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For sealing leaking cracks or joints in concrete structures with continuous moisture exposure, Mountain Grout Gel Foam is a hydrophilic polyurethane formulation that reacts with water to stop active leaks. The single-component system is formulated without TDI or solvents, reacting directly with the water it encounters inside the concrete to create either a foam or a gel barrier depending on the moisture volume present.
How it works
Mountain Grout Gel Foam can be pumped as a single component directly into wet concrete cracks, or injected as a dual-component system alongside water. Upon contact with water, the liquid expands up to 25 times its initial volume to fill voids and seal paths of water ingress. Because the formulation is hydrophilic, it requires continuous moisture exposure to maintain its physical seal, curing into an inert, non-toxic barrier that handles ongoing structural movement without losing adhesion.
Where to use it
- Concrete dams and tunnels experiencing water ingress
- Storm water systems and waste treatment plants
- Underground vaults, elevator pits, and water-related facilities
Numbers that matter
- 400% elongation (ASTM D-638): High elasticity allows the cured gel-foam to stretch and flex with moving concrete joints and cracks without shearing the bond.
- 650 cps viscosity (ASTM D-1638): Low viscosity allows the liquid grout to penetrate deep into fine cracks and fissures before reaction begins.
- 30-second initiation time: Rapid start to the reaction when mixed at a 1:1 ratio with water at 25ºC, reaching full rise in approximately 6 minutes to choke off active water flows.
- 170 psi tensile strength (ASTM D-638): Provides the mechanical strength necessary to withstand hydrostatic pressures in underground vaults and pits.
Limitations
- Formulated for concrete structures with continuous moisture exposure; requires water to react and ongoing moisture to maintain its seal performance.
Frequently asked questions
What differentiates Gel Foam from Flexible resin?
Gel Foam is hydrophilic and reacts with water to form either a gel or foam. Flexible resin is hydrophobic. Gel Foam is for applications with continuous water contact.
What is the expansion rate of Gel Foam?
The resin expands up to 25 times its original volume. This expansion rate depends on available water, allowing it to fill voids and seal leak paths effectively.
Is the cured Gel Foam flexible?
Yes, the cured gel exhibits high elongation. This allows it to accommodate substrate movement and joint behaviour without compromising watertightness.
Can this product be used in potable water structures?
Yes, Mountain Grout Gel Foam cures to an inert, non-toxic seal. It is suitable for structures that will be in contact with potable water once fully cured.
Applications and benefits
| Application | Key benefit | Primary trades |
|---|---|---|
| Active leak repairs in cracks and joints | Hydrophilic reaction ensures expansion and penetration in wet conditions. | Remedial waterproofers, civil contractors |
| Manhole and pipe penetration sealing | Forms a flexible gel curtain, stopping infiltration under hydrostatic pressure. | Asset maintenance crews, wastewater utilities |
| Stormwater and wastewater infrastructure | Provides a durable, inert seal that maintains effectiveness under constant water exposure. | Civil contractors, specifiers |
| Tunnels and dams | Single-component injection allows rapid mobilisation and effective water cut-off. | Infrastructure contractors |
| Elevator pits and basements | Penetrates fine cracks and expands up to 25 times for comprehensive leak sealing. | Waterproofers, facility maintenance |
Applying Mountain Grout Gel Foam: Enhanced Protocols & Best Practices
-
Surface & Leak Assessment
Map crack or joint water inflow. Install injection ports from lowest point upwards to capture leak path. Lightly pre-wet dry zones.
Pro Tip: Stage injection zones to prevent resin bypass. -
Injection Preparation
Pump Gel Foam as a single component. Ensure resin temperature is 15–30 °C for optimal handling.
Pro Tip: Use a reliable injection pump with pressure control for consistency. -
Injection & Monitoring
Inject slowly until grout flows from adjacent port or water flow stops. Resin reacts with water to form foam or gel depending on availability.
Pro Tip: Maintain steady flow; do not over-pressurise to avoid resin washout. -
Post Injection Checks
Confirm water cut-off. Remove ports and patch holes once cured. Inspect sealed area for re-infiltration under water head.
Pro Tip: Recheck after rainfall or system surges to verify long-term performance.
Product limitations
- Requires water: Needs water presence to react. In dry substrates, pre-wetting is mandatory for activation.
- Not structural: Intended for leak sealing only, not for structural repair.
- Variable expansion: Expansion ratio and gel formation vary with water quantity. Site testing is recommended to confirm performance for specific conditions.
Safety and handling
Personal protective equipment
Wear nitrile gloves, chemical goggles, and protective clothing. Avoid direct skin or eye contact.
Ventilation
Use in well-ventilated areas. Follow confined-space entry procedures where required.
First aid
- Eyes: Rinse with clean water for several minutes. Seek medical advice.
- Skin: Wash with soap and water. Remove contaminated clothing.
- Inhaled: Move to fresh air. Consult a medical professional if symptoms persist.
- Swallowed: Rinse mouth. Do not induce vomiting. Seek medical attention immediately.
Storage and disposal
Store sealed containers away from extreme heat. Dispose of according to local regulations.
Substrate guide
Proper preparation ensures the resin activates and seals effectively, particularly where water contact is crucial.
Concrete cracks and construction joints
Surface prep: Drill and install injection ports along the crack or joint. Clean surrounding surfaces. For dry sections, pre-wetting is necessary to ensure water contact for resin activation.
Primer: Not required. The hydrophilic resin bonds directly to moist concrete substrates.
Manholes and penetrations
Surface prep: Install a circumferential port pattern around the pipe or penetration. Clean surfaces for secure port seating. Ensure annular spaces are moist to trigger resin reaction.
Primer: Not required. Injection relies on moisture activation, not priming.
Tunnels and dams
Surface prep: Establish port layouts across seepage areas. Clean surfaces to remove loose laitance and ensure secure packer seating. Maintain moisture presence for activation.
Primer: Not required. Gel Foam is designed for direct injection into wet concrete substrates.
Mountain Grout Gel Foam Physical Properties
| Property | Value |
|---|---|
| Base Chemistry | Hydrophilic Polyurethane |
| Curing System | Single Component |
| Viscosity | Low |
| Elongation | High |
| Expansion Ratio | Up to 25x |
| VOC Content | 0 |
| Solids Content | 100% |