Alchatek Blog

A sunken concrete staircase posed a unique challenge in a grand mansion undergoing renovation for sale. The vintage stairs had settled unevenly, with the right side sinking three inches and the left two inches. This issue arose after the driveway slab had been replaced and the supporting slab around the staircase had been partially cut out. Rather than opting for costly replacement, the property owner sought a permanent solution to restore the staircase's level and preserve its aesthetic harmony with the surrounding patio. Enter Lift It Rite, a geotech company called upon by the general contractor to tackle this delicate task.

Powerful Polymers

AP Lift 430 was selected as the repair material for this project. This product features expansive properties, ideal for filling voids beneath the sunken stairs. Moreover, once cured, AP Lift 430 is very strong, ensuring robust support for the concrete staircase. The material's capabilities aligned perfectly with the project's requirements, offering stability and longevity. Importantly, using this material allowed for a cost-effective solution compared to full replacement. Additionally, this approach preserved the vintage look of the concrete staircase, maintaining its match with the existing patio.

Painless Procedures

The repair process began with strategic drilling. Two holes were carefully bored into the slab in front of the steps at a steep angle. This approach ensured the material would travel underneath and towards the back of the stairs against the porch wall. Next, injection commenced from the front in three to five-second bursts. The crew used a dial indicator to monitor movement with remarkable precision throughout the process, detecting changes as small as 1/100th of an inch. As the material spread, lifting became visible. The team paused when material emerged from the sides, allowing for initial curing. Subsequently, re-drilling and more injection from the front raised the stairs further, maintaining the original slant with the right side down. A hole was drilled in the slab next to the back right area to correct the slant. Short bursts of injection here helped level the slab. Finally, injection resumed from the front to complete the lift, achieving the final quarter-inch of elevation. 

Rapid Results

The meticulous approach yielded impressive outcomes. Most notably, the final lift level perfectly matched the newly formed driveway, addressing the customer's primary concern. This precision restored functionality and enhanced the property's aesthetic appeal. The property owner expressed great satisfaction with the results. Furthermore, the successful repair of the antique staircase improved the home's resale value. By preserving the vintage concrete stairs, the project maintained the cohesive look of the exterior, seamlessly blending with the existing patio. The permanent solution eliminated potential concerns for future buyers, positively impacting the property's marketability. Ultimately, this project demonstrated how innovative repair techniques could address structural issues while preserving architectural integrity.

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Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $695.00
(Special pricing for all who register before the end of September. $745 October 1st and later.)

Location

To Be Determined
(in Georgia)

Discount

$50 discount for each additional participant.

Geotechnical Masterclass

Elevate your geotechnical expertise with our comprehensive masterclass covering cutting-edge techniques and solutions. Master:

• Polyurethane Concrete Leveling for sunken slabs
• Polyurethane Soil Stabilization for various soil types
• Geotechnical Testing with precision
• Deep Lock® soil stabilization procedures

Why Attend?

• Gain Hands-On Experience with state-of-the-art equipment
• Learn From Industry-Leading Experts with decades of experience
• Network with Peers and potential collaborators
• Boost Your Company’s Market Reach and capabilities

Consider the low cost of training vs. the high cost of job screw-ups and missed opportunities.

Transitioning from routine geotechnical work to more complex and high-stakes infrastructure and large-scale construction projects represents a significant growth opportunity for your career and business. Get the advanced skills and critical insights needed to tackle challenging projects and succeed in competitive markets confidently.

Join us for this transformative Geotechnical Masterclass. We’ll equip you with the knowledge and techniques to excel across all geotechnical project types.

When addressing sunken concrete slabs, homeowners often choose between two primary methods: mudjacking vs. foam lifting. Both techniques aim to elevate and level concrete without complete replacement. However, these methods differ significantly in their approach and effectiveness. This article examines the details of mudjacking vs. foam to assist in making an informed decision for concrete repair needs.

Traditional Approach: Mudjacking

Mudjacking has been a standard practice for over six decades. This method involves pumping a cement-based slurry under the sunken concrete. The process requires drilling holes in the slab and forcing the thick mixture underneath. As a result, the concrete rises back to its original position.

However, mudjacking has several limitations. The material is quite heavy, weighing up to 100 pounds per cubic foot. This additional weight may contribute to further settling over time. Furthermore, the large holes drilled for mudjacking can be visually unappealing. Even after patching, these holes often remain noticeable.

Modern Alternative: Concrete Leveling with Polyurethane Foam

In contrast, foam lifting utilizes polyurethane to raise concrete slabs. This innovative technique offers several advantages over traditional mudjacking. Notably, the foam is extremely lightweight, typically weighing only 2-4 pounds per cubic foot. Consequently, it doesn't add unnecessary burden to the underlying soil.

