What is ACTFLEX PU200 used for?

PU200 is a hydrophobic polyurethane crack injection resin used for sealing structural concrete cracks and leak remediation in subterranean and moisture-exposed concrete - tunnels, basements, lift shafts, foundations, and below-grade walls.

How does hydrophobic foam injection work?

PU200 reacts with the water present in the crack to expand into a closed-cell hydrophobic foam, sealing the crack from the inside out. The expansion creates pressure that forces resin into every void.

Viscosity 500-600 mPa·s at 25°C, density 1.12-1.2 g/cm³. Foaming time 180-360 seconds. Expansion ratio approximately 0.6 with water present. Elongation greater than 100% (thick) or 250% (thin film).

What equipment do I need?

Use 10mm or 13mm Forspec injection packers, gun coupler, and the INJEXA SWM 1300 (or SWM 1500 for deeper cracks) pump system. Single-component, no mixing required.

Shelf life and safety?

12-month shelf life when stored sealed. Solvent-free, low-odour, zero shrinkage after foaming. Safe for use in confined spaces with appropriate PPE per SDS.

Forspec Actflex PU200 Single Line Semi Hard Foam 20kg hydrophobic polyurethane injection foam for sealing concrete cracks, active water leaks, joints, and voids in waterproofing and structural repair applications

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ACTFLEX PU200 Hydrophobic 20kg

Name: ACTFLEX PU200 Hydrophobic 20kg
Brand: Forspec Protective Coatings
SKU: AACF518
Price: 550.00 AUD
Availability: InStock

$550.00

or 4 interest-free payments with

Single-pack hydrophobic PU injection resin. Meets water, foams 8 to 20 times, stops the leak.

ACTFLEX PU200 is a one-component, solvent-free hydrophobic polyurethane injection resin for stopping active leaks and sealing cracks in concrete. Pump it in neat. When it hits water it expands into a closed-cell foam that fills the crack and blocks the water. It is a water-stop, not a structural repair.

Where to use it

Crack injection in structural and non-structural concrete
Basements, foundations, retaining walls and slabs
Tunnels, subways and underground services
Dams, reservoirs and wastewater tanks under hydrostatic pressure
Bridges, car parks, manholes and pits

Why waterproofers buy it

One component. No mixing ratios on site
Solvent free and low odour, so it suits basements and tunnels
Expands 8 to 20 times on contact with water
Low viscosity, gets into fine cracks and porous concrete. No shrinkage
Hydrophobic closed-cell foam. Does not need permanent water contact to stay stable
Bond to concrete greater than 2.28 MPa. Elongation over 100% in thick sections
20 kg pail. 10 year Forspec product warranty

Coverage

No fixed rate. Consumption depends on crack width, depth and voids. Estimate from crack volume and confirm by trial injection on the first section.

Not for

Structural crack repair (use PROBOND 1100, CRACK PRO 1200PS or CRACKLOCK E400L), dry cracks unless pre-wetted through the packers, below 10°C, UV exposure, movement joints, or drinking-water structures without written Forspec confirmation.

All times at 25°C and 50% RH. Forspec R&D typical values.

Expands 8-20 times on contact with water to seal active leaks

One-component, no on-site mixing ratios, injected neat from the pail

Solvent-free and low odour for enclosed spaces such as basements and tunnels

Quantity: 1

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ACTFLEX PU200 Hydrophobic 20kg

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Product Details

This solvent-free formulation emits no harsh odors and exhibits excellent penetration capabilities. It features fast reaction kinetics, ensuring efficient sealing, with no shrinkage or post-application dimensional instability. The cured material maintains high durability and long-term resistance to moisture, making it ideal for applications in below-grade structures, tunnels, basements, and other water-exposed concrete elements.

