Technical Memorandum No.

MERL-2013-58

Guide to Chemical Grouting of

Joints & Cracks in Concrete

U.S. Department of the Interior

Bureau of Reclamation September 2013
Mission Statements
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.
Contents
Page
Introduction ....................................................................................................... 1
Definitions ..................................................................................................... 1
Overview of Chemical Grouting ....................................................................... 2
Background ................................................................................................... 2
Applications................................................................................................... 2
Materials ........................................................................................................ 3
Polyurethanes ........................................................................................... 3
Acrylics ................................................................................................... 3
Epoxy ...................................................................................................... 4
MERL’s Product List ............................................................................... 4
Equipment & Tools ........................................................................................ 6
Cartridges ................................................................................................ 6
Pumps ...................................................................................................... 7
F-Assembly............................................................................................ 12
Accessories ............................................................................................ 14
Additional Information (or Tips & Tricks) ............................................. 16
Chemical Grouting Process ............................................................................. 17
Product Selection ......................................................................................... 17
Project Requirements ............................................................................. 17
Exposure Conditions .............................................................................. 17
Joint Design & Impacts on Chemical Grouting ....................................... 18
Equipment Requirements ....................................................................... 19
Refusal Criteria ...................................................................................... 19
Preparation .................................................................................................. 20
Injection Holes ....................................................................................... 20
Surface Sealing ...................................................................................... 21
Injection Ports ........................................................................................ 22
Equipment, Facility and Material Protection........................................... 23
Water and Dye Tests .............................................................................. 24
Flowing Water ....................................................................................... 25
Grouting ...................................................................................................... 25
Cup Test ................................................................................................ 25
Water Injection ...................................................................................... 26
Resin Injection ....................................................................................... 26
Intermittent Grouting ............................................................................. 28
Secondary Injections .............................................................................. 28
Cleanup ....................................................................................................... 29
Equipment & Tools ................................................................................ 29
Material Storage..................................................................................... 31
Port Removal & Patching ....................................................................... 31
References ........................................................................................................ 32

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Introduction
The purpose of this guide is to provide general direction for the user through the
process of chemical grouting of cracks and various joints in concrete. However,
anytime work is considered, personnel with experience in this field should be
consulted. The process contained herein is applicable to contraction joints,
expansion joints, control joints, cold joints, and cracks, particularly for water
control or leakage prevention.

Definitions
The Bureau of Reclamation uses the following definitions for its structures:

Chemical Grout: A solution of products in water or a non-aqueous solvent,

which when combined with one or more additional solutions
forms a gel or expansive rigid or flexible foam. They are
used when there is a need for a low viscosity material with
rapid strength gain, high durability, adjustable and
controllable setting time, and/or resistance to high water
flows. The viscosity of these materials is essentially constant
for a specific time until setting occurs, at which point the
material can gel or foam in a matter of seconds. [1]

Cold Joint: A joint which occurs where one concrete placement ends and
another begins after the concrete in the first placement has
cured. Cold joints can also form when an unexpected
interruption occurs during concrete placement. These joints
may exhibit the same characteristics as construction joints.

Construction Joint: A joint which occurs to aid construction, or due to unplanned

circumstances, where bond is required. These joints may
exhibit the same characteristics as cold joints.

Contraction Joint: A formed joint in mass concrete placements to allow for the
contraction of the concrete prior to subsequent placements.
Contraction joints oftentimes contain joint filler and
waterstop material.

Control Joint: A joint which is either formed or tooled into the concrete to
control the location and propagation of potential cracks.

Expansion Joint: A formed joint in concrete walls and slabs to allow for
expansion and contraction of the concrete. Expansion joints
contain a joint filler, and in certain instances include a
waterstop.

1
Overview of Chemical Grouting

Background
The first chemical grout was developed in 1886 by Jeziorsky [2]. It was a
combination of sodium silicate and a coagulant mixed at the injection hole.
Within the next 23 years, several different patents were submitted for materials
consisting of combinations of silicates and acids, or sodium silicate and aluminum
sulfate solutions. Advances in polymer chemistry lead to the development of
polyurethane based grouts in the 1950s, and acrylamide based grouts in the 1960s.

Today there are many different formulations of chemical grouts, with hundreds of
products available from numerous manufacturers. They have gained acceptance
in the construction industry and are now used in a wide variety of situations.

The Bureau of Reclamation has successfully used chemical grouting procedures

and products on many of its facilities and continues to utilize them today. The
Bureau of Reclamation’s Materials Engineering and Research Laboratory
(MERL) has staff trained in the use of chemical grout materials and application
techniques. MERL has recently initiated an effort to raise client awareness of
these capabilities and has received much interest from Reclamation’s Regional
and Area Offices.

Applications
Chemical grouts are versatile materials that can be used in a wide array of
situations. Common applications of chemical grouts include, but are not limited
to, the following:

• Sealing construction, contraction and expansion joints in concrete for

water control
• Sealing cracks in concrete structures for water control or structural
bonding
• Water cut-off for active or potential leaks and flows
• Filling voids beneath concrete slabs
• Filling voids between steel and concrete elements, or behind steel
structures such as draft tubes and penstocks
• Slab lifting
• Soil stabilization
• Soil compaction grouting
• Cut-off walls or curtain grouting

2
Materials
This section describes the most common forms of chemical grouts available and
in use today. This is not a complete list, and information on other types of
chemical grouts can be found on manufacturer websites.

Polyurethanes
Polyurethane grouts are the most commonly used chemical grouts on the market
today. They are generally separated into two categories: hydrophilic and
hydrophobic.

Historically, hydrophilic resins produce a flexible foam or gel once reacted due to
the water requirement in the reaction process. Many classical hydrophilic grouts
were composed of one part resin and one part water. Conversely, historical
hydrophobic resins produced a rigid foam and required little or no water during
the reaction process, thus the term “hydrophobic.” Presently, the chemical
grouting industry continues to use the terms “hydrophilic” and “hydrophobic,” but
the general properties of those grouts have changed slightly.

Modern hydrophilic resins still require water to react, typically at a water-to-resin

ratio of 1:1, but that ratio can be as high as 20:1. Depending on the amount of
water used for the reaction, the end product will be either a foam (1:1 to 5:1 mix
ratios) or a gel (5:1 and higher mix ratios). A potential problem with hydrophilic
grouts is shrinkage. If the final product is not in a high relative humidity
environment or in contact with water, shrinkage will occur due to water
evaporating from the cured grout. After drying and shrinking, many products
will swell after additional exposure to moisture. Many products can go through
multiple wet-dry cycles, but the effectiveness of the products may be severely
impacted after several of these cycles.