Mudjacking vs. Foam: Key Differences

Foam lifting demonstrates superiority in multiple areas where mudjacking falls short:

• Smaller injection points: Foam injection requires tiny 3/8-inch holes, which are much less noticeable after patching.
• Rapid curing: The polyurethane foam cures quickly, reaching 90% of its total strength in just 15 minutes. This allows for almost immediate use of the repaired concrete.
• Minimal disruption: Foam lifting requires less heavy equipment, reducing mess and inconvenience for property owners.
• Strong adhesion: The foam creates a permanent bond with the concrete's underside, ensuring long-lasting support and stability.
• Water resistance: Unlike mud, foam resists water, helping to prevent future erosion and settling caused by moisture issues.

Evaluating Polyurethane Foam vs. Mudjacking

When comparing mudjacking vs. foam, the latter is the preferred choice for most scenarios. Its lightweight nature, quick curing time, and superior bonding capabilities make it an excellent option for concrete leveling. Moreover, the foam's ability to resist water and prevent future settling gives it a significant advantage over mudjacking.

Precision and Longevity in Concrete Lifting

Concrete leveling with foam offers a more effective and durable solution for sunken concrete. While mudjacking has been a long-standing method, foam technology has significantly advanced the concrete repair industry. By opting for foam lifting, property owners can benefit from a faster, cleaner, and longer-lasting fix for their uneven concrete surfaces.

It's important to note that consulting with experienced professionals is crucial when considering concrete leveling options. These experts can assess specific situations and recommend the most appropriate action. With the right approach, restoring concrete to its original level and ensuring a safe, stable surface for years to come is achievable.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on lifting slabs with polyurethane foam?

At Krog Street Market in Atlanta, a shop about five feet below grade had water infiltration issues during heavy rains. The foundation wall was leaking, causing problems for the shop owner. To address this issue, leak seal experts Lift It Rite were called in to implement a solution. Their approach involved creating a curtain wall to waterproof the affected areas. This waterproofing method is particularly effective for structures below ground level, where traditional methods may not suffice.

Powerful Polymers

The technicians chose Spetec PUR HighFoamer for this project due to its extraordinary expansion rate. Moreover, Spetec PUR HighFoamer can quickly stop leaks across large areas. After injection, it follows the infiltration path and effectively seals leaks off. As a result, this material was ideal for addressing the shop's water infiltration problem. This versatility makes it an excellent choice for various waterproofing applications, especially in challenging underground environments.

Painless Procedures

The repair process began with driving injection rods down the outside of the wall. These rods were inserted to a depth of five feet, reaching the footing. The rods were spaced two feet apart along about 30 feet of wall to ensure thorough coverage. Next, the material was injected through each rod at one gallon per vertical foot. This method created a curtain wall, completely waterproofing the leaking areas. The precise spacing of the injection rods and the carefully calculated injection rate were crucial factors in achieving a uniform and effective waterproof barrier. 

Rapid Results

The entire repair process took only one day to complete. As a result of the curtain wall installation, the leaking was stopped immediately. Furthermore, this solution will prevent future leaking, ensuring the shop's safety from further water infiltration. In the end, mall management was satisfied with the quick and effective resolution of the problem. The shop can now operate without concerns about water damage during heavy rains. This successful intervention solved the immediate issue and provided long-term protection for the shop. 

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Administrators at Orange County, Florida Public Works had a pressing issue. Settlement was occurring along a quarter-mile stretch of a three-lane roadway. The culprit? Loose, sandy soils combined with a high water table. Before repaving could begin, stabilizing the supporting soil was crucial. This case study explores how the problem was addressed and resolved. This project showcases innovative solutions for common infrastructure challenges in areas with problematic soil conditions.

Powerful Polymers

AP Fill 700 was selected as the repair material for this project. Its low viscosity allowed for effective soil permeation, and its curing strength promised to create a permanent soil mass. These properties made AP Fill 700 the perfect choice for stabilizing the loose soil beneath the roadway. The selection of this material demonstrated the importance of choosing the right product for specific geotechnical challenges. AP Fill 700's unique characteristics ensured a robust and long-lasting solution.

Painless Procedures

A methodical approach was essential for this project. First, a large grid pattern for injections was carefully planned out. Each injection point was spaced five feet apart, and the depth of each injection reached approximately 15 feet. At each point, one gallon of material was injected per vertical foot. This systematic process ensured thorough coverage and stabilization of the problematic soil. The precise spacing and depth of injections were critical factors in the project's success. By following this detailed procedure, the team could address the soil instability comprehensively.