How to Use

Inject with single-component, high-pressure polyurethane injection equipment through 10 mm mechanical packers set at maximum 200 mm intervalsProbe and assess any void of unknown volume before injecting, and confirm the resin quantity by trial injection on the first section
Drill 10 mm holes at maximum 200 mm intervals along the crack, offset from the crack line and angled at 45 degrees
Drill deep enough to intersect the crack at a depth of 60-100 mm, alternating sides of the crack where access allows
Blow or vacuum all dust from the drilled holes
Insert 10 mm mechanical packers with non-return valves, leaving approximately 20 mm of the packer proud of the surface
Tighten each packer firmly with the T-handle wrench to seal against injection pressure
Flush the pump and lines with urethane thinner before charging with resin; never use equipment or lines containing residual water
Where the crack is dry or water content is low, inject clean water through the packers to activate the reaction
Charge the pump, filling approximately two-thirds of the reservoir before sealing the lid
Begin injection at low pressure and increase gradually
Vertical cracks: inject from the bottom packer upward. Horizontal cracks: inject from the ends toward the centre
Continue at each packer until resin extrudes from the crack approximately 100 mm either side of the packer, then move to the next packer
Do not over-inject
Leave the non-return packers in place to hold the resin under pressure while it cures
Trim and dress the cured foam once it is firm and no longer expanding
Allow 24 hours at 25C and 50% RH for full reaction and a stable seal
Remove the packers and patch the drill holes flush with a FORSPEC repair mortar, FORBUILD 100 or FORCRETE 100 per its TDS
Flush the pump and lines with urethane thinner immediately after use
Record batch numbers, injection dates, packer locations and spacing, injection pressures and resin consumption per packer in the project quality records

Technical Specifications

Product Type: One-component hydrophobic polyurethane injection resin for water-stopping
Composition: One-component hydrophobic polyurethane resin
Colour and Form: Light brown, low-viscosity liquid
Density at 25C: 1.12-1.20 g/cm3*
Viscosity at 25C: 500-600 mPa.s*
Foaming Magnification: 8-20 times, water-contact dependent; free-foam above 13 times*
Foaming Time at 25C, 50% RH: Approx. 180-360 seconds, free foam*
Bond Strength to Concrete: Greater than 2.28 MPa*
Elongation, Thick Sections: Greater than 100%*
Elongation, Thin Sections: Greater than 250%*
Reaction Time at 25C, 10:1 Water to Resin: 300-350 seconds, 16-20 times magnification*
Full Reaction and Stable Seal: 24 hours at 25C, 50% RH*
Application Temperature: Greater than 10C, substrate and material
Packer Spacing: 10 mm holes at maximum 200 mm intervals, angled 45 degrees to intersect the crack at 60-100 mm depth
Packaging: 20 kg pail
Shelf Life: 12 months, unopened, 5-30C, protected from moisture
Hazard Classification: Hazardous Chemical, Non-Dangerous Goods under the WHS Regulations and the ADG Code
* Typical Forspec R&D characteristic values, not subject to third-party certification

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System Build-Up Guide

Correct application makes all the difference.

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Pool System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX HYDROPLUG
5 ACTFLEX AT MESH
6 ACTFLEX 988 CWP (2 Coats)
7 Tile Adhesive
8 Pool Finish

Retaining Wall System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX MS PRO
4 ACTFLEX AT MESH
5 ACTFLEX 988 CWP (2 Coats)
6 Protection Board (Optional)
7 Drainage System
8 Backfill

Tank System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX AT MESH
5 ACTFLEX 988 WMP (2 Coats)
6 Protective Coating (Optional)
7 Water

Technical overview

ACTFLEX PU200 is a one-component, solvent-free, hydrophobic polyurethane injection resin for sealing active water leaks and cracks in concrete structures. On contact with water the resin reacts to form a rapidly expanding, closed-cell polyurethane foam that fills the crack or void and blocks water ingress. The low-viscosity resin penetrates fine cracks and porous zones, cures without shrinkage, and remains dimensionally stable in permanently damp, below-grade environments. It is a water-stopping resin, not a structural repair. No Australian Standard specifically governs polyurethane injection resins for water-stopping, so every performance value published here is a Forspec R&D characteristic value determined on standard production material and is not subject to third-party certification. The product is not certified for contact with drinking water under AS/NZS 4020.

