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Use Mountain Grout Gel Foam for: Sealing active water leaks in cracks and joints within concrete structures, especially those with continuous moisture exposure requiring a flexible, long-term seal.
Mountain Grout Gel Foam is a specialist, low-viscosity hydrophilic polyurethane injection grout designed to stop water leaks in concrete structures. Its unique hydrophilic formulation actively seeks out and reacts with water (either present in the crack or co-injected) to form a flexible yet durable foam or gel seal. With an outstanding elongation of 400%, Gel Foam can accommodate significant movement within the structure without compromising the seal. This single-component system (pumpable as 1-component reacting with site water, or 2-component with water) is ideal for remedial contractors and infrastructure maintenance teams tackling leaks in tunnels, dams, underground vaults, waste treatment plants, and elevator pits across Australia. Notably, it is formulated without TDI or solvents, offering a 100% solids, Zero VOC solution for safer application and handling.
Primer Information: Priming is generally not required when injecting Mountain Grout Gel Foam into clean, damp concrete cracks. Its hydrophilic nature promotes excellent adhesion to wet surfaces where it reacts to form the seal.
Cure Time / Reaction Profile: Mountain Grout Gel Foam reacts upon contact with water. When mixed 1:1 with water at 25°C, reaction typically begins in approximately 30 seconds, with full rise (expansion) occurring in about 6 minutes. Reaction times are temperature-dependent: faster in warmer conditions, slower in colder conditions. Applicators must manage injection timing accordingly. The material forms a stable foam/gel quickly, with full cure taking longer.
Coverage Rate / Yield: Coverage is dependent on the volume of the cracks or joints being filled and the degree of expansion achieved (up to 25 times its initial liquid volume, influenced by water availability and confinement). Usage is typically measured by the volume of liquid grout injected to achieve refusal or fill the void.
Application Temperature Range: Standard practice for polyurethane grouts is typically between 5°C - 35°C. Be aware that low temperatures will significantly slow the reaction, while high temperatures will accelerate it rapidly. Always monitor site conditions.
Chemical Properties: A single-component hydrophilic polyurethane liquid. It contains no TDI (toluene diisocyanate), no solvents, and has zero VOCs. It reacts with water (H₂O) to cure into an inert, non-toxic polyurethane foam or gel. It is non-flammable in its liquid state and classified as non-hazardous for shipping.
Key Features of Mountain Grout Gel Foam
- Hydrophilic Water-Activated Seal: Actively reacts with water in leaks to form a tenacious seal. Ideal for damp or actively leaking cracks.
- Exceptional Flexibility (400% Elongation): Cured seal accommodates significant joint and crack movement caused by thermal changes or vibration, ensuring long-term effectiveness.
- Low Viscosity Penetration: At 650 cps, easily penetrates fine cracks and fissures in concrete for thorough sealing.
- High Expansion Potential: Expands up to 25 times its liquid volume (depending on water) to effectively fill voids and compress into cracks.
- Safer Chemistry (TDI-Free, VOC-Free): Contains no TDI or solvents, is 100% solids with zero VOCs, contributing to better applicator safety and suitability for confined spaces. Non-hazardous shipping.
- Excellent Adhesion: Bonds strongly to wet concrete surfaces, critical for effective leak sealing.
- Durable & Non-Toxic Seal: Cures to form an inert, permanent, non-toxic seal resistant to typical groundwater chemicals.
Why Choose Mountain Grout Gel Foam:
- Stop Active Leaks Effectively: Its water-activated chemistry targets the source of the leak for a reliable seal.
- Achieve Long-Lasting Flexible Repairs: High elongation prevents seal failure in moving cracks/joints, offering superior durability over rigid solutions.
- Seal Fine Cracks Thoroughly: Low viscosity ensures the grout penetrates deep into the concrete defect for a complete seal.
- Versatile Application: Can be pumped as a single component (using existing water) or dual component (mixing with water) to suit site conditions.
