Leaking concrete can be detrimental to safety and property values. The products offered by Alchemy-Spetec deliver the ultimate solution for hairline cracks, gushing leaks and other waterstop issues.

Sealing Leaks with Concrete Crack Injection

Concrete starts decaying immediately after it cures. Even brand new construction can require leak seal follow up work. Older concrete structures are even more susceptible. Leaks through concrete are generally going to be through cracks, joints, and honeycomb (areas in poured concrete of mainly course aggregate with voids in between). Depending on water volume and pressure, and the size of the joint or crack, you are going to encounter weeping leaks, steady leaks, and gushing leaks. These leaks can be sealed with crack injection resin.

Stopping Multiple Leaks with Curtain Wall Grouting

Curtain wall grouting is often required when cracks cannot be identified, when the walls are made of material that does not respond well to crack injection (such as masonry, stone and CMU), and when previous leak seal methods have failed.  Curtain wall grouting is the process of injecting water reactive resin behind the leaking wall in a grid pattern. 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.

Waterstop

Newly constructed floor/wall joints with no waterstop lining can be vulnerable to water infiltration. When designers and builders neglect to line the joints, water can seep into the structure and out onto the floor. Needless to say, water on the floor can be an inconvenience, it can be a safety hazard, and it can damage property. In addition, floor/wall joint leaks can cause the concrete to decay and spall over the long run. Alchemy-Spetec offers a variety of waterstop solutions.

Want more leak seal resources?

The U.S. Department of the Interior and the Bureau of Reclamation recently conducted a study in which they evaluated methods for sealing contraction joints in dams. They tested 8 methods. Spetec PUR F400 was used in one of only two methods that reduced water flow 100%. We'll share some excerpts from their report in today's blog post...

The U.S. Department of the Interior protects America’s natural resources and heritage, honors our cultures and tribal communities, and supplies the energy to power our future. The mission of the Bureau of Reclamation is to manage, develop, and protect water and related resources in an environmentally and economically sound manner in the interest of the American public. 

All Reclamation concrete dams have joints which experience pressure caused by the reservoir water elevation. These joints have waterstops between the formed drain and the upstream face of the dam to prevent water leakage through the joint. Over time, the waterstops can begin to leak which can become a significant maintenance issue. These leaks can lead to millions of dollars of increased maintenance costs across numerous facilities, since they corrode metalwork, increase operation costs through increased pumping to remove excess water, and reduce worker productivity as they work around the leaks, etc. In some cases, the water leaks can threaten or damage expensive equipment.

Conventional leaking contraction joint repair methods are either very expensive or do not last long. Based on work from previous years looking into cheaper repair options, where we developed an inexpensive method to deliver repair materials to a specific location deep under water, several prototype repair methods were developed. To test those methods, we built a laboratory fixture to simulate a leaking contraction joint in a dam under pressures as high as 35 psi. With this fixture we tested different repair options. These options included sawdust, hydrophilic waterstop chips, chemical grouts used for sealing water leakage through concrete, and combinations of the chips and grouts.

In this testing we found that sawdust didn’t slow the water flowing through the test fixture joint. Hydrophilic chips slowed the water by as much as 65%, and Hydrophilic chips combined with some chemical grouts completely stopped the water flow through the test fixture joint. These results could have substantial implications at Reclamation facilities with leaking contraction joints. These methods can be implemented to significantly reduce or completely stop the infiltration of water and are much cheaper than many alternatives.

Here is the product comparison table excerpted from the report...

You can read more about the report here and download the entire report here.

Want more information on Alchemy-Spetec leak seal products?

We've blogged about this before, but it's worth repeating. Twin streaming is a technique in which you use a high pressure 3,000 psi F-valve to inject resin AND water at the same time. As you can see in the photo, the F-valve has two supply connections - one for water and one for resin. The water and resin come into contact before they exit the coupler.

Advantages:

1. Ensures there is enough water for the resin to react with.
2. Starts the reaction immediately.
3. Promotes faster reaction in cold water.

Filling Voids Above the Water Table

When working on jobs that require void filling behind walls, also known as curtain grouting, it is imperative that you are prepared for any obstacles that may occur. If the voids are large and dry, resin may not have enough water to react with when injected in the conventional manner. In this case injecting water behind the wall prior to injection might not be sufficient (especially if the void is open or filled with gravel, giving the water an easy path to escape). With twin streaming you are guaranteed there is enough water for the resin to fully react and fill the voids.

Injecting Resin Into Cold Water

Twin streaming also works well if you find yourself having to inject into a cold, underwater environment. You can inject warm water along with the resin to jump start the reaction process before the cold water gets a chance to slow down the process. The ratio of water to resin can be controlled by opening the valves at different angles. Some products such as Spetec PUR H100, Spetec PUR H200 and AP Fill 700 only need a little water to react with (10:1 resin to water is plenty). In this case, you would crack the water valve slightly, then open the resin valve all the way. Other products such as Spetec PUR GT500 and Spetec PUR GT350 need more water. A 2:1 or 1:1 ratio of resin to water both work well. In this case, you may want to open both valves all the way.