Rapid Results

This massive project was completed in about a week. As a result, the once-loose soil was successfully stabilized. The municipality now had a solid foundation to repave the quarter-mile stretch of road. In the end, Orange County Public Works had effectively addressed the settlement issue. The roadway was now ready for safe, long-lasting resurfacing. This efficient resolution solved the immediate problem and prevented potential future issues. The success of this project demonstrated the effectiveness of proactive infrastructure maintenance and the value of employing advanced soil stabilization techniques.

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A critical safety issue arose at a large paper manufacturing plant. Large voids up to 18 inches deep were discovered beneath concrete slabs supporting heavy water pumps. This hazardous condition put both employees and equipment at risk. SiteMix Pressure Grouting, LLC was called in to fill the voids and secure the slabs. 

Powerful Polymers

The technicians chose AP Lift 475 for the job. This material offers strong load-bearing capacity and cures quickly, minimizing plant downtime. Fast-curing was essential for a swift return to full operation, making AP Lift 475 the ideal solution for this repair task.

Painless Procedures

The repair began with the drilling of 3/4-inch holes. Workers drilled these holes roughly every 3 feet across the affected area. Then, they injected the repair material into each hole until the substance flowed beneath the slab from one drilled hole to the next. This method provided comprehensive coverage of the voids beneath the slabs, ensuring no areas remained untreated.

Rapid Results

The entire repair took only one day to complete. After the work, the slabs were securely stabilized, and the pump equipment and workers were safe. The paper manufacturing company expressed satisfaction with the outcome. Due to the quick turnaround time, minimal disruption occurred. Most importantly, eliminating the dangerous voids created a safer work environment.

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Many property owners face the frustrating issue of sinking concrete slabs. This problem not only affects the appearance of the property but also poses safety risks. Fortunately, modern solutions can effectively address sinking concrete without the need for complete replacement. Let's explore the causes of this common problem and discuss innovative repair methods.

Why Does Concrete Sink?

Several factors contribute to concrete settlement. First, erosion can wash away soil beneath the slab. Second, poor soil compaction during initial construction may lead to instability. Finally, biological decay of buried organic matter can create voids. As a result, the ground beneath the concrete becomes unstable, causing the slab to sink.

The Dangers of Ignoring Sinking Concrete

Failing to address sinking concrete can lead to serious consequences. For instance, uneven surfaces may cause trip hazards, potentially resulting in injuries and liability issues. Moreover, sunken slabs can damage vehicles and expensive structures. In extreme cases, a neglected settlement might even lead to sinkhole formation.

Traditional vs. Modern Repair Methods

Replacing the Slab

Historically, replacing the entire slab was a common solution. However, this approach is messy, time-consuming, and expensive. Additionally, it often involves significant disruption to the surrounding area.

Mudjacking

Another traditional method is mudjacking, which involves pumping a cement-based slurry under the slab. While effective in the short term, the injected material may crack or erode over time, leading to future issues. Furthermore, this technique requires large drill holes and disruptive heavy equipment.

Polyurethane Foam for Lifting Sinking Concrete

In recent years, polyurethane foam lifting has emerged as the preferred method for repairing sinking concrete. This innovative technique offers numerous advantages over traditional approaches.

Strength and Durability

Polyurethane foam features impressive strength, often surpassing that of bedrock. Once injected, the foam continues to gain strength, providing long-lasting support for the repaired slab. As a result, this solution offers exceptional durability compared to other methods.

Minimally Invasive Process

Unlike mudjacking or replacement, foam lifting requires only small drill holes. Consequently, this method causes minimal damage to the existing slab and surrounding area. The lightweight equipment used also reduces the risk of disruption and further soil compaction.

Rapid Results

One of the most significant advantages of polyurethane foam lifting is its speed. The foam cures to 90% strength in just 15 minutes. Therefore, repaired areas can often be used the same day, minimizing disruption to daily activities.

Environmentally Friendly

Alchatek offers polyurethane lifting foams that are NSF-certified to meet strict environmental standards. These products won't leach harmful chemicals into the soil or groundwater. As a result, property owners can feel confident in choosing contractors who offer this eco-friendly solution.

The Foam Lifting Process

The concrete lifting process using polyurethane foam is straightforward and efficient. First, technicians drill small holes in the slab. Next, they inject the foam through these holes. As the foam expands, it fills voids and gently lifts the slab. Finally, the holes are patched, and any cracks are sealed.