When to Choose Mountain Grout Gel Foam versus Alternatives:
- Choose Gel Foam over Hydrophobic PU when: The crack/joint is continuously damp or wet, flexibility is essential for movement, and a tenacious bond to the wet substrate is needed.
- Choose Gel Foam over Epoxy Injection when: Sealing active leaks (epoxy cannot displace water effectively) or when flexibility is required (epoxies are rigid). Gel Foam is for sealing, not structural bonding.
- Choose Gel Foam over Cementitious Grout when: Injecting fine cracks (PU has better penetration), rapid sealing is required (PU reacts much faster), or flexibility is needed (cement is rigid and brittle).
- Consider other options when: Structural repair/bonding is the primary goal (use epoxy), sealing very high-flow leaks rapidly (hydrophobic PU might be faster initially), or injecting into dry cracks where no water source can be introduced (hydrophilic needs water).
Trade-Specific Applications for Mountain Grout Gel Foam:
For Specialist Leak Sealing Contractors:
- Application: High-performance sealing of active leaks in tunnels, basements, underground car parks, concrete tanks, manholes, and elevator pits. Injecting into leaking construction joints or cracks.
- Technique: Utilise single or dual component injection pumps with appropriate packers installed into drilled holes intersecting the leak path. Inject methodically until grout extrudes or refusal pressure is met.
- Performance Benefits: Effectively stops persistent water ingress in challenging below-ground structures. High flexibility ensures long-term performance despite structural movement or vibration. Safer chemistry advantageous in confined spaces.
For Civil Infrastructure Maintenance Crews:
- Application: Sealing leaks in concrete dams, spillways, culverts, stormwater systems, wastewater treatment plant structures, and utility vaults.
- Technique: Employ standard concrete injection techniques appropriate for the scale of the structure. Manage reaction times based on ambient and water temperature.
- Performance Benefits: Provides a durable, flexible, non-toxic seal suitable for water-related infrastructure. Excellent adhesion in continuously wet environments common in these facilities.
For Remedial Waterproofing Applicators:
- Application: Addressing specific leak points in existing concrete structures as part of a broader remedial waterproofing strategy, such as sealing leaking floor/wall joints or isolated cracks before applying membranes or coatings.
- Technique: Precise injection into identified leak sources using low-pressure or high-pressure injection methods depending on the situation.
- Performance Benefits: Reliably stops localised water ingress. Flexibility prevents re-occurrence of leaks at treated points if minor movement occurs.
Application Information
- Required Tools: Appropriate injection pump (single or dual component polyurethane grout pump), mechanical or inflatable injection packers/ports, electric drill with masonry bits, safety equipment (see below).
- Trade-Specific Tips: *Preparation:* Drill injection holes strategically (typically angled) to intersect the crack/joint plane. Install packers securely. *Flushing:* Optionally flush crack with water before injection to clean debris and provide water for reaction if needed. *Injection:* Start injecting at lowest point for vertical cracks, working upwards. Inject slowly and deliberately, monitoring pressure and grout travel (e.g., appearance at adjacent packer). *Temperature Management:* Be mindful that warmer temperatures accelerate cure significantly, requiring faster work; colder temperatures slow cure, potentially needing longer injection times or pre-warming.
- Common Issues and Solutions: *Grout Setting Too Fast:* Temperature too high, or excessive water encountered instantly. Inject faster, use fewer packers simultaneously, or cool material if possible. *Grout Not Setting/Foaming:* Insufficient water in crack and not co-injecting water. Introduce water or switch to dual-component injection. *Packer Leaks:* Packer not set correctly or concrete around packer spalled. Reset packer or use surface seal paste around packer base. *Material Bypass:* Grout travels through unforeseen paths; adjust injection sequence or use faster-reacting grout (if necessary, e.g., hydrophobic pre-injection).
Storage and Shelf Life
- Storage Requirements: TDS excerpt does not specify. Typically, polyurethane grouts should be stored in tightly sealed original containers in a cool, dry place, protected from moisture contamination and direct sunlight. Check product packaging and full SDS for specific requirements.
