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Leak Repair- Cast Iron
 
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1.   Locate the bell-joint – Use maps, ground markings, leak pinpointing, and other locating means to precisely locate the bell-joint
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2.   Vacuum excavate down to the pipe and expose the upper half of the bell-joint
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3.   Clean a small area on top of the joint approximately 2 ½”-4” from the face of the joint. (This position may vary but is typically two fingers from the face of the bell).
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4.   Drill an 11/32” hole through the hub to the spigot using a long-handled pneumatic drill. Presence of pieces of jute on the drill bit indicates that the drill position is correct. Do not drill through the spigot. Soap test the newly drilled hole for a leak. If no leak is present, it will not be possible to inject sealant.
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5.   Tap the 11/32” hole with the 1/8” NPT pipe tap.
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6.   Thread the aluminum nipple end of the injection kit into the hub until hand tight.
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7.   Close the white plastic tube clamp to minimize gas from entering the injection hose.
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8.   After choosing the correct viscosity sealant, install sealant cartridge into gun and attach nozzle adaptor.
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9.   Attach the injection hose assembly and tighten with small wrench. Pump the injection handle twice to pressurize, and release tube clamp. Pump the handle five times and wait 40-45 seconds. Pump once every 40-45 seconds until cartridge is empty.
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10.   When sealing process is complete, close the tube clamp and unscrew hose assembly from the joint. Install 1/8” brass plug and tighten to seal bell.
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11.   Soap test bell to make sure leak is stopped. Soap test plug.
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12.   Backfill, compact the soil, and repair or replace the ground surface.
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Cast Iron- Anaerobic
 
Two methods are commonly used for sealing leaking joints in cast iron pipe; anaerobic, and encapsulation. The anaerobic method involves drilling a small hole in the bell of the cast iron pipe, installing a nipple, and then injecting the joint with an anaerobic compound. Once the anaerobic cures, the joint is sealed. Below is a quick overview of the strengths of the two processes.

Encapsulation is more labor intensive and requires the additional sandblasting step. In addition, the soil underneath the main has been disturbed. The backfill process is very important because the main must be stabilized.

Anaerobic sealing is ideal for small diameter mains from 2” to 4”. As joint sizes increase, the success rate of anaerobic sealing decreases. It is also not as successful for higher pressure applications such as 10-20 psi.
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