KNOWLEDGE · PENETRATIONS AND UNDERGROUND STRUCTURES

Penetrations: continuous sealing around the perimeter

Water may travel beside the pipe, sleeve or through surrounding concrete. First identify the correct annulus, then plan access and inspection of the full perimeter.

Assessment Procedure and options Selection and next step

EXPLORE THE METHOD

Penetration: from annulus assessment to inspection of the entire seal

First read the cross-section: the penetration face retains material, while the actual seal forms in the assessed space around the pipe. Then follow preparation, drilling, injection and inspection. The drawings show one option through concrete; a sleeve or pipe movement requires detail adaptation.

Cross-section of a pipe through a wall: exposed space around the pipe and mortar applied at the face. — The cross-section explains the surface seal's role. Mortar at the face must retain subsequently injected material within the assessed zone.

01 · Assessment

Cross-section: distinguish face closure from deep sealing

The repair aims to seal the space around the pipe, including deep inside the wall. Mortar at the face restricts discharge during injection. Filling the visible perimeter alone does not confirm internal filling.

On site, establish whether water flows beside the pipe, between pipe and sleeve, at the sleeve–concrete interface or through damaged concrete nearby. Also determine whether the pipe moves in service. The seal and main material must suit that connection; rigid mortar should not block required movement.

Identify the actual leaking connection on the cross-section.
Distinguish sealing depth from the face closure layer.
Account for a sleeve and service movement where present.

Volume of the assessed annulus →When the connection must retain movement →

A brush removes contamination and loose residues from the accessible space beside the pipe. — Cleaning reveals edge condition and the area to which the face seal must bond.

02 · Installation

Expose and clean the area for the face seal

Remove contamination, loose fragments and ineffective previous repair residues from the accessible zone. After cleaning, it is easier to assess whether the edge is sound and where water emerges. Select tools for the pipe and substrate materials so preparation does not damage services or retained sealing.

With strong inflow, first create conditions for preparing and retaining the main material. A leak-stopping stage, for example selected using WaterStopper, is then a separate part of the method. Do not fill the entire accessible space with it without control if further sealing access will be needed.

Check the soundness of cleaned edges.
Re-identify the discharge location after removing deposits.
With active inflow, plan access for the main seal.

CrackOn.5 — preparation and sealing →WaterStopper — inflow-reduction stage →

Drilling concrete around a service penetration; hole entrances lie above and below the pipe. — Holes around the penetration provide access to the repair zone. Their positions must follow the actual cross-section.

03 · Installation

Drill to reach the correct space around the pipe

Set out injection and observation points around the perimeter and at the required depth. A borehole must reach the assessed space beside the penetration, not the pipe interior. Before drilling, check service routes, reinforcement and retained sealing components.

Select hole number, angle and spacing for the assessed penetration. Also establish the packer sleeve position: it must seal in sound substrate and leave clear access to the selected zone. The first holes allow the assumed cross-section to be checked.

Compare borehole depth with the annulus position.
Maintain a clear connection between the packer end and injection zone.
Include observation of the lower part and full perimeter.

Hole length and packer installation zone →Geometry and injection trial →

Blue arrows and drops indicate water flushing of boreholes and accessible space beside the pipe. — Blue arrows indicate flushing, not resin. The cleaning method must be compatible with the selected material.

04 · Installation

Clean holes and prepare the face seal

Remove drill cuttings from the entire injection path. In this option, holes are flushed with water before packer installation. Match preparation to the main material: water presence affects HydroGum's reaction and CrackFlex behaviour, and moisture at the entrance alone does not confirm conditions deeper inside.

After preparing the surface, form the specified face seal shown in the first cross-section. CrackOn.5 restricts uncontrolled discharge there; retain planned injection and observation holes. Install packer bodies before resin appears on hole walls and check their stability. Relate injection start conditions to the mortar instructions and selected detail.

Confirm clear passage through cleaned holes.
Retain access to observation points after face sealing.
Check that preparation has not blocked required pipe movement.

CrackOn.5 — conditions for forming the seal →HydroGum — water contact and injection →

Penetration cross-section during injection through the lower packer; pale material begins filling the space around the pipe. — The lower point injects material, while other points allow progress assessment. The pale filling shows an intermediate stage.