- Handling Considerations: Although TDI-free and non-hazardous shipping, standard chemical handling precautions apply. Keep containers sealed to prevent moisture entry which can start reaction.
Certifications and Compliance
- Cures to an inert, non-toxic permanent seal.
Frequently Asked Questions About Mountain Grout Gel Foam
Q: What's the main difference between hydrophilic (like Gel Foam) and hydrophobic polyurethane grout?
A: Hydrophilic grout (Gel Foam) loves water, reacts with it to form a flexible, water-tight seal that bonds well in damp conditions and can re-swell if it dries/re-wets. Hydrophobic grout repels water, reacts quickly to form a rigid, closed-cell foam often used to rapidly stop high water flow but doesn't handle movement as well.
Q: Will Mountain Grout Gel Foam add structural strength to the cracked concrete?
A: No. Mountain Grout Gel Foam is designed for sealing leaks and providing a flexible barrier. Its primary function is waterproofing, not structural repair. For structural strengthening, an epoxy injection resin would typically be used (in dry cracks).
Q: Can I use Gel Foam to inject a crack that looks completely dry?
A: Gel Foam requires water to react and cure properly. If the crack is truly bone dry, you would need to pre-inject water or co-inject water alongside the Gel Foam using a dual-component pump setup. If the crack is simply dormant but previously leaked, there may be enough residual moisture within the concrete pores for it to react.
Q: How much does Gel Foam actually expand? The TDS says "up to 25 times".
A: The expansion rate depends heavily on the amount of water available and the degree of confinement within the crack/joint. With abundant water and space, it can expand significantly (towards the 25x potential). In tighter cracks or with limited water, it will react to form a denser gel or foam with less expansion, focusing on sealing the void.
Q: What injection pump pressure should I use?
A: This depends on the pump system, crack width, and concrete condition. Generally, start with low pressure and increase slowly as needed to move the grout through the crack without damaging the concrete or blowing out packers. Typical pressures might range from low (under 500 psi) to high (several thousand psi) for very fine cracks. Consult pump manufacturer and assess site conditions.
Q: Is Mountain Grout Gel Foam safe for use in drinking water tanks?
A: The provided TDS states the cured product is non-toxic. However, it does not explicitly state certification for contact with potable water (like AS/NZS 4020 in Australia or NSF/ANSI 61 internationally). You MUST verify this certification status with the manufacturer or supplier (Mountain Grout / Adheseal) before using it in drinking water structures.
Use Mountain Grout Gel Foam for:
- Sealing Active Leaks in Concrete: Effectively stopping water flow through cracks and joints in below-ground structures (basements, tunnels, pits).
- Waterproofing Construction Joints: Sealing leaking cold joints or movement joints in concrete infrastructure like dams, tanks, and reservoirs.
- Remediating Leaking Infrastructure: Repairing water ingress issues in wastewater treatment plants, stormwater systems, manholes, and utility vaults.
- Creating Flexible Crack Seals: Providing a durable, highly flexible seal in cracks subject to movement from thermal changes or vibration.
- General Concrete Leak Injection: A reliable solution anywhere a flexible, long-term seal is needed to stop water leaks in continuously damp or wet concrete.
Why Use Mountain Grout Gel Foam for:
- Proven Leak Sealing Performance: Its hydrophilic nature effectively targets and seals water pathways within concrete cracks and joints.
- Unmatched Flexibility: The 400% elongation capacity ensures the seal remains intact even with significant structural movement, preventing future leaks.
- Deep Penetration Capability: Low viscosity allows the grout to flow into fine fissures that thicker materials cannot reach, ensuring a more complete seal.
- Enhanced Safety Profile: Being TDI-Free, Solvent-Free, and Zero VOC makes it a safer choice for applicators and better for sensitive environments compared to older technologies.
