LCR CRACK REPAIR HOW TO VIDEO

They say a picture is worth a thousand words….so how many words is a how to video on repairing a foundation crack with our LCR Repair kit??  Click here to watch the YouTube video.

POLYGEM FLOORING

We are incredibly excited that after many months of preparation we are finally ready to launch our new and improved flooring division that will be run under the watchful eye of our own April Dimmick Smith.  April brings along 20+ years of experience in all facets of polymer flooring that includes extensive formulating knowledge, years of conducting training classes and workshops on the proper installation of epoxy decorative and industrial seamless flooring as well as a wealth of expertise on the installation of decorative flooring systems.  We are introducing many new formulations from chemical resistant, self leveling and trowel down overlays, waterbased urethanes bot high gloss and matte finishes.  A new hybrid Polyurea system that has outstanding UV resistance.  The most exciting part is our line of custom media blends available in mica, flakes/chips, color quartz and metallics.  As April will tell you we have a “World of Possibilities” to offer our customers and their clients.  Even more so, we offer custom formulating and color matching services as well.

Take a look at our new Flooring Brochure  and feel free to call April with any questions or to order product and you can email her at april@polygem.com

 

Zoopoxy

We have recently launched our mirror/satellight site dedicated to our “Zoopoxy” sculpting epoxies you can visit at  Zoopoxy.com   Many of our customers affectionately know our sculpting epoxies as “Zoopoxy” and decided it was time to give them it’s own website.  Our main website still contains all the original information, pictures and how to’s and you can purchase products online here.  And keeping up with social media we also have a facebook page and an Instagram Page.  As always contact us directly with any  questions about our products and services at (630) 231-5600.

Come see our New and Improved Website!

I am inviting you to stop by and take a look around our new website at http://www.polygem.com.  There you will see lots of new products and content especially our new Flooring Division that showcases our newer seamless epoxy floor coating #1618.  Stop by regularly to read up on what’s new at Polygem, Inc.  See you there!

GUIDELINES FOR PROPER STORAGE, HANDLING AND USAGE OF EPOXY PRODUCTS

 

GUIDELINES FOR PROPER STORAGE, HANDLING AND USAGE OF EPOXY PRODUCTS

 

STORAGE: 

Epoxy can have a shelf life of 2 years or more when stored at between 65 – 75 degrees.  Store unmixed epoxy in original containers with lids or caps tightly secured.  Store products off the floor and do not leave exposed to cold environments even if only over night in work or delivery vehicles.  Epoxy can “Freeze” or thicken and become solid if exposed to temperatures below 60 degrees.  Epoxy product that becomes “Frozen”, thickened or solid because of exposure to cold can be re-warmed to at least 80 – 100 degrees until it thins up again.  Heaters, submersion in hot water or placing the epoxy product inside air compressors cabinets are common ways of re-warming product.  Cartridge product can be re-warmed in a microwave at 15 seconds for 10 ounce tubes or 30 seconds for 22 ounce cartridges and only 10 seconds additional intervals at a time until product is warmed sufficiently for use.  Use caution; over microwaving can cause a cartridge to leak or burst.  DO NOT let product become hot and let product cool to room temperature before use.

HANDLING: 

 

Always wear protective clothing, gloves, eye protection and follow proper procedures per Manufacturers Safety Data sheets.

USAGE:  

 

Always follow manufacturers printed instructions and any project specifications for the intended use of the product.  Thoroughly mix product at the specified weight or volume ratio.  Dispense dual cartridge product until equal amounts flow from cartridge PRIOR to attaching mixing nozzle and then dispense an additional 4” – 6” ribbon of product to ensure proper mixing prior to use or installation.

In cold weather or environments, never apply epoxy to frozen concrete.  Frozen concrete can contain ice-crystals that will act as a bond-breaker when the concrete thaws.  Pre-warm the surfaces that the epoxy will contact and warming the epoxy is also advisable.

In hot weather or environments, maintain the epoxy at below 80 degrees.  The surfaces the epoxy will contact and any aggregates should also be cool or below 80 degrees.

Clean up tools and uncured epoxy with a recommended solvent.  For disposal of empty containers, contact your state or local waste agency or US EPA RCRA hotline at 800-424-9346.

