CHEM-CRETE® FLEX FOAM CCC524

APPLICATION

Consumption:  variable depending on moisture content and water pressure.

Limitations: application at ambient temperatures below approx. 5°C is not recommended.  Exposure to temperatures exceeding 65°C for prolonged periods is not recommended.

Pre-treatment of Substrate: the substrate must be sound, clean and free from oil and grease.  All loose material and laitance along the crack length should be removed with suitable hand tools such as needle guns, wire brushes or angle grinders.

Injection Packers: two types of injection packers are available, adhesive (surface) packers and drilled packers. The selection of the packer type depends on the thickness of the substrate and the nature of the crack (width, depth, shape and propagation). The crack nature will affect the operating pressure used in the injection process. Normally, drilled packers can be operated at higher pressures than adhesive packers.

Setting Injection Ports: the crack nature and substrate will affect the distance between the packers. Generally, packers should be installed at distances between 20-50cm along the crack length.

Adhesive Packers can be recommended mainly on dry or slight damp concrete. Adhesive Packers are recommended for wide or surface cracks and clear in nature cracks and when the substrate thickness is small. Injection of minor cracks is possible but subject to site inspection and demonstrations and will be dependent on a slow and low operating injecting pressures.

Drilled Packers can be recommended for both dry and wet concrete and for all sizes and nature of cracks. Drilled packers can be installed along the crack length or alternating on both size of the crack length. When drilling on the side of the crack 45° inclination a special care must be taken in insuring that drilled holes crosses the crack section.

Sealing of Cracks: after the completing of surface preparation and drilling the injection ports, clean the surface and injection ports adequately by dry and oil free compressed air. Adhesive packers should be fixed using CHEM-VERSATILE GEL crack sealing compound. Drilled packers are installed and tightened in the drilled ports. Seal the crack length completely by applying a minimum of 50mm band of CHEM-VERSATILE GEL crack sealing compound. Allow the applied CHEM-VERSATILE GEL to cure for a minimum 8-12 hours before commencing the injection process.

Mixing: Pour the accelerator component “B” into component “A” and shake well for a minimum 2-3 minutes to insure a homogenous mix of the two components.

Pot Life: The mixed CHEM-CRETE FLEX FOAM CCC524 do not possess any pot life. The activation starts upon contract with water or moisture.

• Induction: 35-40 seconds the reaction starts.
• In 60-90 seconds, the water and resin star reacting.
• Complete reaction is 3-5 minutes and becomes like a creamy gel. This stage is considered tack free.
• Curing time is 3-5 minutes.

Injection: Pour the mixture of CHEM-CRETE FLEX FOAM CCC524 into a suitable injection pump. For a wall, commence the injection at the lowest point. For a slab, commence the injection at once side of the crack then progress to the adjacent packer, until the whole crack length is completely injected. Due to the low viscosity and long pot life of CHEM-CRETE FLEX FOAM CCC524 and with the adequate injection pressure, the injection resin will flow, fill and seal all voids and subsiding cracks.

In the case that the concrete is dry, it is possible to inject the cracks with water. Allow the water to dissipate and damp the concrete surrounding the crack section before commencing the injection process.

Curing: Allow the injected resin to cure for at least 48 hours. Knock-off the adhesive packers with a hammer or cut-off the injection packers using angle grinder.

The cured CHEM-VERSATILE GEL can be removed from the concrete surfaces using angle grinder with concrete grinding disc or by flame scaling method with blowtorch and scrapping out the burnt CHEM-VERSATILE GEL.

Injection Works – Leaking/Water Bearing Cracks or Expansion Joints:

Injection Packers: Sealing of leaking cracks and bonding of adhesive packers onto the wet crack or cold/expansion joint is usually not possible. Therefore, injection packers should be installed in wet conditions.

Inject CHEM-CRETE FLEX FOAM CCC524 through all injection packers ensuring the stop of water flow as it quickly reacts with water, foam and cures. This will ensure a complete durable and impermeable seal of water bearing cracks/expansion joints.  Gushing water with high pressure might require an extra amount of CHEM-CRETE FLEX FOAM ACCELERATOR CCC524X Accelerator or the injection of CHEM-CRETE FLEX FOAM CCC524 first.

Curing: allow the injection resins to cure for 48 hours, before cutting the injection packers using angle grinders.  Repair irregularities in the concrete surface using CHEM-VERSATILE GEL if needed.

QUICK REFERENCE CHART: depending on nature of the crack, different polyurethane resins can be injected:

• ¨ CHEM-CRETE RIGID FOAM CCC530: For non-moving cracks and gushing water–hydrophobic.
• ¨ CHEM-CRETE FLEX FOAM CCC524: For moving cracks, expansion joints or moving hairline cracks – hydrophobic.
• ¨ CHEM-CRETE HYDRO FOAM CCC526H: For moving cracks in continuously MOIST environments – hydrophilic.

Expansion dependent upon pH level of water and confinement:

Cleaning: tools and equipment must be cleaned immediately after use, with CHEM-CRETE BLENDED SOLVENTS, Xylene, Toluene, etc.

Caution:  Solvents are flammable and they may affect the seals of injection pumps if exposed to solvent for longer period.