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Polymeric filling material (injection resin)
Injection resins can consist of one or two components that react chemically with each other. Initiators and accelerators are mixed in as additional components as required. By injecting polymeric filling materials, various injection targets are pursued, such as sealing of components or the non-positive connection of components. For this purpose, different packer types from the DESOI quality range can be used to successfully carry out an injection task.
Inhibition or prevention of access of corrosion-promoting substances in concrete components by cracks (closing)
Force-locking connection of cracked components
Removal of crack-related leaks (sealing)
Making a limited expandable connection of crack flanks (limited expandable connection)
Instructions for use
Filling in the area of cavities can be provided for comparable application aims
Areas of application of the crack fillers and fillers depend on the moisture content of the cracks and the crack widths
Injection pressure of the crack fillers should be limited according to the component requirements and tasks for execution
Example: C 20/25 - 25/3 x 10 bar = approx. 80 bar
Material to be used
Epoxy resin
Polyurethane
Quick-foaming polyurethane
Acrylate gel (with special certificate of suitability)
Demands on the injection devices
Simple operation and verifiability of functionality
Low susceptibility
Injection pressure adjustable (can be limited depending on crack filling material, component properties and area of application)
Easy cleaning and maintenance
Suitable objects
Residential and industrial buildings
Civil engineering structures
Underground and canal construction
Hydraulic structures
Traffic structures
Information
Cracks have to be filled completely, i.e. at least up to a filling degree of 80 % of the component cross-section to be filled.
(Observe the specifications of the planner)
Bore packer
Demands on the bore packers
Compatibility of materials (packer components) with fillers used
Reliable fixing in the component
Corrosion resistance of the parts remaining in the structure
Drill alternately at an angle of 45° to the crack to hit the crack in the middle of the component (depending on the object)
Clean (e. g. with compressed air) and prepare the boreholes, depending on the filler
Set and clamp packer (in the case of dry cracks, prewet crack flanks)
Close crack with insulating material, leave crack end free for venting and level control, at the highest point for vertical cracks
Inject the packer until the crack filler emerges from the next packer, reinject each packer within the processing time of the crack filler
After the injection the injection packers are removed or non-corrosive parts can remain in the building (agreement with the builder required)
Seal boreholes
Plugging
The insulation prevents the filler from escaping during injection
Repair of leaks with fast-reacting substances
Desoi Sealing cone system
Procedure according to ZTV-ING
According to ZTV-ING*, cracks must be fi lled in such a way that the escape of water and / or air during the injection is ensured. In order to ensure that a crack is completely fi lled with injection material, the injection process must be continued until the material emerges from the next packer. With the help of the round head and pan head nipples with sealing cone, this requirement can be met without additional effort.
Due to the integrated check valve no injection material may run back through the packer
Tightness at low and high injection pressures (depending on component)
The end off the packer is knocked off
The borehole can be sealed with appropriate material
Opening pressure approx. 10 – 15 bar
Operational sequence
Place polymer packer
Inject injection material
Knock off polymer packer
Seal borehole
For vertical application, additional insulation and ventilation must be provided.
1-day steel packer with special retaining retaining
Procedure
Alternate drilling
Clean and prepare boreholes
Set packer
Screw on round head nipple
Insert deairing tool
Connect ball valve
Inject until material emerges from packer with deairing tool
Repeat procedure
Inject until material escapes from uninsulated crack end
Post-injection within the processing time
Remove thrust piece
Fill boreholes with mortar and close them
Advantages / Information
All working steps can be carried out on one day
Due to the integrated check valve no injection material may run back through the packer
The thrust piece can be removed directly after the injection
The borehole can be sealed with appropriate material
The sealing system keeps the clamping rubber tensioned
Opening pressure approx. 10 – 15 bar
The exact bore diameter has to be observed for safe high-pressure injection
Nominal diameter = borehole diameter, exception Ø 13 mm = 14 mm borehole
deairing tool
For deairing of 1-day packers by using the nipples with free passage.
