Alchatek Blog

A public park in New York had critical erosion issues at its waterfront staircase and adjacent beach, which were built over a landfill. Over the years, natural erosion pulled back sand, exposing uneven foundation areas and creating safety hazards for visitors. The partially buried concrete staircase exhibited significant subsidence and shifting soil, posing a threat to structural collapse. The New York City Parks Department required a rapid solution to stabilize the site before further degradation occurred.

Initial Assessment

The staircase and surrounding sand exhibited signs of differential settlement, likely due to uneven soil compaction and erosion. Technicians identified voids beneath the stairs and along the beachfront, with sand migration exacerbating instability. Traditional excavation or pier-and-casing methods were impractical due to limited access and the need to avoid displacing adjacent structures.

Proposed Solution

The team selected AP Fill 720 (a single-component polyurethane) for soil compaction/stabilization and AP 430 (a two-component foam) for structural void filling. AP Fill 720 addressed loose sand through permeation and consolidation, while AP Lift 430 filled critical voids beneath the staircase, providing lift and support.

Procedures

1. Stabilization Pattern: Injected AP Fill 720 every 4 feet at 6–8 feet depth to bond sand particles and prevent further migration.
2. Structural Foam Injection: Applied AP Lift 430 directly beneath the staircase’s granite slabs through strategic ports, filling void spaces with approximately 1 gallon per linear foot.
3. Final Treatment: Reserved excess AP Fill 720 to seal surface gaps around the staircase, preventing sand washout.

Results

The dual-material injection rapidly stabilized the waterfront staircase, eliminating soil migration and structural risk without closing the park. Compared to traditional heavy reconstruction, the approach cut costs by an estimated 97% and completed the work in under two weeks with minimal marine or community disruption. Post-repair inspections confirmed lasting results with no recurrence of erosion.

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Initial Assessment

An Atlanta real estate company faced significant challenges with their large warehouse, where uneven concrete slabs ranged from 0.5 to 2.5 inches below level. This unevenness led to foundation instability, wall cracking, and compromised usability of the facility. A local slab lifting company was contracted to perform void filling and slab lifting to restore the warehouse floor.

Proposed Solution

The technicians recommended using AP Lift 475, a two-component polyurethane foam designed for lifting and stabilizing concrete slabs. This material was selected for its high strength, controlled expansion, and ability to effectively fill voids while lifting sunken slabs to the desired elevation. The approach included using a large concrete cutting machine to clear joints, ensuring precise preparation without extensive disruption to warehouse operations.

Procedures

1. Established a grid pattern for injection points based on the extent of slab settlement on the warehouse floor.
2. Used a large concrete cutting machine to clear joints, ensuring unobstructed access for injections.
3. Drilled holes through the concrete slabs at predetermined injection points to access voids beneath.
4. Injected AP Lift 475 polyurethane foam into the drilled holes to fill voids and lift slabs, monitoring elevation in real-time to raise slabs up to 2.5 inches.
5. Performed multiple injection passes in areas with significant settlement to ensure even lifting.
6. Patched drilled holes to restore the surface integrity of the concrete slabs.

Results

The slab lifting project at the warehouse was a complete success. The application of AP Lift 475 effectively filled voids and raised all uneven slabs to a uniform level, eliminating foundation issues and wall cracking. The restored warehouse floor enhanced the facility’s functionality, enabling the real estate company to rent out the space, thereby maximizing its commercial potential.

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Initial Assessment

The management team at a corn syrup plant faced significant challenges with sinking concrete slabs supporting critical infrastructure, including water tanks and raw material tanks. The uneven slabs posed risks of tank instability and potential structural failure. A geotech contractor was engaged to perform void filling and stabilize the affected areas, ensuring a solid foundation for plant operations.

Proposed Solution

The technical team recommended using AP Lift 475, a two-component polyurethane foam that is ideal for void filling and slab stabilization. This material was selected for its high compressive strength, controlled expansion, and ability to effectively fill voids while providing robust support for heavy loads. The approach ensured minimal disruption, as it required no extensive excavation.

Procedures

1. Established a grid pattern to guide the placement of injection points in the affected areas beneath and around the water and raw material tanks.
2. Drilled holes through the concrete slabs at predetermined injection points to access the voids beneath.
3. Injected AP Lift 475 polyurethane foam into the drilled holes to fill voids and stabilize the soil beneath the slabs, ensuring comprehensive void coverage.
4. Patched drilled holes to restore the surface integrity of the concrete slabs.

Results

The void-filling project at the corn syrup plant was a success. The application of AP Lift 475 effectively filled all identified voids, stabilizing the concrete slabs and restoring a solid foundation. The stabilized areas now securely support the water and raw material tanks, eliminating concerns about sinking or tipping. The facility can resume full operations with confidence in the structural integrity of the tank foundations.

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An Atlanta contractor contacted Alchatek for assistance with a void filling job in the parking garage at Brookhaven City Hall. The bottom floor of the garage exhibited significant voids beneath the concrete slab, posing risks of settlement and structural instability.

Initial Assessment

An Alchatek support technician worked with the contractor to conduct a thorough assessment and implemented a targeted void-filling solution to restore stability.