- Long-Term Durability: Cures to an inert, non-toxic, permanent seal that resists degradation in typical underground or immersed conditions.
How to apply Mountain Grout Gel Foam (Typical Injection Process):
- Identify & Assess Leak: Determine the location, nature (crack, joint), width, and flow rate of the water leak.
- Drill Injection Holes: Drill holes (typically 10-16mm diameter) at an angle (approx. 45°) to intersect the plane of the crack or joint within the concrete's depth. Space holes appropriately along the defect (e.g., 15cm to 50cm apart, depending on crack width and grout travel).
- Install Injection Packers: Clean drill holes and securely install suitable injection packers (mechanical or inflatable) into each hole.
- Flush Crack (Optional): If desired or needed to clear debris or provide reaction water, flush the crack by injecting water through the packers.
- Prepare Grout & Pump: Prepare the injection pump (single or dual component). Ensure Mountain Grout Gel Foam is at a suitable temperature (affects viscosity and reaction speed). If pumping dual-component, set the correct ratio with water (e.g., 1:1).
- Inject Grout: Connect pump line to the lowest packer on vertical cracks (or start at one end for horizontal). Begin injecting slowly. Monitor pressure and watch for grout extrusion from the crack face or adjacent packers. Once grout appears at the next packer, stop injection at the current one, move to the next packer, and repeat the process until the section is filled (indicated by grout extrusion or pressure refusal).
- Monitor & Clean Up: Observe injected areas for any further leakage. Once grout is cured, packers can be removed and holes patched if required. Clean pump and equipment immediately according to manufacturer recommendations (often involves flushing with specific cleaning agents).
- Safety First: Always wear appropriate PPE (gloves, eye protection, suitable clothing) and follow safe work procedures for drilling and high-pressure injection. Ensure adequate ventilation, especially in confined spaces. Consult the SDS.
Mountain Grout Gel Foam limitations:
- Not for Structural Repair: Designed for sealing and waterproofing, not for restoring structural integrity to cracked concrete.
- Requires Water: Being hydrophilic, it needs water to react and cure. Not suitable for bone-dry cracks unless water is introduced.
- Temperature Sensitive Reaction: Reaction speed (initiation, foaming/gelling) is significantly affected by temperature, requiring adjustments to application technique.
- Expansion Varies: Actual expansion depends on water availability and confinement, so yield calculations are approximate.
- Not for Very Wide/Dry Voids: Best suited for cracks and joints. Large, dry voids may require bulk fillers or different techniques.
Safety precautions when using Mountain Grout Gel Foam:
- Personal Protective Equipment (PPE): Wear chemical-resistant gloves (e.g., nitrile, butyl), safety glasses with side shields or goggles, and protective clothing to avoid skin contact.
- Ventilation: Although Zero VOC, ensure adequate ventilation during application, especially in confined spaces like pits, tanks, or tunnels, as large volumes are often used.
- Isocyanate Awareness: While TDI-Free, it is still a polyurethane product. Avoid breathing vapours or mists. Use appropriate respiratory protection (e.g., respirator with organic vapour cartridges) if working in poorly ventilated areas or if recommended by SDS/WHS assessment.
- Injection Safety: Follow safe operating procedures for high-pressure injection equipment. Never point injection gun towards people. Be aware of potential for blow-outs.
- First Aid & SDS: Consult the Safety Data Sheet (SDS) for Mountain Grout Gel Foam before use for detailed information on hazards, safe handling, emergency measures, first aid, and PPE recommendations.
- Handling: Avoid moisture contamination of the liquid product in storage. Keep containers tightly sealed.
Mountain Grout Gel Foam can be used on the following substrates:
- Concrete: Primarily designed for injection into cracks, joints, and voids within concrete structures (e.g., poured concrete, precast concrete, shotcrete).
- Substrate Condition: Adheres excellently to damp or wet concrete. The concrete surrounding the crack/joint must be structurally sound enough to hold injection packers and withstand injection pressures. Loose or friable concrete should be repaired first.
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