most standard industry hoses. For custom fittings, please consult your local pneumatic or hydraulic parts supplier.

Other common industry offerings are also available in zinc and aluminum designs, which offer variances in weight, price point, and chemical resistances. Plastic bang-in types are available in 3/8” and 5’8” diameters, and are most commonly used on concrete slab-lifting and soil stabilization projects allowing for higher volumes of material to be pumped prior to reaction.

Alchemy-Spetec is also very pleased to bring back the high-pressure blue and red 5/8” and 1/2" diameter mechanical packers with a large washer on the top. An industry go-to packer for many years, these packers feature a specialty rubber allowing for even higher tolerances for pressure hold. Rounding out the accessory items offered by Alchemy-Spetec are flush wands to clear drill holes of debris, injection needles to point-inject behind oakum or existing sealants, and F-assemblies that permit the ultra-effective twin-streaming technique of pre-mixing water and hydro-active chemical grout.

Please take a few minutes to familiarize yourself with the Alchemy-Spetec Mechanical Packer and Accessories brochure (see download button below). Call us directly at 404-618-0438 for samples, pricing, and/or local distributor contact information.

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The term ‘Mechanical Packer’ probably doesn’t mean much to those not in the concrete repair industry. But for those close to chemical grouting, this term certainly brings about thoughts of both form and function. Mechanical packers are also referred to as ports, or more simply, packers. But we would like to be very clear that a port is not a packer.  

Mechanical packers were designed to withstand high pressure injection applications by inserting them into pre-drilled holes in a concrete substrate at various diameters ranging most commonly from 1/4" – 5/8”. Mechanical packers feature a rubber base with a threaded shaft. As the threaded shaft is tightened, the rubber base is compressed, creating a compression seal inside the drill hole. The ultimate pressure tolerance is dependent upon the amount the rubber is expanded and the total surface area of the rubber base that is in contact with the drill hole. That is, a smaller diameter packer will have considerably less surface area of rubber compressed against the concrete side walls, and thus holding a lower amount of pressure when connected to high pressure equipment. Most job site and substrate conditions will permit successful injection results with a diameter of 3/8” – 1/2".  Of course, some contractors have personal preference of smaller or larger sizes.  

Concrete packers also come in various types. Suppliers will market benefits of steel, brass, zinc, or aluminum. All things considered, steel packers tend to be the most versatile packers as they are compatible with all chemical grout types, while the brass, aluminum, and zinc can exhibit signs of deterioration when using oxidizing agents such as the salt component in a polyacryate gel. However, some contractors insist that the breakdown is not as quick as marketed by suppliers, therefore utilizing brass and aluminum packers in these applications as well.  

Each packer features an anti-return ball valve that is opened under pressure, allowing the passage of chemical grouts. Upon depressurizing, the ball valve will close, prohibiting the return flow of the injection resin out of the drill hole. This ball valve can be located on the top of the packer, in the base of the packer, or even freely-floating in the packer shaft to allow for maximum flow. There are pros and cons to each ball valve location depending on job site condition and application and finishing techniques.  

Lastly, there are plastic alternatives commonly referred to as ‘bang-in’ or ‘hammer-in’. These packers do not have the threaded metal shaft, but as they are driven into the drill hole, the same compression seal theory takes hold as the tapered edges become lodged into the drill hole sides. Another form of plastic ports is a plastic, surface-mounted version that is commonly used in epoxy injection and/or in the event that drilling into the substrate would be considered harmful or ill-advised.  

For more detail on your specific project needs and packer or port recommendation, please contact a knowledgeable Alchemy-Spetec representative at 404-618-0438. Alchemy-Spetec offers all of the packers and ports listed above, as well as all of the chemical grouts and pumping systems required to make your next chemical grouting job a success!

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The Alchemy-Spetec PolyBadger lifting system is tough and compact. This system is an affordable entry-level slab lifting option for new contractors, as well as an extremely portable addition to the experienced contractor’s arsenal. The PolyBadger is a lot less expensive than your standard 20 foot trailer rig. The set up is simple and requires minimal equipment. The entire system can easily fit in the back of a pickup truck!

The genius of the PolyBadger is the auto calibrator. It keeps the flow of A-side and B-side slab lifting material on ratio, eliminating the possibility of crossover clogging in the gun or the whip hose. The two low-pressure transfer pumps and auto calibrator are literally the only moving parts in the whole system. That means less downtime, less maintenance, and more productivity on the job. This system is easier to use and a more affordable than many options on the market.

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