Nitofill Steel Injection System - Technical Details and Specifications

Overview

The Nitofill Steel Injection System comprises steel mechanical packers and couplers designed specifically for high-pressure injection of polyurethane resins into cracked and leaking concrete structures. This system represents a critical component of the Nitofill product portfolio for concrete repair and waterproofing applications.

System Components

Steel Injection Packers

The Nitofill system includes two primary packer variants, each engineered for precise hole placement and resin delivery:

Nitofill Steel Packer 10mm x 95mm

• Minimum order quantity: 100 units per pack
• Part number: FC344228-UNIT
• Dimensions: 10mm diameter × 95mm length
• Compatible with multiple polyurethane formulations including Nitofill PU130, PU140, and PU150

Nitofill Steel Packer 13mm x 100mm

• Minimum order quantity: 100 units per pack
• Part number: FC344227-UNIT
• Dimensions: 13mm diameter × 100mm length
• Suitable for larger diameter holes and deeper concrete penetration
• Compatible with Nitofill PU130, PU140, and PU150 resins

Nitofill Coupler 4 Jaw

The Nitofill Coupler 4 Jaw (part number FC344226-UNIT) serves as the critical connector interface within the injection system:

• Minimum order quantity: 5 units per pack
• Reusable design: Can be reused multiple times with different packers
• Quick connect/disconnect capability: Enables rapid hose attachment and removal
• Positive shut-off mechanism: Prevents material loss and pressure drops during connections
• Grease nipple valve: Facilitates reliable connection and disconnection of pumping hoses
• Compatible resins: Works with both Nitofill PU130 and Nitofill PU150 formulations

Key Features and Advantages

Material and Construction

• Manufactured from steel for maximum strength and durability
• High-pressure rated to withstand demanding injection forces
• Single-use packers that can remain in place or be removed after polyurethane foam cures
• Reusable coupler component reduces replacement costs

Functional Advantages

• High pressure capability enables reliable application of polyurethane resins
• Grease nipple valve mechanism allows for quick connections and disconnections without loss of pressure or material
• Positive shut-off design maintains system integrity during operations
• Flexible application options - packers can be left in place or extracted post-cure

Application Specifications

Hole Preparation

• Drilling angle: 45-degree angle recommended
• Hole positioning: Drilled to intersect cracks approximately midway through concrete thickness
• Example: For a 300mm thick wall, drill to a 150mm depth to ensure proper intersection with the crack

Packer Spacing Configuration

Packer spacing depends on specific crack characteristics and is determined by two critical factors:

• Crack width: Wider cracks may require closer packer spacing
• Crack depth: Deeper cracks influence penetration distance requirements

Critical spacing principle: Packer spacing must be close enough to ensure that injected resin will penetrate along the crack length to reach the next injection point, preventing gaps in the seal.

Injection Procedure

1. Start at the lowest point of the crack structure
2. Work upwards progressively through the crack system
3. Pump resin slowly until material appears on the crack face
4. Monitor pressure to ensure full penetration between spaced packers
5. Repeat at subsequent packer locations

Compatible Polyurethane Resin Systems

The Nitofill Steel Packer system is engineered for compatibility with three primary polyurethane formulations:

Nitofill PU130

• Hydrophobic semi-flexible polyurethane grout
• Supplied in 20kg drums
• Shelf life: 12 months
• Reacts with water to form semi-flexible polyurethane foam
• Suitable for variable reaction times with optional accelerator additive

Nitofill PU140

• Hydrophilic flexible polyurethane grout
• Multi-purpose injection resin for crack sealing and void filling
• Reacts with water to form closed-cell foam
• Compatible with single component or twin piston pump applications

Nitofill PU150

• Multi-purpose hydrophilic flexible polyurethane grout
• Supplied in 20kg containers
• Expands up to 25 times initial volume
• Reacts with available water to form expanding foam
• High elongation and flexibility characteristics

High-Pressure Application Equipment

The steel packer system integrates with high-pressure injection equipment:

• Single component injection pumps equipped for high-pressure delivery
• Twin piston pump configurations available for variable water-to-resin ratio control (particularly for PU140 and PU150)
• Pumping hose connections via the Nitofill Coupler 4 Jaw with positive shut-off

Cleaning and Maintenance

Post-application cleaning protocol:

• Clean all tools, equipment, and injection pumps immediately after use
• Use Fosroc Solvent 10 for removal of uncured resin
• Thoroughly clean injection pumps following each application cycle
• Cured material can only be removed mechanically

Product Supply and Ordering

Complete system components are available through standard supply channels:

Product	Part Number	Quantity
Nitofill Steel Packer 10mm x 95mm	FC344228-UNIT	100 units
Nitofill Steel Packer 13mm x 100mm	FC344227-UNIT	100 units
Nitofill Coupler 4 Jaw	FC344226-UNIT	5 units
Nitofill PU130 20kg	FC300899-20KG	As required
Nitofill PU140 20kg	FC300902-20KG	As required
Nitofill PU150 20kg	FC300900-20KG	As required
Fosroc Solvent 10 4 litre	FC600800-4L	As required

Standards and Safety

Safety Data Sheets (SDS) and Technical Data Sheets (TDS) are available from the Fosroc website for all components within this system. Users should consult appropriate documentation prior to application and in case of emergency medical situations.

References

• [1] Fosroc_Nitofill_Injection_Packers_TDS.pdf
• [2] Fosroc_Nitofill_PU140_TDS.pdf
• [3] Fosroc_Nitofill_PU130_TDS.pdf
• [4] Fosroc_Nitofill_PU150_TDS.pdf
• [5] Fosroc_Nitofill_Accelerator_TDS.pdf