Modern hydrophobic resins require little or no water to react. Some products

consist of a resin mixed with a small amount of catalyst, and require a minute
amount of water to propagate the reaction. Others may be a two component
system with Part A and Part B components and are insensitive to moisture. The
difference between some modern and historical hydrophobic polyurethane lies in
the final product. Today there are hydrophobic resins available that produce a
flexible foam, much like hydrophobic resins, rather than a rigid foam. This is
advantageous because the final product will not shrink in a dry environment,
whereas hydrophilic grouts will shrink. This leads to a much larger product base
to choose from for a given project

Acrylics
Acrylic based grout was first developed in the early 1950s. The first of these
were acrylamide grouts, which were widely used for many years. Acrylamide
grouts have very low viscosity and easily controllable gel times, but have
relatively high toxicity and are considered to be neurotoxins. Acrylamide grouts

3
were later replaced by less toxic acrylate grouts. Acrylate grouts possess cured
and uncured characteristics very similar to acrylamide grouts, but are far less
toxic, not neurotoxic, and possess no known carcinogenic problems [2].

Acrylic based grouts are used extensively for treating soils and sewer sealing
applications, but newer forms of these products are seeing use as sealing agents in
cracked concrete. The ultra-low viscosity of these materials makes them ideal for
penetrating into very fine cracks and fissures. Additionally, the final products can
vary from a stiff brittle gel, perfect for areas where excavation may be expected at
a later date, to a flexible, sticky, strong gel, which is perfect for sealing cracks or
treating soils where some movement may be expected.

An advantage of some of these materials is they can be cleaned up, and pumps
flushed out, simply with water. Soap can be added as an additional cleaning
agent. This is much simpler than the clean-up of polyurethane resins which
require an industrial solvent.

Epoxy
The use of epoxy grouts is usually reserved for structural applications. Epoxy
grouts are generally two-component systems, and are available in a range of
viscosities and solids contents. The final product is typically a non-expansive,
rigid material that has the capability of transferring loads, usually compression
loads, while simultaneously providing a water barrier.

There are many commercially available epoxies, but care should be taken when
selecting a product for use. Epoxies used for concrete crack injection should meet
the applicable ASTM C881 requirements. The run of the mill epoxies available at
home improvement stores will typically not be suitable or as durable or long
lasting as higher grade materials from the manufacturers specializing in epoxy for
concrete.

MERL’s Product List

The following table lists the products MERL has direct experience with and
regularly recommends to clients interested in the application of chemical grouts at
their facilities. This is just a small sample of the hundreds of materials available
from various manufacturers, and we are not limited by this product list.

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Manufacturer Product Name Classification Applications
Avanti [3] AV-248 Hydrophobic Active and potential water leaks in
Flexseal cracks or joints, spaces where
flexibility is required, and oakum
soakum. Ideal in environments
with wet/dry cycles.
AV-202 Hydrophilic Active and potential water leaks in
Multigrout cracks or joints, spaces where
flexibility is required, and oakum
soakum. Use only where cured
material will be in constant contact
with moisture.
DeNeef [4] Cut PURe Hydrophobic Active and potential water leaks in
cracks or non-moving joints, water
cut-off, stabilization, curtain
grouting, and oakum soakum.
Flex LV PURe Hydrophobic Active and potential water leaks in
cracks or joints, spaces where
flexibility is required, and oakum
soakum.
Flex SLV PURe Hydrophobic Active and potential water leaks in
fine cracks where some flexibility
is required.
CFL PURe Hydrophobic Active and potential water leaks in
cracks or joints, spaces where
some flexibility is required, void
filling, cut-off walls and oakum
soakum.
Sealfoam PURe Hydrophilic Active and potential water leaks in
cracks or joints, spaces where
flexibility is required, and oakum
soakum. Use only where cured
material will be in constant contact
with moisture.
Hydro Active Hydrophilic Forms a gel or foam for pipe
Multigel NF joints, water cut-off, curtain
grouting, and oakum soakum.
Superflex Acrylate Hairline cracks, joints, and voids.
Ideal for use in areas with very
fine openings and where
movement is ongoing.
Aqua-Tite Two- Water cutoff, and curtain grouting.
Component Very fast reacting rigid foam to
stop high volume flows.

5
Manufacturer Product Name Classification Applications
Strata-Tech ST-504 Hydrophilic Active and potential water leaks in
[5] cracks or joints, spaces where
flexibility is required, oakum
soakum. Use only where cured
material will be in constant contact
with moisture.
ST-524/525 Hydrophobic Active and potential water leaks in
cracks and non-moving joints,
water cut-off, stabilization, curtain
grouting, and oakum soakum.
ST-530/531 Hydrophobic Active and potential water leaks in
cracks or non-moving joints, water
cut-off, stabilization, curtain
grouting, and oakum soakum.
ST-536/537 Two- Water cutoff, and curtain grouting.
Component Very fast reacting rigid foam to
stop high volume flows.
ST-538/539 Two- Cracks in concrete, void filling,
Component and other instances where a very
rigid, non-expansive material is
needed for stabilization.
ST-540/541 Two- Cracks in concrete, void filling,
Component and other instances where a dense,
strong rubber-like, low-expansion
material is needed for stabilization.
Unitex Pro-Poxy 50 Two- Sealing cracks in concrete where
(Dayton Component structural bonding is required.
Superior) [6] Epoxy

Equipment & Tools

A wide variety of equipment is available for use when applying chemical grouts.
The equipment ranges from the most simplistic, to complicated and precise.
Many of the pumps in use today were adopted from the paint and coatings
industries, while new configurations continue to be developed exclusively for
chemical grouting applications.

Cartridges
One of the simplest ways to inject chemical grouts is the use of caulking guns.
Many chemical grouting materials are now available in small dose, single use
cartridges that are designed to be used with single or dual component caulking
guns. Figure 1 shows a cartridge which contains a polyurethane resin and a
separate reservoir for the catalyst in a single cartridge. A two-component, 2:1
ratio epoxy cartridge can be seen in Figure 2.

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Figure 1. DeNeef Hydro Active Cut Hot Shot cartridge [2].

