??Cracking the Injection Code “1”??

Solving the Problem of Honeycombs in Concrete: Shared Insights and Practical Solutions

Recently, I posted on LinkedIn about the challenges associated with repairing honeycombs in concrete after a failed injection attempt. I was pleasantly surprised by the number of responses and the level of engagement from the community – I received 29 comments from specialists around the world. I decided to compile this valuable input and create an article summarizing different approaches to this issue because such a valuable contribution might be lost as LinkedIn posts expire (after one year).

Here is the link to the original post: https://www.dhirubhai.net/posts/lukaszjanjozwiak_cracking-the-injection-code-a-technical-activity-7247866800019828738-DcaS?utm_source=share&utm_medium=member_desktop

Problem Description

The shared video highlighted the problem of honeycombs in concrete with water leaking out after a failed injection attempt. The main challenge wasn’t selecting the injection material but rather the approach to the repair process:

? How to properly drill the holes?

? Should temporary seals be used to control the leaks?

Summary of Proposed Solutions

The community of experts shared many valuable insights and practical tips. Here are the main approaches that were suggested:

1. Temporary Seals and Fast-Setting Materials

? Using fast-setting cement or hydraulic mortar to temporarily stop the water flow.

? Surface sealing allows for controlling the leak and preparing the area for further injection work.

? Using materials like cloths or covers to redistribute the water flow and enable more effective injection.

2. Proper Drilling and Locating the Source of the Leak

? Identifying the source of the leak before starting the work to avoid ineffective drilling.

? Drilling holes at the correct angle (e.g., 45 degrees – which is only appropriate when correct distance and depth guidelines are met) and at the correct distance from the leak.

? Penetrating 50-70% of the structure’s thickness to ensure injection effectiveness.

3. Injection Techniques and Material Selection

? Structural injection as a method to fill voids and honeycombs using resins.

? Using fast-reacting polyurethane resins with appropriate catalysts to quickly seal leaks.

? Controlling water flow during injection, using water to transport the sealing material.

? Curtain injection as a method to fill voids and honeycombs using resins or acrylic gel (as one of the options).

4. Planning and Quality Control (QA/QC)

? Developing a solid quality control plan before starting the repair work.

? Monitoring progress and adjusting strategies during execution.

? Ensuring durability and effectiveness by following industry best practices and standards.

My Observations and Recommendations

Considering the variety of proposed solutions, I would like to share my own observations:

Proper Drilling is Key

? Avoid too shallow angles and drilling too close to the leak.

? Drill at an angle of 30-60 degrees and maintain proper distance to achieve the required depth within the concrete structure.

? Careful planning of hole positions and depth increases injection effectiveness.

The picture shows a screenshot from the free injection calculator available at www.resinbau.com :

Choosing the Right Injection Materials

? Fast-reacting polyurethane resins, such as ResinBau WaterStopper, are effective for intense leaks.

? Heating the resin in a water bath to around 40°C can speed up the reaction, especially in colder conditions.

? Consider secondary injection the next day using two-component materials with a stable structure, such as ResinBau CrackFlex.

Controlling Flow and Pressure

? Using a cloth or other material to press down on the leak can help balance hydrostatic pressure.

? Monitoring resin reaction and adjusting injection speed based on site conditions. A flow rate of at least 2 L/min is required to reach the crack.

? Using immediate sealing agents like fast-setting cement to stop leaks, such as ResinBau LeakFix.

The Importance of Planning and QA/QC

? A solid action plan and quality control are essential for the durability of the repair.

? Regularly checking progress and documenting results helps identify potential problems early on.

Technical Drawing – Recommended Injection Points

Acknowledgements

I would like to sincerely thank all the experts who participated in the discussion. Your experience and knowledge are invaluable. By sharing knowledge, we can raise the standards in our industry and solve encountered problems more effectively.

Thank you to all the experts who professionally and insightfully shared their experiences:

Alex Obradovic Andriy Mikhaylov Mohamed Hosny Matthew Palmer AHMED MALIK Modser Taha Keith Thomas Vasant Sankpal Michael Vargo Mohit kale Mohd Azhar Shaikh abid ali

Conclusion

Solving the problem of honeycombs in concrete is a challenge that requires knowledge, experience, and collaboration. I hope this article will be helpful for all those facing similar issues.

I invite you to continue the discussion and share your experiences in the comments below. If you have any questions or additional suggestions, I would be happy to respond.

MAKE INJECTION GREAT AGAIN