Step-by-step 45-degree mechanical packer installation and hydro-active polyurethane resin injection at 50–250 bar to permanently arrest high-pressure gushing leaks.
1. Hydro-Active Polyurethane Chemistry & Rapid 30x Closed-Cell Expansion
Hydro-active polyurethane resins used in PU injection grouting are low-viscosity prepolymers that react aggressively with incoming water. Upon contact with moisture, the resin initiates a rapid foaming reaction, expanding up to 30 times its original volume within 30 to 45 seconds to create a tough, flexible closed-cell elastomeric plug.
2. Step-by-Step 45-Degree High-Pressure Mechanical Packer Installation
Packer holes are drilled alternately on both sides of the crack at a 45-degree angle to intersect the crack plane at mid-depth of the structural element. High-pressure mechanical packers are locked into place and flushed prior to injecting specialized polyurethane injection grouts at pressures between 50 and 250 bar.
3. Dual-Stage Injection: Water Cut-Off Foam Followed by Flexible Resin Seal
In severe active water bursts, a rapid-foaming single-component PU resin is first injected to instantly stop the gushing water. A secondary low-viscosity elastic polyurethane resin is then injected to permanently seal micro-fissures, complementing primary structural waterproofing chemicals and accommodating ongoing structural movement.
Conclusion
Active-leak injection requires diagnosis, controlled packer installation, and a resin system suited to the water and movement conditions. A staged approach can address immediate water flow and the longer-term flexible seal, but product TDS requirements and site-specific engineering controls should govern the work.