Figure 2. Pro-Poxy 50 epoxy cartridge with static mixer and quick-coupler.

Pumps
Hand pumps are a simple way to inject chemical grouts. The simplicity of hand
pumps gives the end user the opportunity to design and build their own custom

7
pump. Size, shape, and capacity are all characteristics that can be customized to
fit the needs of the applicator. The hand pump shown in Figure 3 was designed
and built for Reclamation staff to be used in confined spaces and pumps at a 1:1
ratio.

Figure 3. Hand pump for use in confined spaces such as inside draft tubes.

The next piece of equipment commonly used for chemical grout injection is a
paint pump. Many manufacturers produce airless pumps for the paint industry,
and they work well for pumping chemical grouts. Examples of airless paint
pumps currently in use by MERL staff include the Titan Impact 440 (Figure 4)
and the Graco Ultra 395 Highboy (Figure 5). Both of these pumps are capable of
output pressures up to 3300 psi and can be used to pump either water or resin.
Two pumps can be used simultaneously in instances where some combination of
water and resin are to be injected together. An infinite number of water-to-resin
or part A/B ratios are possible when using two separate pumps by varying the
pressures of each pump to achieve the desired ratio.

8
Figure 4. Titan Impact 440 airless pump.

Figure 5. Graco Ultra 395 Highboy airless pump.

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Pneumatic pumps are also readily available to use for chemical grout injection.
Many chemical grout manufactures work with pump manufacturers to create
specialized pumps. If starting from scratch, pumps can be made for virtually any
pumping ratio, or even made adjustable. These pumps generally have the
advantage of being small in size, are easy to transport and allow for more precise
control of pumping pressures. The Graco Falcon (Figure 6) is a perfect example
of a small, 1:1 ratio, pneumatic pump used for chemical grouting. This pump has
been used for much of the grouting we perform.

Figure 6. Graco Falcon pneumatic pump.

The stainless steel Graco pump shown in Figure 7 is a 1:1 ratio pneumatic pump
that was designed to be used with certain acrylic resins. All internal components
of this pump are made of stainless steel to prevent corrosion due to contact with
the acrylic resins and the sodium persulfate catalyst commonly used with these
grouts. In addition to the two standard cylinders, one for water and one for resin,
this pump has a third cylinder, operated by a separate air motor, dedicated to
flushing water only. While designed to be used for acrylic resins, this pump can
certainly be utilized for pumping other products, but care must be taken to ensure
it is properly flushed to prevent contamination.

10
Figure 7. Graco stainless steel pneumatic pump.

Epoxy injection requires dedicated pumps to avoid contamination of other resins

or the epoxy itself. As mentioned above, epoxy resins are available in cartridges,
but pneumatic or electric pumps can be used for injecting larger amounts of
material or where higher injection pressures are needed. A pneumatic, cart-
mounted pump, manufactured by Lily, is shown in Figure 8. Various resin
reservoirs are available depending on the amount of resin needed for a given
project. A static mixing head is affixed to the pump to allow thorough mixing of
the two components before entering the injection line. After this point, the
injection line can be connected to a manifold to allow simultaneous injection at
multiple ports.

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Figure 8. Lily two-component epoxy pump.

F-Assembly
When injecting multiple-component chemical grouts, the components must mix
prior to entering the injection holes. In the case of hydrophilic polyurethane
grouts there are two components: water and resin. Each of the components is
delivered from the pump in a separate line, and mixing takes place in an F-
assembly (Figure 9). When dealing with some acrylic resins it is necessary to use
stainless steel for the assembly just as was the case for the pump. The assembly
used with that pump has three inputs, with the third input being dedicated to the
water flush line (Figure 10).

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Figure 9. F-Assembly for hydrophilic or two-component injections.

Figure 10. Three-component stainless steel assembly for acrylate based grouts.

Many chemical grout manufacturers produce and sell F-assemblies, but they are
easily built using parts from a specialized hardware store. The components of an
F-assembly include quick-connect couplers to connect to the pump hoses, pipe
nipples, check valves, pipe tees, pipe elbows, and pipe plugs. One component that
may need to be specially ordered is the check valves, as these may not be readily
available. The tip of the F-assembly can be fitted with a variety of parts,
including quick-connect couplers, zerk couplers, or injection needles.

13
Accessories
A successful chemical grout injection requires equipment and supplies beyond the
pumps. These items include drilling equipment, such as a hammer drill and
concrete drill bits, various tools (hammers, wrenches, screwdrivers, etc), injection
ports or packers, couplings and connectors, and temporary surface sealing
supplies.

Many types of injection ports and packers are available from most chemical grout
manufacturers and other sources. Epoxy grouts are typically injected through
surface mounted ports. These are affixed to a clean surface, directly on a joint or
crack, via an epoxy adhesive. Other chemical grouts are often injected into
hammer-in ports or mechanical packers. These are usually fitted with zerk
fittings, and thus require a zerk coupler on the F-assembly. Other mechanical
packers may utilize button-head couplers or quick-connect couplers. Standard
ports and packers range in size from 3/8” to 1” diameters, but custom mechanical
packers can be produced. Figure 11 displays some of the various injection ports
and packers used for chemical grouting.

Figure 11. Injection ports and packers used for chemical grout injection.

In some instances it may be necessary to use an inflatable packer (Figure 12) that
can withstand high pressures or when dealing with large amounts of grout.
Inflatable packers can be custom made for any diameter or length that may be
needed. A rubber sleeve surrounds an inner pipe, and is typically inflated with
nitrogen gas once in the injection hole. Meanwhile, the grout is injected through

14
the inner pipe, and once injection is completed, the nitrogen gas is released, and
the packer moved or removed.

Figure 12. Inflatable packer used for grout injections at high pressures.

Injection needles and tubes are used when injecting grout into soils or other
penetrable media. The needles do not require drilling prior to grout injection, and
thus some time and cost savings may be realized. A typical injection needle is
shown in Figure 13. A manchette tube, which has drilled holes at regular
intervals, is commonly used when injecting into permeable soils. Manchette
tubes allow grout to be injected simultaneously at various levels within a soil.

Figure 13. Injection needle of 12" length used for injecting through oakum or other
penetrable materials.

