Many types of infrastructure, including roads, bridges, and buildings, depend on compacted soil in order to stay in place. Therefore, in order for these structures to last, a specific degree of compaction must be achieved. When soil does not adequately compact, the problem is known as poor compaction, and that can lead to more serious issues. Concrete repair contractors always need to be on the lookout for signs of poor compaction which include settling slabs, cracking foundations, and dips in roadways and railroads.

What causes poor soil compaction?

There are a variety of causes of poor soil compaction. However, much of it boils down to soil texture and soil properties. Some soils are more prone to compaction than others. Excess soil salt content, high clay fraction soils, low pH soils, and soils with high water content tend to compact less favorably. It should also be noted that decisions made by construction contractors and their teams can also influence soil compaction. For example, failure to select proper compaction equipment or compaction materials can contribute to poor compaction. Furthermore, some areas are more prone to poor compaction than others, such as portions of soil set against a foundation.

How can poor soil compaction be corrected?

Luckily, poor compaction can be corrected. The solution is to strengthen the soil until it is properly compacted. As mentioned in the previous post, voids can be filled, soil consolidated, and water migration halted with Alchatek soil stabilization products. Once the bearing capacity of the soil has been increased with this process, then the structure can be lifted if necessary.

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What is erosion?

In geological terms, erosion can be defined as an exogenic process that moves a portion of the earth’s crust from one location to another. This includes a range of different processes, including water flow, wind, and even human action, that move dirt, soil, rock, etc. They are called exogenic processes because they originate outside of the earth’s crust, or externally. In more practical terms, erosion can best be described as the way in which the earth is worn away by water, wind, or ice. So when a river carves a canyon out of stone (such as when the Colorado River carved out the Grand Canyon in Arizona over the course of so many years), that is an example of erosion. The formation of sand dunes by the wind moving across the desert is also an example of erosion, as are changes in rocks along a shoreline due to the constant thrashing of waves. 

Why does erosion cause unstable soil?

You’ve probably heard that erosion is dangerous because it causes unstable soil. It is important to remember that the consequences of erosion can potentially be dramatic, causing landslides and structural damage. After investing money in the construction of a building, the last thing you want is for unstable soil to put the whole project at risk. 

How can erosion be repaired?

Voids can be filled, soil consolidated, and water migration halted with Alchatek soil stabilization products. Once the bearing capacity of the soil has been increased with this process, then the structure can be lifted if necessary.

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Unstable soil can be defined as soil that will not stay in place on its own and therefore requires extra support. It should be noted that unstable soil can threaten the stability, security, and safety of infrastructure and can damage, degrade, and even destroy a number of structures, such as buildings, bridges, and roads.

Let's look at the four main causes of unstable soil...

Erosion

Erosion refers to processes in which external elements (wind, water, etc.) remove soil or rock from a certain location and transport it to another location. There are a variety of different erosion types, including river and gull erosion, wind erosion, and erosion attributed to human activity. Erosion ultimately destabilizes soil and can lead to landslides and sinkholes.

Poor Compaction

One of the most common causes of unstable soil is poor compaction. In some cases, certain types of soil are simply very loose and subsequently not compact. The cause of this is typically an imbalance of mineral pieces, organic matter, air, and water. For example, clay soil with very high moisture content will inevitably become unstable, as it will be incredibly difficult to compact. Similarly, soils with high sand content will be difficult to compact.

Freeze/Thaw

Processes of freezing and thawing essentially accelerate erosion processes. Cold weather freezes moisture trapped in tiny cracks. When this water freezes, it expands, subsequently pushing on the rocks and breaking them into smaller pieces. As processes of freezing and thawing continue, rock and sediment are continually broken down.

Decomposition

When soils contain a high concentration of organic materials, such as topsoil and plant matter, they will decompose, subsequently causing them to become unstable. This is because organic materials rapidly change form and mass as they decompose in the soil. In fact, up to 90 percent of organic material will disappear over the course of the decomposition process.