Want more info on Leak Seal products?

In a structure that holds water, you need something flexible to inject into cracks or joints. These types of structures are usually above ground and exposed to changing temperatures. As concrete heats up during the day it expands; joints and cracks squeeze together. As it cools, the concrete shrinks and joints and cracks open up. Thus, you need an injection foam that has flexibility to handle the movement.  You also need to do the injection work in the early hours of the day. Some contractors have injected cracks in the afternoon; stopping leaks, only to find them leaking again in the morning. 

For these scenarios, we recommend the Spetec PUR GT500 or Spetec PUR F400.  The GT500 is hydrophilic and absorbs some water during the reaction. In a tight crack or joint it's great and has minimal shrinkage if it dries out.  It has lower expansion, maybe 4-6x by volume, so for wide joints it may take more product and will likely require oakum to retain the resin in the joint. It does not have an adjustable set time. 

The F400 is a flexible hydrophobic. It combines higher expansion properties with flexibility. It also has a catalyst which allows you to adjust the set time. The F400 is excellent for crack injection, joint injection (especially larger joints), and infrastructure injection as well.  It does not shrink because it's hydrophobic and unaffected if no moisture is present. 

Now let’s talk a little about hydrostatic pressure. Most injection work is done less than 40' below the water level and head pressure is less than 20 psi. Considering we recommend injecting with pumps capable of 3000+ psi, getting the product in the crack is not the problem. The challenge is keeping the polyurethane in the crack or joint long enough for it to set up. That's where experience comes into play. The contractor must know how to adjust the set time, how to drill the injection holes properly, how to use oakum, and how long to inject on a single packer/port.   

We have not seen failures on dams or locks where pressure blew out the polyurethane. Dams across the globe have been injected this way. Where we do see failures (continued leaks, not blowouts) is when the wrong material is selected, or the injections are done during the hotter hours of the day. In fact, some water authorities only inject during the cold months of the year.

Want more info on Alchemy-Spetec leak seal products?

Nationwide, municipalities regularly deal with the issue of infrastructure deterioration. One of the most common types being the constant appearance of water leaks. Active leaks, when untreated, can cause an accelerated deterioration of reinforcement within concrete, as well as settlement issues caused by voids below and next to structures.

The purpose of this article is to illustrate how polyurethane injection can be used as a preventative measure to prevent more serious problems.

Municipal Structures Vulnerable to Infiltration

Various areas in the wastewater, drinking water and storm water system may require polyurethane to stop infiltration. This is mainly due to its clean application and rapid results. These areas include but are not limited to:

• Manholes
• Water Treatment and Storage Tanks
• Lift Stations
• Storm and Sanitary Pipes

How Spetec GT500 Seals Hairline Cracks

This graphic depicts the polyurethane leak seal process when applied to the wall of a water tank. Our leak seal resin, Spetec PUR GT500, reacts when it comes into contact with water. It bonds to concrete in a durable manner, yet remains flexible so as not to crack if the concrete shifts in the future. High pressure injection insures that every part of the crack is filled and permanently sealed. This product is certified To NSF 61-5 (approved for contact with drinking water).

How Spetec PUR H200 Stops Gushing Leaks

This graphic depicts the process when applied to a larger leak with a void in the soil on the other side. While the graphic depicts a box culvert, voids like this can develop next to water tanks that are built against a hillside, manholes, pipes, etc. Spetec PUR H200 is used to fill the void and stop the gushing leak in the process. This product is certified To NSF 61-5 (approved for contact with drinking water).

Another Common Issue: Leaks in Equalization Tanks

Another common issue is leaks around the bases of equalization tanks. This untreated water can present a hazard to employees. Left unaddressed, it just costs more and more money to keep pumping this water back out.

Conclusion

Regardless of the leak seal issue at hand, one thing is certain: left untreated it will cost more money and do more damage in the long run. In this case the old adage “An Ounce of Prevention is Worth a Pound of Cure” is completely appropriate. Are you a municipal manager facing any of these issues? Technical Consultants at Alchemy-Spetec have a great deal of experience with leak seal solutions for municipalities. Call us at 404-618-0436.

Want more in-depth info on polyurethane leak seal?

(Today we feature a guest blog from our customer Randy Serhan, owner of JACC Structures in Saskatchewan.)