Occasionally, it may be necessary to seal the surface of a crack or joint prior to or

during grout injection to prevent leakage. Almost any material may be used for
this purpose, but the common methods include using a cementitious surface rub or
inserting oakum into the crack or joint. Oakum may be used dry, so as to provide
a sponge-like material to absorb any grout that may be leaking from the crack or
joint. It is quite common to soak the oakum in a water activated resin, place it
where needed, and then activate the grout. This provides a temporary or
permanent installation that acts as a physical barrier to any grout or water that
may leak through the crack or joint. Open cell backer rod can also be used in a
similar fashion. Figure 14 displays examples of oakum and open cell backer rod.

15
Figure 14. Oakum (jute) and 1" open cell backer rod.

Additional Information (or Tips & Tricks)

It is important to stay organized and keep equipment, tools, and materials clean
and uncontaminated. Perhaps one of the most important things to do is to keep
water and water-sensitive materials separated at all times. It is recommended that
pumps, hoses, and all connections be labeled such that water will not enter the
resin side, and resin will never enter the water side of the pump or hoses. This
can be accomplished by applying different colors of tape or zip-ties to respective
connection sites on the pumps and hoses.

Another method MERL has applied is to use either different sizes of connections,
or to maintain male or female only connections for certain components. For
example, hoses with both water and resin lines will have male ends on both ends
of the water line, whereas the resin line will have female ends. The opposite is
true on the pump side, and the F-assembly side. This ensures the water and resin
lines will never cross, eliminating one source of possible cross contamination.

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Chemical Grouting Process

Product Selection
Product selection is perhaps the most important part of the chemical grouting
process. Many products are available on the market today, some sharing similar
characteristics, but most possessing vastly different characteristics. Even the most
experienced, highly trained applicators will fail if the wrong product is used for a
given situation.

Project Requirements
The first step in choosing a chemical grouting product involves analyzing the
project requirements. It is important to answer the following questions before the
injection work begins:

What is damaged and/or leaking water?

What is the cause of the damage or leakage?
Where is the water entering the structure?
What is the flow rate of the water?
What are the sizes of the joints, cracks or voids to be filled?
How far will the grout need to travel before setting up?
Are the joints or cracks actively moving (expansion/contraction)?
What are the exposure conditions?
Is the objective to find a temporary or permanent fix?

Answers to the above questions will aid in determining the type of grout,
quantities required, and certain desired grout properties. These are all major
drivers of the cost and schedule of performing chemical grouting.

Exposure Conditions
It is important to assess the final exposure conditions to which the grout will be
subjected. Hydrophilic polyurethane grouts, for example, must remain in a high
relative humidity environment or in contact with water to remain in a steady state
capable of sealing leaks. If placed in a dry environment, the water within the final
product will evaporate, leading to a volume decrease. Some materials have the
ability to withstand wet-dry cycling, meaning they shrink during dry times due to
water evaporating out of the foam or gel, but will swell when reintroduced to
water. This ability varies from product to product, but most products will lose
effectiveness with subsequent cycles.

Conversely, hydrophobic polyurethanes grouts contain little or no water, and are

thus stable in dry environments. This characteristic makes these materials ideal
for use in areas that won’t always be in contact with moisture, such as parking
decks, roof decks, etc. This is also useful in climates such as the southwest where

17
most of the year is sunny and dry but experience occasional bouts of heavy
precipitation. Additionally, some new hydrophobic grouts have the ability to
remain flexible like hydrophilic grouts. This gives the added benefit of
applicability to active cracks and joints.

In-place materials may also be exposed to UV and freeze-thaw cycles. Many

chemical grouts will discolor and breakdown if constantly exposed to UV, but the
performance characteristics of the material are generally unaffected if they are
injected deep enough into the joint or crack. The ability to withstand freeze-thaw
cycling varies from product to product, but most perform quite well in these
conditions.

The last exposure condition to consider is contact with potable water sources and
aquatic life. Certain chemical grouts are approved for potable water use (NSF
61), while others do not meet standards and should be avoided when working in
sensitive environments. Even if a product is approved for potable water use, best
efforts should be made to keep the grout in the intended areas, as should be done
in all cases. For products approved for potable water, it is important to remember
that the final product (cured grout) is usually listed as safe, but the individual,
uncured ingredients may not be.

Joint Design & Impacts on Chemical Grouting

Reclamation concrete structures contain a variety of concrete joints details.
Construction joints, cold joints, expansion joints, and contraction joints all have
different purposes, but may be approached in similar manners while grouting.
While similar in design, contraction joints and expansion joints have different
uses. Contraction joints are those within a mass concrete placement and allow the
concrete to contract as it cools during curing. Contraction joints prevent any
restraining forces on the concrete during the curing process. Expansion joints are
those joints within a typical concrete placement and allow thermal expansion and
contraction of the concrete throughout its service life.

The design of a given expansion or contraction joints depends on the year of

construction. Many older structures have expansion joints that contain corkboard
filler, typically some type of waterstop, either rubber or metal, and sometimes a
cap at the surface. In some instances an expansion joint may have both a rubber
and a metal waterstop separated by a relatively small distance. Other structures
may have sponge rubber filler in the joints, and in some cases there may be no
waterstop present. The material within the joint will have an impact on the type
and desired properties of chemical grouts to be used. If the material within the
joint is highly porous or deteriorated, a thick, fast setting grout may be needed to
avoid run out. If the material within the joint is in good shape and has a small,
tight pore structure, a thin, slow setting grout may be needed to ensure adequate
penetration and travel. Likewise, the design of the joint can impact the best
location to inject the grout. Sometimes that point might be between a metal and

18
rubber waterstop, sometimes under a rubber waterstop, and sometimes above the
waterstop.

Equipment Requirements
There are a few items to consider when choosing the equipment needed for a
given project. The availability of power and supplied compressed air will affect
the type of drilling equipment and injection equipment used for the project. It
may be necessary to use a portable generator to supply power for lights, drills,
fans, heaters, pumps etc. A portable air compressor may be needed to run a
pneumatic pump where air is not supplied or is inconveniently located. There
may be instances where both are needed.

As discussed in the Equipment & Tools section, a variety of pumps are available
for use in chemical grouting work. Some chemical grouts may require a different
physical pump configuration due to mixing ratios, while others may require
pumps made of a special material, such as stainless steel. However, most
chemical grouts do not have any special equipment requirements and may be
injected using a single component pump, multiple single component pumps, or
plural component pumps. If a specialized piece of equipment is required for a
given chemical grout, the manufacturer will provide recommendations.