Proposed Solution

Alchatek recommended using AP Lift 430 Fast, a high-performance polyurethane foam designed for rapid void filling and stabilization. This material was selected for its quick-setting properties, high compressive strength, and ability to effectively fill voids while providing robust support for the concrete slab. The approach ensured minimal disruption to the parking garage operations, as it required no extensive excavation.

Procedures

1. Established a grid pattern to guide the placement of injection points on the bottom floor of the parking garage.
2. Drilled holes through the concrete slab at strategically determined injection points to access the voids beneath.
3. Injected AP Lift 430 Fast polyurethane foam into the drilled holes, ensuring comprehensive void coverage from bottom to top.
4. Patched drilled holes to restore the surface integrity of the concrete slab.

Results

The void-filling project at the Brookhaven City Hall parking garage was a success. The application of AP Lift 430 Fast effectively filled all identified voids, eliminating the risk of further settlement. The stabilized concrete slab restored the structural integrity of the garage floor, ensuring a safe and functional environment for vehicles and pedestrians. The solution minimized operational downtime and avoided costly excavation, preserving the facility’s functionality.

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In this interview segment from Groundworks' Stability Matters podcast, Alchatek VP of Sales Andy Powell recounts a dramatic incident during a Florida water treatment plant expansion. A deep excavation for a large clear well structure suddenly flooded when a test pile fractured the underlying limestone bedrock about 30 feet below the excavation floor (50 feet below ground level). Water from an aquifer surged in at 300–500 gallons per minute, filling the site and stopping work entirely.

The bold fix: the "polyurethane bomb" technique. A two-inch pipe was drilled beside the leaking pile, and AP Fill 700 polyurethane resin with a fast catalyst was rapidly pumped in using high-flow diaphragm pumps.

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In this interview segment from Groundworks' Stability Matters podcast, CEO Stephen Barton and VP of Sales Andy Powell provide an overview of Alchatek's advanced geotechnical chemical grouts designed to fill voids, stabilize soil, and control water infiltration. These materials address issues caused by erosion, providing structural support and preventing further damage.

The core philosophy: "Where water finds a way, we find a way to stop it." Highlighting a common company theme, "Water is Relentless," the segment concludes with a memorable anecdote involving a four-star Army Corps general who enthusiastically endorsed their mission.

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In this interview segment from Groundworks' Stability Matters podcast, Alchatek VP of Sales Andy Powell discusses the high cost and challenges of replacing sewer system manholes using the traditional method. A manhole replacement, particularly one in a road, can cost a million dollars and requires shutting down the road.

Alchatek's polyurethane technology saves time, cost, and disruption over traditional methods by getting to the root cause of the problem.

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In this episode of Groundworks' Stability Matters podcast, host Justin Bryant sits down with Alchatek CEO Stephen Barton and VP of Sales Andy Powell in Atlanta to discuss polyurethane solutions for geotechnical and leak seal issues. Stephen shares his journey from young concrete repair worker to industry leader, while Andy recounts the story of his career pivot to polyurethane expertise. They cover Alchatek’s product evolution, significant projects, and the importance of engineer outreach - offering insights on many industry challenges and key topics.

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AT&T Plaza in downtown Dallas had persistent water infiltration issues in its basement and sub-basement levels, resulting in structural concerns and operational disruptions. The building's below-grade concrete walls developed multiple active leaks, allowing groundwater to penetrate the structure and causing dampness at wall-floor transitions, which raised concerns about potential corrosion of the reinforcing steel. Building management required an immediate solution that would effectively seal the leaks while minimizing disruption to commercial operations.

Initial Assessment

Engineering inspections by B|S|A Design Group revealed multiple active leak points throughout the basement and sub-basement concrete walls, with water infiltration occurring through cracks, joints, and penetration points. The moisture intrusion patterns indicated that several leak locations had been active for an extended period. Traditional waterproofing methods would require extensive excavation and reconstruction, making them impractical for a busy downtown commercial building. The assessment concluded that targeted injection would be most effective while allowing the building to remain operational.

Proposed Solution

The engineering team specified Spetec PUR F400, a hydrophobic polyurethane grout designed for water cut-off applications in concrete structures. This single-component material was selected for its ability to react with water to form a flexible, closed-cell polyurethane seal that permanently stops water infiltration. The material's low viscosity allows deep penetration into crack networks while its hydrophobic nature ensures effective sealing in wet conditions. This approach would eliminate disruptive excavation while providing a permanent solution.

Procedures

1. Engineers identified and mapped all visible leak points, prioritizing the most severe infiltration locations.
2. Injection ports were drilled at strategic locations to intersect water migration pathways through the concrete structure.
3. Spetec PUR F400 was mixed with appropriate catalyst ratios and injected using controlled pressure techniques.
4. Technicians monitored for complete crack filling and leak cessation, with post-injection inspections confirming successful sealing.
5. Work was coordinated to minimize disruption to building tenants throughout the process.

Results

The injection process successfully eliminated all water infiltration throughout the treated areas. Post-repair monitoring following significant rainfall events confirmed the complete cessation of leaks, with previously wet areas remaining dry. The project was completed with minimal disruption to building operations. The injection approach achieved 98%+ cost savings compared to traditional excavation and membrane installation methods. Additionally, avoiding a building evacuation prevented an estimated $25,000-$ 50,000 in lost rental income and tenant relocation costs.

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