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Mountain Grout Flexible: A Technical Overview
Mountain Grout Flexible is a low-viscosity, hydrophobic polyurethane injection system that reacts with water to form a durable, closed-cell grout. Pumped as a single component with optional Accelerator “B”, it gives professional applicators precise control over gel and rise times to suit leak severity and temperature. The cured grout retains volume through wet/dry cycles, adheres tenaciously to concrete, and delivers a reliable, inert, non-toxic seal — ideal for remedial waterproofing in civil and building infrastructure.
30×
Expansion on reaction for effective void filling
Core Features & Specifications
- Hydrophobic polyurethane forms closed-cell grout that resists shrinkage through wet/dry cycles.
- Pumps as a single component; add Accelerator “B” to tailor reaction profile to site conditions.
- Low viscosity liquid (~500 mPa·s) promotes penetration into fine cracks and hairlines.
- Up to 30× volumetric expansion to chase water paths and fill voids efficiently.
- No VOCs, 100% solids; non-flammable with high flash point for safer handling.
- Cured properties: density ~64 kg/m³; elongation ~44% for dynamic service conditions.
- Reaction control: at 1.25% B, expansion starts ~50 s, completes ~4 min; at 2.5% B, starts ~15 s, completes ~65 s (at 25 °C).
- Designed for critical remedial tasks: manholes, stormwater, dams, tunnels, elevator pits, parking structures, and treatment plants.
The Mountain Grout Flexible Advantage
- Engineer confidence: stable, closed-cell structure delivers a permanent, inert seal under cyclic wetting.
- On-site control: dial in gel/rise times with Accelerator “B” to match leak severity and temperature.
- Productivity: single-component pumping reduces setup complexity and speeds mobilisation.
- Coverage certainty: 30× expansion tracks water pathways to seal beyond the visible crack.
- Safer handling profile: non-flammable, no VOCs, high flash point.
Proactive Troubleshooting
Scenario: Minimal water at the crack face
Potential Outcome: Incomplete reaction and insufficient rise in dry sections.
Adheseal Best Practice: Pre-wet the crack path (not flood) to ensure consistent contact water; select Accelerator “B” dosage to achieve reliable gel at site temperature.
Scenario: High-flow active leak washing out resin
Potential Outcome: Resin displacement before foaming, leaving leak pathways open.
Adheseal Best Practice: Increase Accelerator “B” to shorten start time, stage-inject from downstream ports, and reduce injection pressure to favour in-situ foaming and capture.
Scenario: Sparse port layout on thick concrete
Potential Outcome: Unfilled voids and intermittent sealing.
Adheseal Best Practice: Tighten port spacing based on element thickness and water path behaviour; inject until adjacent ports show material or flow reduction is observed.
Applications in Practice: Trade Scenarios
For Remedial Waterproofers (On-site Applicator): Stopping active leaks in basement cracks
The Professional's Challenge
Active water is displacing materials during injection. You need reliable gel and rise before washout while maintaining penetration into hairlines.
The Adheseal Solution: Engineered Certainty in Practice
Pump Mountain Grout Flexible as a single component and tune Accelerator “B” to 2.5% for rapid start (≈15 s) and completion (~65 s at 25 °C). Stage injections from downstream to upstream, keeping pressures modest so foaming locks the pathway.
Best Practice Note
Confirm pre-wetting on very dry sections. Continue until steady backflow or dampening appears at the next port.
For Asset Maintenance (Specifier/Engineer): Infiltration at manhole penetrations
The Professional's Challenge
Intermittent inflow and seasonal wet/dry cycling cause prior repairs to shrink and open up.
The Adheseal Solution: Engineered Certainty in Practice
Specify Mountain Grout Flexible for its hydrophobic chemistry and closed-cell structure that retains volume through cycles. Dose Accelerator “B” ~1.25% for controlled rise (start ~50 s, complete ~4 min at 25 °C) to ensure thorough grout development around the penetration.
Best Practice Note
Map inflow points and port from least to most active. Validate seal by observing reduction in infiltration under normal head.
For Civil Contractors (Business Owner/Operator): Rapid mobilisation on tunnels or culverts
The Professional's Challenge
Multiple leak points with limited possession windows demand fast setup and predictable outcomes.
The Adheseal Solution: Engineered Certainty in Practice
Single-component pumping streamlines plant and labour. Hydrophobic reaction tracks water to seal beyond visible defects, reducing call-backs and downtime.
Best Practice Note
Sequence teams by zone, standardise Accelerator “B” dosages per ambient temperature band, and document backflow/pressure response for QA.
Frequently Asked Questions
How do I control gel and rise times?
Adjust Accelerator “B” in the base resin to tune reaction. At ~1.25%, expansion starts ~50 s and completes ~4 min; at ~2.5%, start ~15 s and complete ~65 s (all at 25 °C). Increase dosage for rapid, high-flow leaks; reduce for controlled rise on slow seepage or cooler conditions.
Does the resin require water to react?
Yes. The hydrophobic formulation reacts on contact with water to foam and expand. Ensure at least minimal moisture is present along the crack path; pre-wet very dry sections to support consistent reaction without flooding the area.
Is it suitable for long-term wet/dry cycling?
Yes. The cured grout is a closed-cell, hydrophobic foam that retains physical form and is not prone to shrinkage under wet/dry cycles, supporting durable water cut-off in infrastructure exposed to seasonal changes.
Can I pump it as a single component?