Another item to consider is the physical space in the working area. Tunnels
housing outlet works pipes, penstocks, and other areas can be very tight places to
work, where smaller and/or specialized tools and equipment may be needed. A
perfect example of a confined working area is inside the draft tube shown in
Figure 3. Tight spaces and odd working platforms may require smaller tools.
Cordless hammer drills are significantly shorter than standard hammer drills, and
can be used in tighter areas. Additionally, modifications of F-assemblies may be
needed depending on the available space and angles of injection.

Refusal Criteria
Prior to performing chemical grouting work, it is important to establish refusal
criteria that must be met to signify the completion of the grouting process. For
example, one may establish a minimum quantity of grout to be injected based on a
known or estimated void space. Other situations may require an initial injection,
and then a subsequent injection to help densify the injected material. Injection
pressures may also be tracked and used in establishing refusal criteria. Finally,
some instances may require the use of physical testing after injection to determine
if the grouting is complete. For instance, after injection expansion joints, one may
water test the area through flooding the surface or observations during a storm
event. In any case, it is imperative to use a large enough quantity to complete the
job and provide a quality product, but not so much that it travels into undesired
locations or leads to undesired effects.

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Preparation
Preparation is perhaps the most crucial, time consuming, and expensive step in the
chemical grouting process. Without proper preparation, even the best available
materials may not solve the problem.

Injection Holes
The first step for performing injection work is establishing the location of the
injection holes. This step can help to fast-track the drilling process, and ensure
mistakes in drilling placement are avoided. Once the locations of the injection
holes have been determined and marked on the structure, drilling may commence.
The size of drill hole is dependent on the type of injection port to be used. For
hammer-in ports, a 3/8” diameter drill bit is traditionally used. Most mechanical
expansion packers are ½” diameter, and therefore a ½” diameter drill bit is
required. However, larger sized mechanical and inflatable packers may require
the use of larger drill bits or even core barrels.

For void filling and cut off wall grouting, a grid of injection holes is appropriate.
Spacing of the holes will be dependent on the size, shape, and depth of the void to
be filled or cut off wall to be established. It is recommended that injection holes
in subsequent rows (or columns) be staggered to allow for the greatest degree of
overlap of the injected material. In many cases for void filling or cut off wall
grouting, the injection holes can be drilled perpendicular to the surface of the
structure.

When injecting into joints, the holes should be offset from the joint approximately
the same distance as the desired intersection depth, and drilled at approximately
45° from the surface. Steeper or shallower angles may be used, but care should
be taken when drilling at shallow angles as there is an increased risk of concrete
spalling around the drill hole. The recommended intersection depth is half of the
thickness of the structure (wall, floor, ceiling, deck, etc.) where appropriate. If
the structure is 10 feet thick, it is impractical to attempt to achieve an intersection
depth of half the thickness. In this case, one should aim for the deepest
achievable intersection depth. Spacing of the drill holes is dependent on the size
of the joint opening, and thus the length of possible grout travel. Past experience
suggests hole spacing somewhere between 12” and 18” is appropriate in many
cases.

Injection holes for crack injection should be positioned similarly to those for joint
injection. However, the path of the crack within the structure is unknown, and it
is therefore recommended that injection holes be staggered across the crack. The
crack may tilt one way or another within the structure, but by drilling from both
sides of the crack, one ensures that at least half of the drill holes will intersect the
crack at depth. Spacing between drill holes along the length of the crack is
dependent on size of the crack opening and the viscosity of the grout (and thus the
possible travel of the grout). As every crack is different, it is difficult to provide a

20
recommended spacing. However, experience demonstrates that spacing as small
as a few inches may be necessary to complete the job.

The injection hole should be cleaned out prior to insertion of the injection port.
Injection holes drilled into actively flowing joints or cracks may be self-cleaning
if the water flow is high enough. For dry or damp holes, cleaning can be done
through the use of compressed air. A typical approach for cleaning out holes with
compressed air is as follows:

1. Attach flexible plastic tubing to the end of an air nozzle, insert the tubing
to the bottom of the hole, and release the compressed air.
2. Insert the tubing into the topmost injection hole where possible. If the
process were to start at the bottommost hole, cuttings, dust, or other
material from the upper holes may gather in or around previously cleaned
holes.
3. Spray the compressed air into the hole while slowly removing the tube to
allow the material to escape.
4. Repeat as necessary until no dust is observable.
5. In some cases, it may be beneficial to do air cleaning, followed by water
cleaning. This should be repeated until the air/water does not remove any
additional material.

In some instances, blowing compressed air into one hole may cause material to
eject from the joint or crack, as well as other injection holes. This is indicative of
connectivity of holes and the open nature of a joint or crack. If material or air is
ejected from the surface of the crack or joint, it is a sign that surface sealing may
be required.

Surface Sealing
In cases where the joint or crack is wide enough for water or material to flow out
at the surface, a seal may need to be installed prior to beginning grouting
operations. There are numerous options when sealing the face of a joint. Packing
the joint with jute fiber, or oakum, is perhaps the most commonly used method.
Absorbent matting, paper towels, open-cell backer rod, or elastomeric sealants are
also commonly used materials.

Sealing the surface of cracks is often done through the use of an elastomeric or
epoxy-based sealant. In many cases, this will be much quicker and easier than
trying to pack a crack with oakum or some other material. However, it may
increase the clean-up time at the end of the project if the Client would prefer to
have the surface sealant removed.

If the joint to be sealed is large enough or has flowing water, it may be necessary
or beneficial to use the oakum soakum technique. In this instance, a strand of
oakum is soaked in resin, placed into the joint, and activated. In the case of a dry
joint, either a hydrophilic or hydrophobic resin is used, as there is not a time

21
restriction for activating the resin. In the case of a joint with flowing water, a
hydrophobic resin is usually the material of choice for use with the oakum
because a hydrophilic resin may be washed out before it can react and seal the
joint. Oakum soakum can also be used on cracks, but the strands of oakum used
for packing crack will need to be smaller.

Injection Ports
Once the injection holes have been drilled and cleaned, installation of the
injection ports can begin. The type of grouting to be conducted, and the type of
pressures needed for injection, will dictate the type of injection port to use. When
injection pressures will remain relatively low, hammer-in ports will likely be
sufficient. If injection pressures will be high, mechanical packers may be
required. Another instance when mechanical packers should be used is if the
drilling angles are shallow. The structure of the hammer-in ports is such that at
low angles the head of the port will prevent a complete seal around the port.