How to Fix a Basement Crack with LCR Epoxy

Fixing a crack using the same high strength epoxy that professionals use is now easily done with the LCR Liquid Concrete Repair Kit.  The repair is done from the inside using a standard caulking gun where with low pressure, you “inject’ the liquid epoxy into the crack, filling the entire inside of the crack top to bottom with a high strength epoxy.  The epoxy cures and forms a “permanent” weld of the cracked concrete and water will not be able to re-enter the crack.

The Kit contains all materials you need to repair an average basement foundation crack 8′ tall, 8″ thick and 1/16″ wide.

To begin you start with a dry non-leaking crack and wire brush the crack to clean off dirt, paint or loose material.

Next  Mix equal amounts of of Part A Epoxy Paste with Part B (about golf ball sizes) until mixture is streak free and a uniform gray color.

Roll the edge of the port in the mixed epoxy.

Place the center of the port directly over the crack.

Place each port about 10″ – 12″ apart up the length of the crack

Apply mixed epoxy paste around the base of the port and seal the crack between the ports.  Make sure you apply a heavy layer of paste around the base of each port.  Also apply a bead of epoxy at the base of the crack along the floor/wall joint about 6″ either side of the crack.

Once the entire crack has been sealed, allow to cure for at least 12 hours until plastic hard where the epoxy surface paste can be scratched with a nail.  Follow the mixing instructions for the epoxy injection cartridge and load into a standard caulking gun.  Start at the lowest injection port and begin pumping the liquid epoxy into the crack using firm and steady hand pressure.  Do not force the epoxy, simply let it flow into the crack until it appears at the next higher port and release the pressure on the cartridge before removing the nozzle from the port.
Cap the lower port and move up to the next higher port and repeat until the entire crack has been filled.  Ports and surface paste can be removed the next day after a full 24 hour cure.

Crack Injection Techniques

CRACK INJECTION TECHNIQUES

EPOXY OR POLYURETHANE FOAM?

A casual debate often will arise over the use of either epoxy or polyurethane foam for foundation crack repair.  Both will fill the crack and stop water from entering through the crack.   If stopping a leak is the only concern, then either product is fine to use.

The question remains, which one is better?  That depends on the type of crack and conditions present at the time of the repair.  The obvious difference between the 2 injection systems is epoxy will restore the structural integrity of the cracked wall by filling the crack with a high-strength adhesive that essentially ‘welds’ the cracked wall back together.  Filling the crack with these high-strength epoxies eliminates the movement of the opening and closing of the crack in the wall that occurs during normal expansion and contraction of the soil during the seasonal cycles.

Polyurethane foam also fills the crack with a resin that expands in the presence of moisture and can be flexible enough to accommodate the same movement of the soil due to these freeze/thaw or wet dry cycles.  Since polyurethane resin systems expand during the injection, less resin is required and can be much more economical to install especially in wider cracks or loose soil conditions.  For a majority of foundation cracks the resin selection should be what the contractor is most comfortable using.  Some cracks will have better repair results using one system over the other.  For thin or hairline cracks, low viscosity epoxy resins will more often achieve better results because the epoxy will remain a liquid during the injection process allowing the resin the extra time that may be needed to fill tight hair line cracks when using low pressure cartridge type injection systems.  For very wide cracks, the polyurethane expanding foam systems will fill the crack and do so with a fraction of the resin that would be required if epoxy was used.  Wet or actively leaking cracks often will have better results being injected with polyurethane foam.  There are epoxies that will work well in wet conditions as the epoxy will displace the water during the injection process, but extra care needs to be taken to “flush” out any resin that combines with the water.  This is accomplished by continuing the injection of the epoxy coming out the next higher port and pushing out any resin that appears milky until clear resin flows out the port streak free.

There is a class of cracks that require expert review in terms of resin selection.  Structural cracks due to movement and or settling of the home Cracks that are wider at the bottom or where the walls on either side of the crack appear deflected are often due to settling should be evaluated by a structural Engineer who can provide professional opinion on the best corrective action.  .

HIGH PRESSURE OR LOW PRESSURE INJECTION?

Most foundation cracks can be successfully injected with low-pressure injection systems such as the single caulking style cartridge or the dual side-by-side cartridge systems.  These manually injected systems in conjunction with the appropriate viscosity resin system will require very little pressure to fully inject most cracks.  The issue of injection pressure becomes more relevant when repairing fine or hairline cracks.