05 · Installation

Fill the annulus and observe adjacent points

On the trial section, start injection through the selected point; in the option shown, this is the lower packer. Observe uptake, pressure, water behaviour and material appearing at observation points. Check whether injection material stays in the annulus or escapes to the face or an adjacent void. Communication to the next point confirms a connection, not complete perimeter filling.

CrackFlex can be considered where material can be retained and cure in the zone. ResinBau AcrylGel + Polymer requires reaction time selection and preparation of two mixtures delivered by a two-component pump. HydroGum needs water contact; where moisture availability is uncertain, select the specified system with water. Each option must be checked under the penetration's flow and discharge-confinement conditions.

Distinguish water displaced from the point from arriving material.
Compare uptake with progress around the perimeter and at the required depth.
Stop for uncontrolled discharge or a pressure rise without uptake.

CrackFlex — flexible sealing →ResinBau AcrylGel + Polymer — mixture preparation →Pressure, uptake and observation →

Penetration cross-section with pale filling around the pipe and a hose connected to the upper packer. — Injection through the upper point allows supplementary sealing of another part of the zone. Uniform pale filling represents the intended effect, which must be confirmed on site.

06 · Installation

Top up accessible zones and inspect the entire perimeter

Continue injection through successive points according to the trial result. If the method includes top-up injection, perform it within the material working window; do not try to overcome setting resin merely by raising pressure. Check the top, bottom, sides and ends of the planned zone. Discharge outside the penetration may indicate another water path.

Acceptance covers watertightness of the repaired connection under appropriate water conditions and detail behaviour under expected service movement. Record material, quantities, communication points and finish. Geometric annulus volume helps plan material but excludes unknown cavities; consumption is not calculated by automatically dividing that volume by the resin's free-foaming factor.

Confirm watertightness of the entire zone and absence of a new water path beside the penetration.
Relate injection completion to trial criteria, not material quantity alone.
Reinstate the specified finish and seal holes after the works.

Penetration volume and geometric assumptions →Converting the correct material from litres to kilograms →

Pipe, sleeve and concrete create several interfaces

Check pipe material and diameter, sleeve presence, existing sealing and concrete condition around the penetration. Establish between which components water flows. Sealing the sleeve–concrete interface will not resolve a leak between sleeve and pipe.

Identify the service function and possible movement. Before drilling, establish the pipe route and hidden components. Boreholes must reach the selected space without damaging services, reinforcement or sound sealing components.

Restrict discharge, retain control

Remove loose material from the accessible face and prepare the surface. The seal beside the pipe must retain injection material in the planned zone. It should neither unintentionally stiffen a connection requiring movement nor replace filling inside the structure.

Select injection and observation points around the perimeter and at the required depth. Access only to the upper part does not confirm that the bottom can be filled. A circumferential borehole diagram aids planning; actual positions follow the assessed cross-section.

The flow path determines the sequence

Clean holes appropriately for the material and prepare stable packer installation. Conduct a trial on a limited section. Observe water, material at adjacent points and discharges at the face. Record whether injection covers the intended annulus or reaches an adjacent void.

After achieving communication, continue controlled filling and, where specified by the method, top-up injection within the working window. Do not treat material appearing at one point as acceptance of the entire perimeter. With active inflow, establish a stage that enables retention of the main material.

Annulus volume is a model

The pipe and penetration calculator uses dimensions of the assessed space between components. Enter the correct diameters and filling zone length. Knowing only the pipe's outside dimension does not yet establish the leaking annulus volume.

Uneven concrete, cavities and connections to other voids can change consumption. Compare quantities with the trial. Do not divide the result by the resin's free-foaming factor, assuming it will achieve the same volume in a confined annulus.

Assess the entire detail

Check watertightness around the perimeter and at the ends of the repair zone. Look for new discharge outside the penetration and pipe movement where it occurs in service. Reinstate the specified finish and seal the holes.

Record which interface was repaired, the water conditions and where communication was confirmed. Sealing injection does not itself confirm other functions of the service penetration.

RESINBAU SELECTION

Calculate what you know

CALCULATORAnnulus volume →

Calculate the space you actually intend to fill.

CALCULATORLitres and kilograms →

Convert the correct product or mixture after establishing volume.

Next step

Discuss your project conditions

Prepare a cross-section, a description of water and movement, and results of previous trials. ResinBau helps select the material and application method.

Discuss your project / technical selection ↗