Mechanical injection ports include compressed rubber injectors (also known as

expansion ports) and progressive screw injectors, including wall spears. Various
types of compressed rubber injectors can be seen in Figure 15. Compressed
rubber injectors are inserted into the injection holes and tightened with a wrench
or socket. Care must be taken to not over-tighten the ports, as the body of the
ports can shear apart. Various types of progressive screw injectors can be seen in
Figure 16. These types of injection ports are inserted into the injection holes,
lightly hammered while protecting the ends from damage, and tightened with a
wrench. Wall spears are simply progressive screw injectors with a ball valve.

Figure 15. Compressed rubber injectors with zerk fittings.

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Figure 16. Progressive screw injection ports for use when injection pressures are
high. The top port uses a button-head connection, while the lower port includes a
ball valve and a quick-connect fitting.

When injection deep within a structure is necessary an inflatable packer will be

used. A description of inflatable packers was provided in the

Accessories section. When using inflatable packers, it is necessary to have a clear

path for the packer and related tubing. Once the packer has reached the proper
depth, it will be inflated, and ready for grout. When the time comes to move the
packer to the next stage, the packer is deflated, moved, and inflated.

Care must be taken when installing and using all types of injection ports and
packers. If the angle of an injection hole is too shallow, the insertion of a
hammer-in port or the expansion of a mechanical port may cause damage to the
surrounding concrete. Similar damage can occur if an inflatable packer is placed
too close to the exposed surface of the concrete.

Equipment, Facility and Material Protection

When grouting, it is imperative to keep the equipment and the facility safe, clean,
and organized. This is oftentimes a simple thing to do, but working in a small or
confined space can present challenges. It is important to keep the following
things in mind when organizing a work space:

• Protect the facility by positioning plastic sheeting, barriers, tape, etc. in

locations where grout can spill or leak.

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 • Protect equipment from leaking or spraying water or grout by positioning
the equipment around a corner, behind a shield, or by covering with plastic
sheeting, and use GFCI connections for electrical equipment.
• Protect the materials from contamination by using sealed containers or
covering with plastic sheeting.
• Keep the workspace free of unnecessary equipment, cords, tools,
containers, etc.

Water and Dye Tests

A water test and/or a dye test should be conducted prior to injecting resin or grout.
However, this step is unnecessary, and perhaps detrimental, when injecting epoxy
for structural bonding purposes. A water test is important for the following
reasons:

1. Dislodge material that may be present in the injection hole, joint, or crack
2. Verify connectivity of the injection holes to the joint or crack to be
grouted
3. Verify hole-to-hole connectivity
4. Verify potential travel distance of grout materials
5. Provide moisture within a dry joint or crack, which is critical when
injecting water-activated hydrophobic resins
6. Verify proper operation of equipment, hoses, valves, and injection ports
prior to grout injection

Dye used with a water test can help the grouter identify the flow path of water
within or through a structure, as well as give the grouter an indication of the
required set time for the grout. If the dye is present in the outflow of water in a
relatively short period of time, the grouter can take note and adjust either the type
of material used, or the concentration of a catalyst in a hydrophobic resin.
Conversely, if there is a large amount of time between dye injection and
observation of dye in the outflow, the grouter knows he has sufficient time for the
grout to set. However, if the dye is never observed in the outflow, it may indicate
that the injection hole is connected to another path, possibly an undesirable path.
Care must be taken to ensure the drill holes have not intercepted a drain line,
embedded conduit, or passed through to the opposite side of a wall or slab.

Another way to use dye prior to grouting operations is to use it in an undiluted

fashion. A dye test is useful in situations where water is actively flowing through
a joint or crack, where the location of water infiltration is unknown, where the
water path is unknown, or for tracking flow rate or flow time into or through a
structure. In the case of water leaking into a joint or lift line in a concrete dam,
the dye can either be poured or injected into the reservoir directly above or in
front of the suspected or known intrusion point, and tracked through the structure.
This type of dye test has provided useful information at facilities such as El Vado
Dam and Grand Coulee Dam.

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Flowing Water
Water that is actively flowing from a joint or crack presents a unique set of
challenges. Not only is the work environment wet, but it can impact the type of
material needed for the job and can also impact the sequence of activities to be
completed prior to injecting grout.

When water is flowing from joints or cracks, it is often necessary to attempt to

seal the surface or temporarily stop or slow the water flow. If the flow rate is high
enough, any injected grout could be washed out before it is able to react. If this is
the case, applying the oakum soakum technique is often sufficient. Another
option is to inject a fast acting grout, such as a hydrophobic grout, to temporarily
stop or slow the flow, followed by normal grouting operations. The ideal action
would be to remove the source of water prior to grouting, but this is usually not a
feasible option due to site conditions, grouting location, water or power supply
requirements, etc. However, when water is flowing through a crack or joint, the
elimination of leaking water due to grout injection indicates that the crack or joint
has been sealed.

Grouting
Now that the project has been assessed, the proper materials have been selected,
and the workspace and repair locations have been prepared, grouting operations
can begin.

Cup Test
The cup test is a very important part of the chemical grouting process. A cup test
will aid the grouter in verifying that the material is reacting properly, the reaction
time and set time are appropriate for the conditions, and the pumps and related
equipment are functioning properly. The results of a cup test may lead to a
change in the grouting operations with respect to time spent on each injection
port, time spent on an injection port without actively injecting, port spacing, and
requirements for flushing of the F-assembly.

A cup test should be performed at multiple stages throughout the grouting project.
The following is a list of the times when a cup test is required:

• Each time a new material is being used

• Each time a new container of material is being used, even if the same
material from a different container is performing correctly
• Each morning and after a stoppage of work (i.e. breaking for lunch)
• When temperature control is an issue or temperature control devices are in
place for the material
• When substrate and/or water temperatures are above or below optimal
• When utilizing multiple pumps to deliver the material to one F-assembly

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 • Periodically throughout the grouting process when using a catalyzed resin
to ensure the material is thoroughly mixed

Water Injection
When using certain hydrophobic resins, and occasionally with hydrophilic resins,
it is beneficial or even necessary to inject water prior to grout injection. Water
can help to lubricate the injection hole, joints and cracks, making it easier for the
grout to travel within the structure. Additionally, many hydrophobic resins
require the presence of a small amount of water to start the chemical reaction. As
mentioned earlier in the Water and Dye Test section, water injection can also help
to verify connectivity of the injection holes to the joint or crack, as well as
connectivity with other holes.