The convenient and simple to use cartridge systems can generate pressures far exceeding required pressures for injecting most epoxy resin systems.  A slow, low-pressure injection procedure with a low-viscosity resin will effectively fill even the thinnest of cracks.

Two component polyurethane systems such as Polyfoam LV, which is available both in the single or dual side-by-side cartridges, can be used to inject most foundation cracks whether leaking or not.  Polyurethane foam systems are more commonly associated with higher injection pressure systems utilizing pumps and grease guns.  Fast-reacting cut-off foams will require high pressure to maintain the ‘forward’ progress of the foaming resin being injected.  The drilling required for installing the high-pressure injection packer-ports creates dust that can clog the crack and merely getting the resin past the spring ball valve can require up to 250 p.s.i..  Crack width and other circumstances will mandate which method or system is best but most foundation cracks can be effectively repaired with polyurethane foam and low-pressure cartridge style systems.

EPOXY INJECTION

1.      Surface of the crack must be clean, free of loose material and dry (damp is ok with no surface moisture present).  Old coatings should be removed by grinding or wire brushing to expose bare concrete.

2.      Mix a small amount of epoxy paste according to mix ratio.

a)      Use Polybac #1002FS for 20min. set up of injection ports and when walls are damp or wet.

b)      Use Polybac #1004FS for 45 min. set up of injection ports when low-odor pastes are required.

c)      Use Polybac #1183 or LCR Epoxy Repair Paste when longer pot-life is desired.

3.       Apply a small bead of paste to the back of surface mount injection port and affix the port directly over the crack approximately 4” – 6” up from the floor.  Repeat this procedure and place additional ports as necessary every 10” – 12” up the entire length of the crack.  For horizontal cracks start at one end and work towards the other end.

4.      Mix additional amounts of epoxy paste and apply the paste to the floor/wall cove area at the base of the crack to min. 6” either side of the crack.   Apply the epoxy paste to the entire surface of the crack and around the entire base of each of the ports to effectively seal the entire crack.  In the event the bottom part of the crack is hairline and not visible, continue to apply the paste down to the floor in the general direction of the visible part of the crack to seal any potential leaks during the injection procedure.

5.      Allow the epoxy crack paste to sufficiently harden until it is plastic hard and can be scratched with a nail.  Select the appropriate viscosity of epoxy injection resin based on the width of the crack.  Hairline cracks will require a low viscosity resin and wider cracks will require a higher viscosity resin.  Large cracks should be injected with epoxy gel resins to minimize the potential for seepage of the epoxy resin into the soil before it has set.  Guidelines for resins as follows:

a)      Polyject #1001 LV for hairline to 1/16” cracks

b)      Polyject #1001MV for 1/16” to 1/8” cracks

c)      Polyject #1001 HV for 1/8” to 1/4″ cracks

d)      Polyject #1001 EHV for over 1/4″ cracks

6.      Begin injecting the epoxy resin into the lowest port or start at one side of a horizontal crack.  Continue to inject until resin appears at the next port.  Release injection pressure, cap the lower port and move injector nozzle to the next higher port.  Repeat the injection sequence until the entire crack has been filled.

7.      It is good practice to re-inject one of the higher ports after 10 or so minutes to verify that the crack is completely full and has not lost any resin due to seepage or settling of the resin in the crack.  Footings often crack at the same point as the wall and additional resin will be required to fill the footing crack.

Option 1. The epoxy surface sealer paste can removed after the injection resin has cured.  Use a cold chisel to remove most of the paste and sanding will remove remaining resin.  Grinding or burning of the epoxy paste is not recommended.

PROS                                                                               CONS

High strength bond of crack                                             Lower bond-strengths in actively leaking cracks

Effective long-term repair results                                     Can cause re-cracking in walls under stress or settling

Recommended for finished basements                           Some materials odors can be objectionable or offensive

POLYURETHANE INJECTION

1.      Follow the same general setup procedures for epoxy injection above – steps 1-4

.

2.      After the epoxy crack paste has hardened, although it is not always necessary, pre-wet the crack by injecting a small amount of water to later activate the injected polyurethane resin.

3.      Inject the polyurethane resin as outlined in step 6 of epoxy injection.  Carefully monitor the resin flow at the top port so as not to over inject the resin.  Too much resin will foam out the top of the crack and can overflow onto exterior surfaces such as sidewalks, driveways and decks.  Cured polyurethane resin is almost impossible to remove.