Adhesive packer
Advantages
Inject up to 60 bar
» The special material properties of the adhesive packer promote the bonding between the adhesive
and the adhesive surface of the packer. Depending on the underground, the adhesive packers withstand high pressures.
Time and material savings
» The insulating material only needs to be applied over the crack
» The adhesive is applied very thinly on the adhesive surface of the packer
Application range
On non-wet undergrounds
Structural elements with dense reinforcement
Prestressed concrete
Placing of the adhesive packers
Roughen the surface on both sides of the crack depending on the structural element, remove any debris or loose particles, dust etc.
Distance between packers depends on thickness of structural element (normally: thickness of structural element = distance between packers)
Keep the injection canal free by driving a greased steel pin into the crack
Seal the crack surface with sealing material also embedding the flanges of the adhesive packers but stop before the end of crack for deaeration
Remove all steel pins and screw a round head nipple on the first packer to be injected
Inject the packer until injection material comes out of the adjacent packer, screw in round head nipple
After the injection material has cured remove packers and sealing material
Recondition surface
Information
Adhesive packers are also available in steel
Injection device
general
The self-injecting device is used when the injection process has to be carried out at low pressure (approx. 1 bar) and over a longer time period to ensure a successful result (e. g. with very fi ne cracks).
Material to be used
Cement suspension
Epoxy resin
Polyurethane
Advantages
Injection without machines
Simple working principle
Easy visual monitoring of consumption
Several injection devices can be used at the same time at various places
Can be used overhead
General operation
Hook the tension springs to the packer
Draw in injection material using the material cylinder
Insert material cylinder into the cone
Place the pressing unit on the piston
The injection process starts, the material consumption is indicated at the scale
Repeat fi lling process if necessary
ADHESIVE PACKER
Mark the distance between packers
Grease a steel pin and drive it into the crack
Bonding with Klebfix
Apply adhesive (sealing material) on the adhesive surface of the packer
Place packer
Seal crack surface up to 3 – 5 cm from the end of crack
Bonding with hot glue
Apply adhesive (sealing material) on the adherend of the packer and slip the packer over the steel pin and press the packer on the concrete
Seal possible open cracks between the injection devices with adhesive
Remove steel pin from packer
MULTI TILE PACKER
Mit dem Spezialbohrer Ø 6 mm in die Fugenkreuze der hohlliegenden Fliesen bohren
Remove drill dust
Clamp multi tile packer in the drill hole
SCREED SCREW PACKER
Make a drill hole Ø 6 mm through the hollow screed using a special drill
Remove drill dust
Clamp screed screw packer in the drill hole
Nipple option
For the processing of reaction resins, the injection packers are equipped as standard with a high-pressure (HP) round head nipple with sealing cone. The opening pressure is approx. 15 – 20 bar, i. e. at this pressure the ball valve opens and the flow of the crack filler into the component begins.
Another possibility is to inject in the low-pressure process with an opening pressure of approx. 2 – 3 bar using the low-pressure (LP) nipple. As an alternative, the pan head nipple can be used, for which a sliding coupling is required on the machine side. The nipple with shut-off slide is a variant in which there is no opening pressure to overcome and thus the crack filler can flow unhindered. The use of high or low pressure processes depends on the requirements of the injection.
Procedure according to ZTV-ING – Nipple with sealing cone (pre-assembled)
For delivery, the HP nipples with sealing cone are hand-tightly screwed onto the steel packers
Clamp steel packer in the borehole
Only tighten the HP nipple of the steel packer that is injected first
Loosen the HP nipples of the other steel packers by one turn
Inject the first steel packer until filler emerges from the second steel packer
Tighten the HP nipple of the second steel packer
Inject second steel packer until filler exits third steel packer
Tighten the HP nipple of the third steel packer, etc.
Post-injection is part of the injection procedure
Advantages
Complete filling of the crack or cavity
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