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Definitions

Active Crack: means

Application Procedures for Sealing Leaking Cracks & Joints with Aquagrouts

Sealing / Cleaning Interior Surfaces

If the crack is contaminated on the outside it is necessary to remove this contamination form the surface of the crack so that it can be located exactly. If it is a wide crack with high water flow it may be necessary to seal the surface of the crack with a surface sealing material or stuff the crack with filter fabric and wedges prior to injection of the grout. If the inside faces of the crack is calcified or contaminated, it is necessary to flush out the crack with an acid solution. Usually Aquaflush or a 5-10% phosphoric acid solution.

Injection Holes & Packers

Holes should be drilled at an angle of 45° - 60° (degrees) to the surface. The size of the hole is determined by the type of injection packer being used. The most common is a 3/8" hammer -in plastic or nylon packer. The depth of the hole is approximately 1/2 the thickness of the concrete. The same measurement can be used to determine the drilling distance from the crack. The injection packers can be spaced from 3 inches to 3 feet apart depending on the size of the crack. The drill hole is flushed out with compressed air or water using a tube narrower than the drill hole in order to cleanout the deepest part of the hole. Packers are placed into the hole and hammered firmly into place, the zerk fitting (grease nipple) is then installed using a nut driver.

Injection Equipment

Johnson Group Contracting typically uses portable airless pumps (Titan 440XC) to pump polyurethane grouts although larger capacity pumps are often used when pumping larger volumes at lower pressures. Hand held grease gun are seldom used but may be utilized on small injections. Two pumps, one for water and one for Aquagrouts are usually used, but with proper cleaning one pump can be used for both (Any water left in the pump will activate polyurethane before it can be injected into the crack or joint). It is recommended that the crack be injected with water (or acid then water) prior to grouting. Flushing of the crack is highly recommended. This procedure will remove debris and drill dust, plus it will tell the technician if the drill holes intersect the crack and how the crack will likely "take" the grout during injection.

Injecting Chemical Grouts

Aquacut Very low viscosity for non-moving cracks, gushing water or filling large voids.

Aquaflex S.F. Low viscosity semi-flexible for fine moving cracks and void filling.

Aquaflex Medium viscosity for moving cracks, control joints above or below grade.

Aqualastic For use in manholes, sewer rehabilitation, and areas below grade where high volumes of water are present or anticipated, also for sealing expansion & control joints.

Pumps should be flushed with cleaner prior to any injections of chemical grouts. Mix the predetermined accelerator dosage with the chemical grout. With the exception of Aqualastic, no reaction will occur until the grout with accelerator comes into contact with water. It is Standard practice to begin injection of grout at the lowest packer on a vertical crack, or at the first packer flushed for a horizontal crack. During injection the water in the crack will be displaced by the grout, this is a good indicator of material movement. Injection should continue until the chemical grout appears at the adjacent packer or beyond. The coupler will be disconnected and injection will start at that adjacent packer until the entire crack is done. Injection of all the packers a second time is recommended as some of the packers will take more grout. This will densify the grout in the crack. Injection pressures can vary from 100psi up to 2500psi depending on site conditions. The technician will make the judgement as the injection progresses.. Injection of a small amount of water into the packers after grouting will help to cure the resin in the drill holes. After the grout is fully cured, the packers can be cut off flush to the concrete surface and the resulting divot can be filled with a variety of filler materials. (epoxy paste, hydraulic cement, parge mix etc.) Polyurethane which has run down the wall can be removed with mechanical means. Johnson Group Contracting will sometimes use a bond breaker material applied to the wall just prior to injection to allow for easy removal of excess urethane. Since field conditions vary widely the technician must determine the suitability of the product for the particular use and a method of application (experience).

Polyurethane Injection
Limitations

Temperature:

Application Procedures using Epoxy Injection

Sealing / Cleaning Interior Surfaces

If the crack is contaminated on the outside it is necessary to remove this contamination from the surface of the crack so that it can be located exactly. Cracks with active water flow should not be injected with epoxy as the water may "wash out" the epoxy from the crack. Refer to polyurethane injection for water stops. Cracks may be wet or damp prior to epoxy injecting as the epoxy is insensitive to water. It is our recommendation that every crack be "descaled" with an acid flush or Aquaflush and water flush prior to surface sealing and epoxy injection.

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