Polyurethane injection

stops water tunnel leaking

BY W. GLENN SMOAK
RESEARCH CIVIL ENGINEER
BUREAU OF RECLAMATION
DENVER, COLORADO

valve at the Pacheco Con-

A duit inlet in California lets

workers drain the conduit
without draining the 5.3-
mile-long tunnel that feeds it. Dur-
ing tests after construction in 1986,
howe ve r, Bureau of Reclamation
engineers found a 125-gallon-per-
minute leak at the concrete valve
structure expansion joint. The leak
shown in Figure 1 progressed up the
joint as the conduit filled.
Engineers stopped the tests and Figure 1. Before repair, water
partially drained the tunnel to get leaks through an expansion joint
an inside look at the leaking joint. in a California water tunnel
Although a waterstop had been in- project. The inset photo shows
stalled at the joint (Figure 2), inade- the area of the leak.
quate concrete consolidation was
permitting water to bypass the wa-
terstop. Soundings and visual in-
spections also revealed two large
voids, one at the joint invert and one
at the top.
Removing and replacing the valve
structure concrete would have been
too costly. Repair by epoxy injection
was rejected because liquid epoxy
would penetrate the sponge rubber
filler in the expansion joint, gluing
the faces together. Then the re-
paired section wouldn’t be able to Figure 2.
accommodate seasonal tempera- Expansion joint
ture change movements between between the
the tunnel portal and valve struc- Pacheco Tunnel
ture. We needed a way to plug the and a steel pipe
leak while still allowing movement conduit includes
at the joint.
a 1-inch sponge
Injected resin turns to foam rubber filler and
On several other projects, the Bu-
a waterstop
reau of Reclamation had successful- around the joint
ly repaired smaller leaks using hy- circumference.
drophilic polyurethane resin,
injected like an epoxy. The urethane
resin reacts with water to form an
expansive foam that cures to a
tough, flexible, cellular rubber.
If unrestrained, the reacted foam

has a very low density and a volume
10 to 12 times that of the initial
resin. Containing the expansion
produces a higher density material
better suited for plugging leaks in
concrete stru c t u re s. The Bu re a u
p re p a red specifications and con-
tracted with Te ra L i t e, Inc., of San
Jose, California, to do the work with
a commercially available hy-
drophilic polyurethane resin.
Resin injected outside and
inside the tunnel
The contractor began the repair
by drilling a series of injection holes
on 12-inch centers around the exte-
rior of the joint. Holes started in
Figure 4. Workers inject urethane
resin into the joint with a positive
displacement, airless pump.
Figure 3. Injection holes
drilled at an angle from
the outside intercept the
joint at a depth of 8 to
12 inches. At the invert,
only interior holes were
drilled.
Figure 5. Excessive resin leakage
both the tunnel portal concrete and wastes material. When this happened,
the valve structure concrete were the contractor stopped injecting and
angled to intercept the joint at a forced resin-soaked oakum strips into
depth of 8 to 12 inches (Figure 3). the joint. This contained the foam.
Because the valve structure lay on
bedrock, no exterior injection holes
were drilled at the bottom.
Workers installed plastic injectors
in the holes, then washed and
flushed each hole with water. This
showed which holes would accept
resin and indicated relative flow
rate. Also, the washing ensured that
the joint contained enough water to
react with the injected resin.
Using a positive displacement,
airless pump, workers injected the
resin (Figure 4). During injection,
the contractor monitored resin leak-
age from outside and inside the
joint. When too much resin leaked
out (Figure 5), workers stopped in-
jecting and forced resin-soaked
oakum strips into the joint to con- Figure 6. Workers also drilled and
tain the foam. After injecting all ex- injected resin into holes inside the
terior ports, the contractor let the water tunnel. Resin injected from the
resin cure overnight. outside of the tunnel portal extrudes
Interior holes were also drilled from the joints.
and injected in the same way the ex-
terior ones had been done (Figure Workers drilled and injected 11
6). The contractor drilled interior more holes with 4 more gallons of
holes from the tunnel portal side of resin to stop this minor leakage. Af-
the joint, at the invert, and around ter removing excess foam from the
the tunnel circumference. No holes concrete, they patched the injection
were drilled through or into the holes with epoxy mortar. Since the
m o rt a r-lined steel pipe. About 25 repair 2 years ago, no leaks have oc-
gallons of urethane resin were in- curred.
jected into the expansion joint.
The day after interior joint injec-
tion, the tunnel was filled with water PUBLICATION#C881073
to test the repair. Water leaked at Copyright © 1988, The Aberdeen Group
less than 0.5 gallon per minute. All rights reserved