First of all, I'd like to thank Alchemy-Spetec for asking me to write a guest post on their blog.  If you're interested in polyurethane leak seal, I think you'll like this one.  I recently did a leak seal job for a homeowner up here in my Candian hometown of Nipawin, Saskatchewan.  He had water coming into his basement around a water line access sleeve.  It was leaking approximately 1/2 litre of water per minute.  He called me to see if I could resolve the issue.  I packed some oakum saturated with Spetec PUR GT500 into the sleeve around the water pipe.  The leak was stopped in under a minute.  I used a moderate quantity of the resin-saturated oakum to ensure the plug was approximately two inches deep.  It won't leak again.  The customer was extremely happy as this repair means he will no longer have to babysit the water pails all night.  He also has the peace of mind of knowing that this is a long lasting fix, so he doesn't have to re-visit the problem each spring or heavy rainfall.  When that leak shut down so fast, he look at me and said "that stuff is magic".

And now for the best part: click below to watch me shutting down that link in this video clip I took on the job!

Want more information on Alchemy-Spetec leak seal products?

Leak Seal & Geotech Products & Procedures

March 14 & 15, 2019 at Alchemy-Spetec HQ in Tucker, GA

Last chance to register!

Get ready for a thorough education in Leak Seal, Slab Lifting, Soil Stabilization and the Alchemy-Spetec Deep Lift™ process. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Thursday - Leak Seal

• Leak Seal Product Line Overview
• Curtain Grouting
• Permeation Grouting
• Leak-Seal Product Mixing
• Pump & Packer Overviews
• Leak-Seal Accessories
• Municipal Applications
• Live Injection Demos
• Open Discussions

Friday - Geotech

• Geotech Product Line Overview
• Soil Stabilization
• Geotech Product Mixing
• Rig & Mobile System Overviews
• Geotechnical Accessories
• Slab Lifting Live Demo
• Deep Lift™ Overview
• Soil Testing with the
• GPR & Penetrometer
• Maintenance Discussions
• Pricing / Estimating / Cost Savings
• Open Discussions

Participants receive a Samsung tablet loaded with training material.

Your Instructors:

Stephen C. Barton (President/CEO), Jim Spiegel (VP Sales & Business Development), Andy Powell (Southeastern Regional Manager), Anthony Sandone (Eastern Regional Manager), and Charlie Lerman (Western Regional Manager). Each instructor is a seasoned professional with at least a decade of experience in the industry.

Leak Seal & Geotech Products & Procedures

March 14 & 15, 2019 at Alchemy-Spetec HQ in Tucker, GA

Balance your skill set with Leak Seal AND Geotech training!

Get ready for a thorough education in Leak Seal, Slab Lifting, Soil Stabilization and the Alchemy-Spetec Deep Lift™ process. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Thursday - Leak Seal

• Leak Seal Product Line Overview
• Curtain Grouting
• Permeation Grouting
• Leak-Seal Product Mixing
• Pump & Packer Overviews
• Leak-Seal Accessories
• Municipal Applications
• Live Injection Demos
• Open Discussions

Friday - Geotech

• Geotech Product Line Overview
• Soil Stabilization
• Geotech Product Mixing
• Rig & Mobile System Overviews
• Geotechnical Accessories
• Slab Lifting Live Demo
• Deep Lift™ Overview
• Soil Testing with the
• GPR & Penetrometer
• Maintenance Discussions
• Pricing / Estimating / Cost Savings
• Open Discussions

Participants receive a Samsung tablet loaded with training material.

Your Instructors:

Stephen C. Barton (President/CEO), Jim Spiegel (VP Sales & Business Development), Andy Powell (Southeastern Regional Manager), Anthony Sandone (Eastern Regional Manager), and Charlie Lerman (Western Regional Manager). Each instructor is a seasoned professional with at least a decade of experience in the industry.  

Leak Seal & Geotech Products & Procedures

March 14 & 15, 2019 at Alchemy-Spetec HQ in Tucker, GA

Only a few spots left! 

Get ready for a thorough education in Leak Seal, Slab Lifting, Soil Stabilization and the Alchemy-Spetec Deep Lift™ process. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Thursday - Leak Seal

• Leak Seal Product Line Overview
• Curtain Grouting
• Permeation Grouting
• Leak-Seal Product Mixing
• Pump & Packer Overviews
• Leak-Seal Accessories
• Municipal Applications
• Live Injection Demos
• Open Discussions

Friday - Geotech

• Geotech Product Line Overview
• Soil Stabilization
• Geotech Product Mixing
• Rig & Mobile System Overviews
• Geotechnical Accessories
• Slab Lifting Live Demo
• Deep Lift™ Overview
• Soil Testing with the
• GPR & Penetrometer
• Maintenance Discussions
• Pricing / Estimating / Cost Savings
• Open Discussions

Participants receive a Samsung tablet loaded with training material.

Your Instructors:

Stephen C. Barton (President/CEO), Jim Spiegel (VP Sales & Business Development), Andy Powell (Southeastern Regional Manager), Anthony Sandone (Eastern Regional Manager), and Charlie Lerman (Western Regional Manager). Each instructor is a seasoned professional with at least a decade of experience in the industry.