Epoxy Injection Preparation Tips

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1 March 2022 - 16:23, by , in Epoxy, No comments

Epoxy Injection Preparation Tips – Installing Surface Mount Tri-Base Ports

With Epoxy Injection, all sides of a crack are sealed with a high-strength low viscosity epoxy resin that binds them together structurally.

In order to prepare the crack for injection, a wire brush and dust must be used to clean it. For the epoxy paste-over to bond properly, the surface must be free of contaminants, such as oils or paints. Dust and debris must be removed with clean compressed air if possible. Ensure that the crack and the surface are completely dry before epoxy injection preparation. Any water seeping from the crack should be stopped prior to epoxy injection. 

After the surface is cleaned, the Surface Mount Epoxy Injection Ports are installed directly over the crack, 6″ to 8″ apart (15-20 cm). As the crack becomes finer, the spacing between the ports should become closer.

For specific applications, corner ports and 12.5″) drill in ports are available in addition to the standard surface mounted Tri-Base ports shown in this example.


Epoxy is placed on each of the three tabs on the base of the Tri-Base Port in order to mount it. In order to seal the crack, non-sag paste is applied to both sides of the wall after the ports are installed.

It is recommended to apply the paste generously at about 1/8″ (3-4 mm) thickness, and to mounded up the paste around each port to at least 1/4″ (6-7 mm) thick. Paste-overs along cracks should be a minimum of one inch (3 cm) wide. Paste that is not applied thick enough may crack, causing epoxy to escape during injection. This prevents epoxy from properly penetrating and flowing within the crack. Temperature and ambient conditions determine the length of time it takes for epoxy paste to fully cure.

Inject structural strength epoxy resin after the surface paste has hardened, starting at the lowest point of the crack. For horizontal or lateral cracks, start on one side and work your way up.

The next port in line will require its cap to be removed since the crack has been sealed on both sides. Once Epoxy resin can be seen escaping from the next injection port, the applicator is disconnected from the port and the port is capped.

Following the applicator connection, the process is repeated with the next port. The port and paste can be ground off once the Epoxy resin has cured and the crack has been fully injected.

Epoxy does not Flow as Expected – Troubleshooter

  • Injected crack is not continuous or the area being injected is saturated
  • Crack is blocked by debris or cured epoxy paste
  • Surface mount port does not align with the crack
  • Epoxy has cured in injection nozzle, port or crack
  • Epoxy resin viscosity too high

Epoxy injection resin into structural concrete walls, slabs, columns, and piers is an efficient and economic way to repair cracks.  High strength epoxy can be applied in accordance with all recommendations and specifications in order to restore concrete structures to their pre-crack strength.


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