It is not necessary to inject large amounts of water, but care should be taken to
provide a sufficient amount of water for the chemical reactions to occur. In cases
where joints and cracks are already wet, or where water is actively flowing
through them, it may be unnecessary to inject water.

Resin Injection
Now that the product has been tested, and the cracks or joints have been wetted,
injection of the resin or grout can begin.

The sequence of injections will vary depending on the orientation of the cracks or
joints, as well as the presence of water within them. The amount of time spent
injecting material into a given port will depend on the characteristics of the
structure, as well as the port spacing and the material itself. The thickness of the
wall or slab being injected and the width of the crack or joint will impact the
amount of material injected to fill the void. If the port spacing is large, a greater
amount of material, and thus time spent injecting, will be required for the material
to reach the next port. Conversely, if the port spacing is small, less material and
time is needed. Lastly, higher viscosity materials will take more time and effort
to travel through a crack or joint than a material with lower viscosity.

Resin injection is typically a two-person operation. One person will operate the
pump(s) and manage the material, while the second person will act as the
nozzleman and will operate the F-assembly at the injection ports.

The pump operator will have control over the speed of injection by adjusting the
air pressure on pneumatic pumps, or by adjusting the speed on electric pumps.
They also have the ability to immediately stop the injection should problems
arise. The pump operator will also manage the grouting materials throughout the
grouting operation by refilling both the resin and water reservoirs, as well as
maintaining a properly catalyzed material (where applicable). This also allows
the pump operator to record how much material has been injected into a given
port or into the crack or joint as a whole. During resin injection, it is important to
track the amount of resin being used. If volumes are higher than anticipated,

26
grouting should stop, and explanations for larger than expected grout volumes
should be determined before grouting operations continue.

The nozzleman has control of the resin and water at the injection site, and will
control when the grout is injected. The nozzleman must maintain good
communication with the pump operator throughout the grouting process. It is
important for the nozzleman to relay when they are actively injecting grout. This
is typically accomplished by saying or yelling, “Down the hole,” or “Injecting.”
When injection is to stop, the nozzleman will say, “Off.” This indicates to the
pump operator that material flow will stop, and the pump will stop moving.

If the pump stops moving and the nozzleman has not indicated they are “off,”
then the pump operator knows that pressure is building within the crack or joint.
At this time the grouters can decide to either move to the next port, or the pump
operator can increase the pressure at the pump to try to move more material. It is
important to be familiar with the structure and equipment, as too much pressure
can crack the concrete at the crack or joint, or around the injection port, or can
cause hoses and fittings to fail.

The nozzleman or the pump operator may occasionally call, “Gun check.” This
indicates that the nozzleman should place the end of the assembly in a waste
bucket, and open the valves. This allows the grouter to verify material is properly
flowing through the assembly and that it is not plugged in any way. This is also
an opportunity to do another cup test if it is deemed necessary.

Horizontal Orientation
For cracks or joints on a horizontal surface, or oriented horizontally on a vertical
surface, injection can begin anywhere along the crack or joint. However, it is
recommended that injection begin at one end or the other, rather than in the
middle. As grouting continues, injections should progress in a linear fashion
along the crack or joint until grouting of the entire length is complete.

Vertical Orientation
For cracks or joints oriented vertically on a vertical or sloped surface, injection
should almost always begin at the bottommost point. This results in a bottom-up
filling of the crack or joint, and minimizes the occurrence of air voids within the
grout. If there is good port-to-port connectivity, the grout will, in most cases,
eventually start traveling out of the next port if it is not fitted with a zerk fitting or
some other type of check system. At this time the grouter will usually cease
grouting on the current port, and connect to the next port to continue grouting.
However, if the material is traveling well, and can travel beyond the second port
to the third, then the grouter may opt to continue injecting on the first port.
Material viscosity and set times will have an influence on this decision. As
mentioned before, grouting should generally progress from port to port along the
length of the crack or joint until grouting of the entire length is complete.

27
Water Presence
The presence of water in a vertically oriented crack or joint is another reason to
begin injection at the bottommost point. By beginning at the bottom, the grout
will replace the water in that space, and force the water up and out of the crack or
joint. Again, this will ensure full filling of the crack or joint.

However, there may be times when the grouting may initiate at or near the top, or
at least not at the bottom of a crack or joint. This may be done when the goal is to
divert water to a specific location along the crack or joint, or where accessibility
to the bottommost point is difficult or impossible. An example of this scenario is
attempting to grout a leaking joint in a penstock tunnel that is affecting
maintenance of the penstock coating. In many cases, the space between the sides
of the penstocks and the concrete is too small for a person or equipment to access.
In this instance, the grouting would be conducted as low as possible on the
concrete wall. Preferably this location is low enough that any remaining openings
are beyond the point where water would leak onto the pipe, and instead would
travel down the wall to a trough or drain. It may be desirable to start away from,
and work towards the diversion location. Other times it may be acceptable to start
near the diversion location and work away. These are decisions that the grouting
team must make prior to starting the work.

Intermittent Grouting
Intermittent grouting is a technique that may be used in multiple scenarios where
injecting, pausing, and resuming injections may be of benefit. Occasionally,
grout may flow out of the surface of the crack or joint, and it may be necessary to
temporarily stop grouting to allow the grout to set. This will essentially allow the
formation of a bulkhead at the surface, at which point the grouter can resume
grout injection. This newly formed bulkhead will prevent material from spilling
out of the face, and instead will force the grout further into the crack or joint.

Intermittent grouting can also be beneficial when attempting to create a dense

material inside cracks or joints. Grout will be injected to a certain point, and then
the grouter will pause. After enough time has passed to allow the leading edge of
the material to set, again forming a type of bulkhead, the grouter will resume
injections. The injection of material against the grout bulkhead will serve to
densify the previously injected material. This can be repeated numerous times
until the crack or joint is full, oftentimes indicated by material exiting from the
surface. An important step in this process is to resume injections before the
tailing edge of the previously injected material completely sets. This will allow
some mixing of the two stages of material, creating one homogeneous mass.