Choosing a Professional for Sinking Concrete Repair

When dealing with sinking concrete, it's crucial to hire experienced professionals. Skilled technicians can assess the situation accurately and determine the best course of action. Moreover, they have access to high-quality materials and specialized equipment necessary for effective repairs.

Restoring Your Property's Safety and Value

Addressing sinking concrete promptly can prevent further damage and costly repairs. Property owners can quickly and efficiently restore their concrete surfaces by choosing modern foam lifting techniques. This not only enhances safety but also improves the overall value and appearance of the property.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on lifting sinking concrete with polyurethane?

A cooling tower lift station under construction in Iuka, Mississippi, had a significant water leak problem. The facility was losing approximately 1,000 gallons of water daily. The source and destination of the leak were unknown. A solution was implemented using concrete sealing techniques. Leak seal experts at Mid-South Concrete Lifting were called in to perform the repairs.

Powerful Polymers

The technicians chose Spetec PUR F400 for the repair. This polyurethane-based material has a closed-cell structure that seals cracks and joints. It remains flexible after curing, which allows for structural shifts. The material is NSF-certified, meeting environmental standards for water-related applications.

Painless Procedures

Due to the leak's unknown location, a comprehensive approach was necessary. The team injected the solution into all of the control joints and treated any visible hairline cracks within the concrete. The entire process was completed in two days, minimizing operational disruption.

Rapid Results

The treatment showed noticeable effects in the control joints. After the procedure, the company refilled the pit. The results met their expectations. Construction at the facility resumed without further delays. The solution effectively addressed the water loss issue while maintaining the structural integrity of the cooling tower lift station.

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In Salt Lake City, Utah, a historic brick structure built in 1893 showed signs of foundation settlement. The building's sandstone foundation presented a challenge. Traditional stabilization methods like installing helical piers could potentially cause further damage. Rhino Foundation Systems proposed a solution using polyurethane foam to stabilize the foundation. This case study examines how this approach addressed the building's foundation problems.

Powerful Polymers

The technicians selected AP Lift 430 polyurethane foam for the project. This foam was chosen for its ideal soil stabilization and structural support properties. The plan involved injecting the foam beneath the footings to provide a stable support platform. This method would achieve the desired stabilization without requiring extensive excavation.

Painless Procedures

The project began with a detailed site assessment to understand the extent of the settlement and soil conditions. Following this, the team designed a plan to install 63 deep foam injections under the foundation, ensuring comprehensive coverage and stabilization. Specialized equipment was then used to perform these deep injections, with the foam strategically placed to improve the soil and stabilize the foundation.

Rapid Results

The project delivered several key benefits. Deep foam injections improved the soil and provided a strong platform for the foundation, ensuring effective stabilization. The non-invasive process precluded the need for extensive excavation, preserving the structure and minimizing disruption. Notably, the project was completed in just two days, significantly reducing downtime and disturbance to the area. Finally, the polyurethane foam injections offered a cost-effective solution compared to traditional stabilization methods, making it an economically viable option for similar foundation challenges.

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The management team at a community pool in Midvale, Utah, faced a significant challenge. A water leak had saturated the silty soil beneath the structure, causing uneven settlement and safety hazards. To address this issue, they brought in geotechnical specialists from Rhino Foundation Systems, who proposed an innovative solution as an alternative to tearing out and replacing the pool. This approach not only promised to stabilize the pool but also lift it back to its proper position.

Powerful Polymers

The key to this solution was Alchatek's AP Lift 440 polyurethane foam. This powerful polymer was chosen for its soil stabilization, load-bearing, and lifting capabilities. Deep soil injections were planned to address the underlying issues. The foam's expanding properties would displace water and stabilize the soil base. This method offered a non-invasive alternative to traditional approaches like helical piles.

Painless Procedures

The process began with a thorough site assessment. The technicians analyzed soil saturation and settlement patterns. Based on this data, a 3-foot by 5-foot injection grid was designed. Next, holes were drilled through the bottom of the pool, and injection rods were installed. AP Lift 440 was injected beneath the structure. As a result, the expanding foam displaced water and stabilized the soil base. Following this, the pool was lifted by 3.5 inches. Finally, the pool deck was adjusted to match the new level.

Rapid Results

The pool was successfully stabilized and leveled with minimal disruption. Moreover, there was no need for extensive excavation. This method proved to be both effective and efficient. The foam injections effectively displaced water and stabilized the soil. Additionally, the lifting process was precise, raising the pool by exactly 3.5 inches. Perhaps most importantly, this solution was cost-effective. It proved quicker and more economical than complete pool replacement.

Want more information about lifting and stabilization with polyurethane?