PROS                                                                               CONS

Can inject actively leaking cracks                                    Not a structural repair

Economical resin system                                                 Difficult to inject hairline cracks

Recommended for moving cracks                                  Messy and hard to clean-up resin

BASIC CRACK REPAIR WITH HYDRAULIC CEMENT

Caution! Hydraulic cements contain caustic chemicals and can cause skin irritations and chemical burns.  Wear appropriate respirators, safety glasses and gloves to protect against cement dust, debris and chemicals.

1.      Dampen the crack with water.  Mix a slurry of the hydraulic cement and brush or hand apply over the crack and also coat 2” of surface on both sides of the crack.

2.      Using as little water as possible, mix the hydraulic cement into a stiff mortar mix.  Starting at the bottom trowel the mix over the entire crack and fill a cove at the bottom of the crack where the floor meets the wall for 6” either side of the crack.  Mix another slurry mix and brush over the entire repair.

Option 1 – Chip out the crack 1” wide by 1½” deep, top to bottom and along the floor wall joint 6” either side of the crack.  Slot should be “U” shaped or “dove tailed” for best repair results.  Proceed with steps 1 and 2.

Option 2 – Substitute an epoxy gel or grout for the hydraulic cement for added durability and bond strength.

PROS                                                                               CONS

Inexpensive materials                                                       Rigid material; re-cracks easily

Quick repair                                                                      Material can shrink or crack as it dries

Easy low-tech repair method                                            Not recommended for finished basements

WET OR ACTIVELY LEAKING CRACK REPAIR

WARNING! Use of power tools, lights and other electrical tools in wet work areas is extremely dangerous!  Use properly functioning ground fault circuit interrupters at all times and all cords should be intact and undamaged when working in or around wet areas!

SLOW OR MINOR SEEPAGE

1.      Chip out the crack 1” wide by 1½” deep, top to bottom and along the floor wall joint 6” either side of the crack.  Slot should be “U” shaped or “dove tailed” for best repair results.

2.      Mix a slurry of the hydraulic cement and brush or hand apply into the slot of crack and also coat 2” of surface on both sides of the crack.

3.      Start at the top of the crack and work down to the point of heaviest seepage. Mix small batches of a fast-setting hydraulic cement and fill slot to surface.  Fill the length of the crack except for 2”-4” of the area of seepage.  Allow the installed cement to fully harden a minimum of 15 minutes and the longer the cure the better.

4.      Mix a final “plug” batch of the hydraulic cement and work it with you hands until the cement just begins to stiffen.  Firmly press the cement plug into the remaining slot and hold for 2-3 minutes or until the cement is rock hard.  Mix another slurry mix of the hydraulic cement and brush over the entire repair.

HEAVY OR HIGH VOLUME WATER FLOW

a.      Follow steps 1 & 2 above.  Locate area of heaviest water flow and mix one handful of hydraulic cement and create a stiff putty mix.  Use the mix to cement a piece of tubing or pipe as a pressure relief port directly over the flow of water.  Apply additional layers of mix to reinforce the tube into place.  Allow the cement to harden for a few minutes.

b.      Start at the top of the crack work down toward the leak.  If the leak is above the floor level or towards the middle, work also from the bottom of the crack up towards the installed pressure relief pipe until the crack is filled and the water is now flowing out of the pressure relief pipe.  Allow the installed cement to sufficiently harden.

c.      Remove the pipe and mix a final “plug” batch of the hydraulic cement and work it with your hands until the cement just begins to stiffen.  Firmly press the cement plug into the remaining slot and hold for 2-3 minutes or until the cement is rock hard.  Mix another slurry mix of the hydraulic cement and brush over the entire repair to finish.

Note: More than 1 pressure relief pipe and or larger diameter pipes may be needed for heavy leaks.  The final plugging sequence should always begin with the pipe of least seepage or pressure and progress to the heaviest.  Allow the installed cement time to sufficiently harden before proceeding.

BASIC EXTERIOR CRACK REPAIR

Caution! Check with your local utility service providers before you dig to help locate any buried power or other utility service lines.  Also, practice safe digging techniques to prevent collapse or cave in of the hole.