Secondary Injections
There are times when grouting a set of ports will not completely fill the crack or
joint. It is possible that injections at two adjacent ports never made contact, and
void was left between the two grout placements. In this case, an additional
injection hole would be drilled between the two, and subsequently grouted. In

28
some cases, this can be achieved by having primary and secondary holes drilled at
the beginning of the project, and using only the primary holes first, and using the
secondary holes where necessary.

Occasionally, after completion of grouting, water may find another path through a
structure, and leak out of nearby cracks or joints that were previously dry. By
grouting an actively leaking crack or joint, the material has blocked the easiest
path water could take, and it may find the second easiest path. In this instance, a
second grouting program may be required to seal those secondary locations. The
amount of time it takes for water to find this path could be anywhere from
seconds, to years, and is highly variable from structure to structure.

Cleanup
Once grouting operations have been completed the clean-up process can begin. It
will be necessary to spend time cleaning equipment and tools, working areas,
storage areas, and any locations where grout may have traveled. Prompt cleaning
of the pumps, hoses, F-assemblies, and tools at project completion will ensure
proper operation in the future, and reduce the need for rebuilding pumps and
assemblies. At this time it is also imperative to properly dispose of or store the
materials.

Equipment & Tools

Upon completion of the grouting, it will be necessary to flush the grouting
materials from the pump and hoses, and clean them. Chemical grout
manufacturers produce pump flush and washing agents that are compatible with
their products. Care must be taken to use the correct flushing and/or washing
agent for the given grout materials. However, some products, such as the
methacrylic acrylates, need only water for flushing and cleanup. These same
washing and flushing agents can be used to help clean F-assemblies and any
reusable injection ports.

Pump Flushing
The following steps should be followed when flushing the pump and hoses:

1. Move the resin intake into a container filled with pump flush/wash (water
for materials that can be flushed with water).
2. Place both water and resin sides to recirculation mode (for applicable
pumps). If using a single component pump, skip to step 9.
3. Place the recirculation line of the resin side into original resin container if
the material is to be saved for later use, or into a waste bucket. Materials
that have been catalyzed should be stored in a new, standalone container
or pumped into a waste bucket.

29
 4. Run the pump slowly to replace the resin in the pump with the pump
flush/wash. When saving the resin, pump only long enough to preserve
most of the resin. Do not allow pump flush/wash to flow into container.
5. Place the recirculation line in a waste bucket (if not already in a waste
bucket) and pump until the pump flush/wash is flowing through. Turn off
the pump.
6. Return the recirculation line to the container housing the pump flush/wash,
and turn the pump on again.
7. Let the pump run to recirculate the pump flush/wash for several minutes.
8. Turn off the pump, and switch the resin side from recirculation to injection
mode.
9. Place the end of the resin injection hose into the original resin container
(or appropriate container) if the material is to be saved, or into a waste
container if it is to be disposed.
10. Run the pump slowly to replace the resin in the hose with the pump
flush/wash. When saving the resin, pump only long enough to preserve
most of the resin. Do not allow pump flush/wash to flow into container.
11. Place the end of the resin injection hose in a waste bucket (if not already
in a waste bucket) and pump until the pump flush/wash is flowing
through. Turn off the pump.
12. Place the end of the resin injection hose into the container housing the
pump flush/wash, and turn on the pump again.
13. Let the pump run to recirculate the pump flush/wash through the hose for
several minutes, then turn off the pump.
14. Replace the contaminated pump flush/wash with new.
15. Alternate running the pump in recirculation and injection modes. At this
time it is appropriate to occasionally surge the pump to help dislodge any
trapped material.
16. When the pump and hoses are clean, pump the pump flush/wash into a
waste container until the pump and hoses are essentially dry.
17. Acetone may be pumped through the pump and hoses at this time to
remove any water in the system.

F-Assembly Cleanup
The F-assembly or other injection fittings can be cleaned and reused. The same
pump flush/wash or acetone used for cleaning the pump can be used here. Parts
with a lot of material build up can be soaked, which may help loosen the material.
Tools such as wire brushes, pipe brushes, picks, and drills are all very useful
when cleaning these parts.

A drill and drill bit make it very easy to remove most or all of the material
buildup inside the F-assembly. However, parts such as quick-connects and check
valves may need to be disassembled, cleaned, and rebuilt. Cleaning or rebuilding
of F-assemblies, quick connects, and check valves may be necessary throughout a
grouting project, but should always be done at the end of the project to ensure the
parts are ready for the next project.

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Material Storage
Any open material that is to be saved for later use must be fully sealed prior to
storage. Many resins will react due to the moisture in the air, so it is important to
ensure an adequate seal. Catalyzed materials can also sometimes be stored for
later use.

All materials, whether opened or unopened, should be stored according to

manufacturers’ instructions. It is usually recommended to store the materials in a
cool, dry, dark place. While some materials are tolerant to freezing or to hot
temperatures, and the containers are well sealed, it is best to keep the materials
away from hot and cold temperatures and away from wet environments.

Port Removal & Patching

The last part of the cleanup process involves removing all injection ports and
patching the drill holes.

Hammer-in ports can be removed with pliers, slide hammers with a screw
attachment, or with a pry-bar notched such that it fits around the head of the port.
Whichever method is used, it is important to avoid damaging the concrete around
the ports.

Mechanical ports will be removed in the opposite manner in which they were
installed. Those that are of the expansion type must be decompressed by
unscrewing them with a wrench, and those that are of the progressive type (wall
spears) must also be loosened with a wrench.

The most common method for patching the injection holes is by filling them with
a non-shrink cementitious grout. As with many of the steps described in this
guide, it is important to ensure the hole is clean before applying the non-shrink
grout. Occasionally, some chemical grout must be removed from the injection
hole to allow ample space for the non-shrink grout. This can be done by any
means necessary. Once the holes have been patched, the work is complete.

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References
[1] Warner, James, Practical Handbook of Grouting: Soil, Rock, and Structures,
John Wiley & Sons, Inc., Hoboken, NJ, 2004.

[2] Karol, Reuben H., Chemical Grouting and Soil Stabilization, Third Edition,
Revised and Expanded, Marcel Dekker, Inc., New York, NY, 2003.

[3] Avanti International, http://www.avantigrout.com.

[4] De Neef Construction Chemicals, Inc., http://www.deneef.com.

[5] Strata-Tech, http://www.strata-tech.com.

[6] Dayton Superior, http://www.daytonsuperior.com.

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