Key applications

Concrete crack injection - sealing active leaks in structural and non-structural concrete elements
Basements and underground structures - stopping water ingress through foundations, retaining walls and slabs
Tunnels and below-grade infrastructure - leak sealing in tunnels, subways and underground services
Dams and reservoirs - sealing leaks in water-retaining structures subject to hydrostatic pressure
Wastewater treatment structures - sealing leaks in tanks and channels
Bridges and parking decks - sealing cracks and joints exposed to moisture
Manholes, pits and utility vaults - preventing water infiltration in below-grade utility infrastructure

Surface suitability

Concrete cracks in structural and non-structural elements
Concrete foundations, retaining walls and slabs in basements and underground structures
Concrete with sufficient water present; dry cracks pre-wetted through the packers before injection
Substrate and material temperature greater than 10C

Water-stopping product only, not a structural repair - use the FORSPEC structural injection range for load-transferring crack repair. Requires water to react - dry cracks must be pre-wetted through the packers before injection. Do not apply below 10C substrate or material temperature; cold conditions slow the reaction and reduce expansion. Not certified for contact with drinking water (AS/NZS 4020) - do not use in potable water structures unless confirmed in writing by Forspec. Not UV stable - for buried and internal concealed applications, not for exposed finishes. Live movement joints require a purpose-designed movement joint system; injected foam alone must not be relied on across joints subject to ongoing movement. Injection into voids of unknown volume can consume large resin quantities - probe and assess before injecting. Moisture-sensitive - the resin reacts with atmospheric humidity; keep containers sealed until use and use opened containers promptly. Classified as hazardous - handle with chemical-resistant gloves, safety eyewear, protective clothing and, in areas with limited ventilation, suitable respiratory protection.

Technical Specifications

Product Type	One-component hydrophobic polyurethane injection resin for water-stopping
Composition	One-component hydrophobic polyurethane resin
Colour and Form	Light brown, low-viscosity liquid
Density at 25C	1.12-1.20 g/cm3*
Viscosity at 25C	500-600 mPa.s*
Foaming Magnification	8-20 times, water-contact dependent; free-foam above 13 times*
Foaming Time at 25C, 50% RH	Approx. 180-360 seconds, free foam*
Bond Strength to Concrete	Greater than 2.28 MPa*
Elongation, Thick Sections	Greater than 100%*
Elongation, Thin Sections	Greater than 250%*
Reaction Time at 25C, 10	1 Water to Resin: 300-350 seconds, 16-20 times magnification*
Full Reaction and Stable Seal	24 hours at 25C, 50% RH*
Application Temperature	Greater than 10C, substrate and material
Packer Spacing	10 mm holes at maximum 200 mm intervals, angled 45 degrees to intersect the crack at 60-100 mm depth
Packaging	20 kg pail
Shelf Life	12 months, unopened, 5-30C, protected from moisture
Hazard Classification	Hazardous Chemical, Non-Dangerous Goods under the WHS Regulations and the ADG Code
* Typical Forspec R&D characteristic values, not subject to third-party certification

Real Projects. Real Results.

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Frequently asked questions

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What is ACTFLEX PU200 used for?

Compatibility
PU200 is a hydrophobic polyurethane crack injection resin used for sealing structural concrete cracks and leak remediation in subterranean and moisture-exposed concrete - tunnels, basements, lift shafts, foundations, and below-grade walls.
How does hydrophobic foam injection work?

Performance
PU200 reacts with the water present in the crack to expand into a closed-cell hydrophobic foam, sealing the crack from the inside out. The expansion creates pressure that forces resin into every void.
Specifications?

Installation
Viscosity 500-600 mPa·s at 25°C, density 1.12-1.2 g/cm³. Foaming time 180-360 seconds. Expansion ratio approximately 0.6 with water present. Elongation greater than 100% (thick) or 250% (thin film).
What equipment do I need?

Compatibility
Use 10mm or 13mm Forspec injection packers, gun coupler, and the INJEXA SWM 1300 (or SWM 1500 for deeper cracks) pump system. Single-component, no mixing required.
Shelf life and safety?

Performance
12-month shelf life when stored sealed. Solvent-free, low-odour, zero shrinkage after foaming. Safe for use in confined spaces with appropriate PPE per SDS.

ACTFLEX PU200 Hydrophobic 20kg

Frequently bought together

Pool System Build-Up

Retaining Wall System Build-Up

Tank System Build-Up

Technical overview

Key applications

Surface suitability

Technical Specifications

Pool Renovation

Below Ground Retaining Wall

Concrete Water Tank

Commercial Podium

Swimming Pool Construction

The Waterproofing Shop?

Frequently asked questions

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