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Patch’n Plug
Xypex Patch’n Plug is a specially designed, fast-setting hydraulic cement compound for concrete patching and repair. It stops flowing water in seconds and is used to seal cracks, tie holes, and other defects in concrete. The high performance characteristics of Patch’n Plug are enhanced by Xypex’s unique Crystalline Waterproofing Technology.
Advantages of Xypex
- Single component (simply add water)
- Very rapid setting
- Contains Xypex’s unique crystalline chemistry
for self-healing of cracks and other defects - Quick return to service of water holding structures
- Cement based – compatible with concrete and
masonry substrates - Non-toxic
- No VOCs
- NSF 61 certified
Recommended for
- Stopping an active flow of water through cracks
- Repair of concrete substrates before the application of Xypex coating materials
- Repair of leaking construction joints
- Sealing around pipe penetrations
Packaging
Available in 20 lb. (9.1 kg) pails and 60 lb. (27.2 kg) pails.
Coverage
One 60 lb. (27.2 kg) pail of Xypex Patch’n Plug will produce 0.54 cubic feet (0.0154 cu. metres) of mortar.
Storage
Xypex products must be stored dry at a minimum temperature of 45ºF (7ºC). Shelf life is one year when stored under proper conditions.
Patch'n Plug Application Details
Please refer to the Plugging & Patching Instructions section of the Product Data
Xypex recommended procedures for repairing slabs, walls and other flat concrete surfaces that have dry or leaking cracks and cold/construction joints.
Xypex recommended procedures for repairing wall to slab interface joints and other 90 degree concrete joints; including dry or leaking joints.
Xypex recommended blends of Concentrate and Patch’n Plug to create a longer pot life workable repair mortar that can replace Xypex Concentrate Dry-Pac for many Xypex repair scenarios and procedures.
Xypex recommended procedures and general directions for repairing standard, small to large sized spalls, honeycombs, and other deficiencies.
Xypex recommended procedures for repairing water leaks between conduit, pipe and other utility features (including steel, iron, PVC and HDPE piping) and the concrete elements they pass through.
Xypex recommended procedures for repairing leaking form-ties based on the typical “Plastic Cone Snap Tie” forming tie system (can be modified for other styles of form-ties).
Xypex recommended Estimating Table is a guide only. Actual usage may vary according to the project.
General Resources
Holland Township Community Pool
The Holland Township Community Pool in Milford, NJ, has existed since the 1950s. However, deterioration over time has resulted in severe cracks in the concrete. The cracks have compromised the pool’s ability to maintain a watertight structure, necessitating annual repairs.
MDA Levis - Seniors’ Residence Foundation Waterproofing
In the strategic rejuvenation of the MDA Levis Seniors’ Residence, the team faced a significant challenge: a compromised raft slab and basement walls due to the failure of an existing membrane waterproofing system. Positioned 4 feet within the water table and enduring a constant hydrostatic pressure of 1.7 psi, the need for a definitive and enduring waterproofing solution was paramount.
Al-Faihaa Building
The rehabilitation of the Al-Faihaa Building in Khartoum presented numerous challenges, primarily due to its bustling nature and the requirement for the structure’s rehabilitation activities to occur during working hours without affecting the operation of companies within the building. The project's complexity was further heightened by its proximity to the confluence of the White and Blue Nile Rivers, resulting in high groundwater pressure, especially noticeable during the rainy season. This environmental factor has long exacerbated the building's issues with water leakage in its basement and attached concrete water tank, rendering conventional waterproofing solutions ineffective.
Kantaoui Medical Center Below Grade Carpark
The Xypex waterproofing project at the Kantaoui Medical Center in Sousse, Tunisia, completed in 2021, showcases the effectiveness of Xypex products in ensuring the durability and reliability of critical infrastructure.
How to Repair Leaking and Dry Concrete Cracks?
This video will show the commonly employed techniques for using Xypex materials to permanently repair leaking cracks in concrete.
How to Repair Leaking and Dry Concrete Joints?
This video will show the commonly employed techniques for using Xypex materials to permanently repair leaking joints in concrete.
How to Repair Concrete Honeycombs or Rock Pockets?
This video will show the commonly used methods to repair rock pockets, honeycomb, voids, or other similar deficiencies in concrete using Xypex materials.
Projects Using This Product
The Rihand Dam
Being one of the oldest dams in India, the concrete of the dam body has experienced deterioration due to ageing and AAR (Alkali Aggregate Reaction) resulting in cracking and surface loss. Xypex’s unique crystalline technology was chosen as the preferred repair solution due to its cementitious nature and compatibility with concrete along with other technical reasons.
Sydney Harbour Tunnel
Commencing in September of 1991, repair systems using Xypex Concentrate and Patch’n Plug were used as part of an ongoing program of repair and maintenance of the North and South land driven tunnels and transition tunnels of this renown structure.
AASS Wastewater Treatment Plant
The walls of this plant were cast using the Machihembrado method. Because of this approach, Xypex Dry-Pac and Xypex Patch’n Plug were required to seal the construction joints. The same Xypex treatment was used on 518 m of cold joints and cracks. After these structural defects were repaired, the surfaces were treated with a two-coat application of Xypex Concentrate.
Canóvanas Filtration Plant
The thickening tank (92 ft. diameter by 15 ft. deep) of this filtration plant used Xypex Patch’n Plug to repair structural defects followed by a coating of Xypex Concentrate. Upon review, the Xypex treatment proved to be very successful, rendering the tank impenetrable by water.
Chehe River Mine
Xypex products were chosen to rehabilitate these pipes as they resist hydrostatic pressure, chemical attack and are a permanent solution thus avoiding future maintenance intervals and shutdowns. Additionally, they are used on wet concrete so removing the need to dry out the concrete before application. Xypex Patch’n Plug was used to seal active leaks in the pipe joints.
Fiat India Automobiles Private Ltd.
More than 13,000 lbs of Xypex Concentrate and 1,000 lbs of Xypex Patch’n Plug were used to waterproof a surface area of 60,000 sq.ft. Xypex was chosen for its additional benefit of chemical resistance and concrete durability enhancement.
Wastewater Tunnel Repair
The first phase of the project required the Bawax applicator to fill in all of the joints between the precast culvert sections with Xypex Patch’n Plug fast-setting hydraulic cement compound. Patch’n Plug stops flowing water in seconds and is used to seal cracks and other holes or defects.