1.      Locate the crack by examining the exposed top of the wall.  Dig a hole large enough to expose 4 feet of length of the wall with 2 feet exposed on either side of the crack.  The hole should extend out away from the wall far enough to allow for comfortable work access and prevent possible cave in or collapse of the hole.  Dig down deep enough to expose the entire footing.  Scrape the wall clean of all loose dirt and wire brush the entire surface.

2.      Cut a strip of roofing felt, (90 lb. felt works best) 12” wide by the length of the crack plus 10 “ to cover over the footing.  Apply a thick heavy layer of roofing mastic tar (the thick ‘peanut butter’ type) over the entire piece of felt.  Press the mastic side of the felt directly over the crack and down and over the top of the footing.

3.      Cut a second strip of felt to match the width of the exposed wall and again to the length of the wall plus the 10 extra inches.  Once again apply a very thick layer of the roofing mastic to the felt paper.  Press the mastic side of the felt directly over the first piece of felt and down the wall and over the top of the footing.  Firmly press the felt paper so any air pockets are eliminated and mastic squeezes out from the edges.

4.      Backfill the dirt into the hole and tamp the dirt regularly to ensure good tight compaction of the dirt.

Option 1 – Before applying the tar mastic/felt layer, chip out the crack and patch with gel epoxy or hydraulic cement for added waterproof protection.

Option 2 – Substitute a high quality rubber membrane system for the tar-mastic and felt.

PROS                                                                               CONS

Inexpensive materials                                                       Digging/excavation of crack

Easy low-tech repair method                                            Digging/excavation of crack

TIPS OF THE TRADE

“Tack” up injection ports with Crazy Glue Gel.

Temporarily stop actively flowing water by pounding cedar shingles or wood shims directly into the crack.  The wood will swell up and stop the flow of water.

Instead of chipping out cracks which can clog up the crack, core drill holes big enough to set surface mount injection ports with hydraulic cement.  Good tip for actively leaking cracks.

Chip out actively leaking cracks and pack with Oakum or lead wool to stop flowing water.

Soak absorbent rags in Polyfoam and tightly pack into cracks or around pipe penetrations to stop the flow of water.

Core drill directly into an active leak and set port with hydraulic cement.  Place an empty caulking tube over the end of a shop vac hose.  Put cartridge tip into the port and suction the water out of the crack while setting other injection ports with #1002FS paste.

Inject behind furnaces, hot water heaters etc. by affixing clear tubing to static mixer nozzle and injection port with hose clamps.

“Springing a Leak” during injection can be stopped by rubbing a candle over the leak, with modeling clay or plumbers putty.

Insert coffee straws, long brad nails, wire, etc. into the crack and mount injection port over nail, straw etc.  This will prevent the crack from getting clogged by excess crack paste.  Remove straw, nail, etc. prior to injecting.

Do’s and Dont’s

Do read the material data sheet first and consult the Material Safety Data Sheet for additional information including the safety requirements and handling, storage and disposal information.

Do follow mixing instructions as exacting as you can including mix ratio by either weight or volume as listed. DO NOT use more of one component that was is listed on the label or data sheet.

Do wear proper safety gear and mix material with adequate ventilation.

Do protect your skin and eyes against contact with the resins.   Wash off and resins that do get on you immediately with soap and cold water.  DO NOT use solvents on your skin to clean off resins.

Do thoroughly mix the 2 components for 2 -3 minutes until streak free.  It is good practice to transfer the mixed material to another mixing vessel and mix for 1-2 more minutes and then use.  DO NOT leave mixed material to sit as that can initiate a exotherm reaction causing mixed material to prematurely set and or overheat!  DO NOT mix more material than can be applied in the listed “pot life” of the product!

Do mix and apply the epoxy at room temperature!  Warmer temperatures can cause the epoxy to set faster and cooler temperatures can cause the epoxy to set slower or even prevent setting.

Do allow the applied epoxy to follow the cure times listed on the data sheet before using the applied epoxy.  DO NOT expose the curing epoxy to moisture and moisture can cause spotting or blooming to the cured film surface.

Hi!

I am hoping to provide as much information as I can share here about my company Polygem, Inc. and the epoxy systems that we manufacture.  I will share what I know about their uses and the projects that have utilized them as far back as 1978 when Polygem was founded.  Please feel free to contact me directly with any questions concerning epoxies and of course our products.  I look forward to providing many informative posts and hopefully discussions about epoxy adhesives and their many uses!

Jay Schmid

President