Yes. Mountain Grout Flexible is pumped as a single component. Accelerator “B” is pre-dosed into the base resin to manipulate the reaction profile before injection to suit on-site conditions.
What are the cured properties I should expect?
Typical cured foam shows density ~64 kg/m³ and elongation ~44%, supporting crack movement and service conditions. Water absorption is <1%, and the grout remains inert and non-toxic after cure.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Seal leaking cracks in concrete | Hydrophobic, closed-cell foam maintains seal through wet/dry cycles | Remedial waterproofers, civil contractors |
| Stop infiltration at manholes and vaults | 30× expansion chases water paths to create a robust grout curtain | Asset maintenance, wastewater utilities |
| Restore watertightness at construction/cold joints | Controlled reaction times ensure in-situ foaming before washout | Engineers/specifiers, remedial waterproofers |
| Leak cut-off in tunnels, culverts, and dams | Single-component pumping accelerates mobilisation and throughput | Civil contractors, infrastructure maintenance |
| Elevator pits and parking structures | Durable, inert, non-toxic seal for long-term service | Remedial waterproofers, facility maintenance |
Applying Mountain Grout Flexible: Enhanced Protocols & Best Practices
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Assessment & Preparation
Identify leak sources, map water paths, and select port locations to progressively intercept flow. Clean and seal around ports to contain resin during rise.
Leak Mapping
Start at the lowest/outlet point and work upstream. Mark damp areas for pre-wetting if required.
Port Strategy
Use close spacing in thick sections and where flow paths branch. Prepare for staged injections.
Timing: Allow sufficient setup to keep injection continuous once started.Pro Tip: Pre-wet very dry sections to support consistent reaction without risking washout. -
Resin Setup & Accelerator Dosing
Dose Accelerator “B” into the base resin before pumping to suit site temperature and leak rate.
Standard Seepage
~1.25% “B” for start ~50 s and completion ~4 min at 25 °C, promoting deeper penetration before rise.
High-Flow Leak
~2.5% “B” for start ~15 s and completion ~65 s at 25 °C to minimise washout risk.
Timing: Reaction accelerates at higher temperatures and slows when cooler; adjust dosage accordingly.Pro Tip: Mix thoroughly and keep records of dosage vs ambient temperature for repeatable results. -
Injection & Monitoring
Pump as a single component. Begin from the lowest/most downstream port and progress sequentially to upstream ports.
Controlled Pressure
Use modest pressures to favour in-situ foaming and prevent resin bypass.
Verification
Watch for backflow or moisture changes at adjacent ports; proceed once the path is saturated.
Timing: Maintain continuous pumping during the gel window for each port.Pro Tip: If washout is observed, increase “B” dosage and re-stage from downstream. -
Post-Injection QA
Observe leak reduction under the prevailing head. Remove ports and make good once performance is confirmed.
Functional Check
Confirm no visible inflow; monitor for rewetting after pressure equalises.
Documentation
Record port sequence, dosages, and outcomes for asset records.
Timing: Allow foam to fully develop per selected reaction profile before removal.Pro Tip: Re-check after rainfall or system surges to verify long-term stability.
Limitations & Safety
Product Limitations
Requires water contact to react and expand; very dry cracks may need pre-wetting.
Not a surface-applied cosmetic crack filler; designed for injection and subsurface sealing.
Reaction times vary with temperature and moisture; adjust Accelerator “B” accordingly.
Safety & Handling Requirements
Personal Protective Equipment
Wear chemical-resistant gloves, eye protection, and suitable workwear. Avoid skin and eye contact. Wash thoroughly after handling.
Ventilation Requirements
Use in well-ventilated areas. For enclosed spaces, ensure adequate airflow and follow confined-space protocols as applicable.
Fire & Handling Precautions
Store away from ignition sources. Although the product is non-flammable with a high flash point, follow standard chemical handling and storage practices.
Emergency First Aid
Eyes:
Rinse cautiously with water for several minutes. Remove contact lenses if present and easy to do. Continue rinsing.
Skin:
Wash with soap and water. Remove contaminated clothing and launder before reuse.
Inhaled:
Move to fresh air and keep at rest in a position comfortable for breathing.
Swallowed:
Rinse mouth. Do not induce vomiting. Seek medical attention.
Refer to the product SDS for full safety information and consult medical services after significant exposure.
Mountain Grout Flexible Application Guide
Concrete — Active Leaking Crack
Surface Preparation
Identify water path and install injection ports to intercept flow. Clean surfaces around ports for sealing. Pre-wet adjacent dry zones to ensure contact water without creating washout conditions.
Primer Requirements
Primer not required for injection-grade polyurethane grout
Focus on water presence and correct port placement rather than primers.
Concrete — Damp/Seeping Crack
Surface Preparation
Map seepage, clean fines, and ensure consistent moisture film. Use moderate Accelerator “B” to allow deeper penetration before rise.
Primer Requirements
Primer not required
Maintain steady injection and monitor for backflow at adjacent ports.
Concrete — Cold/Construction Joint
Surface Preparation
Port along joint line to intercept leak planes. Remove loose laitance at port faces and seal surface to contain resin during rise.
Primer Requirements
Primer not required
Select Accelerator “B” dosage based on inflow rate and temperature.
Manhole/Pipe Penetrations in Concrete
Surface Preparation
Expose annular paths, install ports to encircle the penetration, and ensure moisture contact along the path. Clean for seal adhesion around port collars.
Primer Requirements
Primer not required
Stage injections to build a complete grout curtain around the penetration.
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