Fortunately, stability can be restored to soil with ultra-low viscosity polyurethane resins. Foaming and permeation polyurethanes can mitigate the damage done by processes of erosion, decomposition, freezing, and thawing, as well as help to rectify compaction problems. When it comes to unstable soil, you can’t afford to take a risk. Stable soil is crucial to maintaining secure structures.

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Raising Concrete with Confidence

When pumping a lightweight material beneath a slab, you need the confidence that it is strong enough for the application. How strong is strong enough? This is a commonly asked question by contractors that are new to slab jacking with polyurethane. Alchemy-Spetec structural foams only need to be as strong as dirt, but they're actually stronger than crystalline bedrock.

The Right Strengths for Concrete Lifting

Slab lifting foams are rated on density (weight per cubic feet) and compressive strength. This testing and rating are based on the foam in a free-rise state; the parts A and B are mixed together and allowed to expand freely. Our AP Lift 430 and AP Lift 475 structural lifting foams, for example, weigh 2.75 – 3.25 lbs (AP Lift 430) to 4.75 – 5 lbs (AP Lift 475) per cubic foot. But they have compressive strengths of 50 psi and 100 psi in a free-rise state. That's the equivalent of 7,200 to 14,000 lbs per square ft of support, just in a free-rise state.

Polyurethane Slab Jacking Compared to Clay and Bedrock

To put that into perspective, the National Home Builders Association and the International Building Code list stiff clay at 4,000 psf and crystalline bedrock as having 12,000 psf of load-bearing capacity. Consider the job site conditions where the foam will be injected into a confined area. Testing data in the lab shows that our lifting foams will increase in compressive strength: In a space confined 25% by volume there will be an increase of 31% in psi and in a space confined by 75% there will be a 79% increase in the psi.

Concrete Leveling for Any Job with the Right Foam

Today polyurethane concrete lifting foams are used to level airport slabs supporting jumbo jets, equipment and building slabs supporting tremendous loads, and even railway sleepers that support the heaviest freight trains. So don't let the word “foam” fool you. These resins cure to strengths beyond what is needed to support any structure.

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If you're a leak seal contractor, you may be familiar with this situation: A property owner with leaking concrete calls you up and says, "Hey, everything is dry right now, so I want to get someone out here to go ahead and waterproof the structure."  Attempting a waterproofing job when the structure is completely dry is not recommended.

Let me give you an analogy. Let's say I hired you to paint a basement. And when you arrive, it's pitch black in that basement. No lights are available and you can't see anything. Can you still paint that basement? The answer is "yes", but when we turn the lights on, will I be happy with the job you've done? There's no way. It would be a terrible paint job.

Similarly, if someone is asking you to waterproof while it's dry, you are basically attempting to seal leaks while blind. You need to waterproof while water is present - not just to activate the grout, but to see where the grout needs to be. Let the leaks lead you to correct grout placement. You won't know for sure if the water is not present. If you attempt a leak seal job in a completely dry environment and then return when the water is present, you'll most likely find leaking cracks that you missed.

Moral of the story? Grout when it's wet.

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The Alchatek app includes a Leak Seal Material Selection Guide and a Polyurethane Estimating Calculator.  The Leak Seal Product Selection guide asks you a series of Yes/No questions about your job and then provides product recommendations.  The Polyurethane Estimating Calculator takes the guesswork out of estimating material for Geotech and Leak Seal jobs. Here's a step-by-step guide...

Install the Alchatek App and Create an Account

1. Search the name Alchatek in your Apple App Store or Google Play Store to install the app. 

2. After installing the app, create an account by clicking "Sign Up" at the bottom and following the prompts.

Polyurethane Estimating Calculator (Estimate Material Quantities for Your Job)

1. Tap the three lines in the top left corner to display the application options. Choose Material Estimation Calculator, then choose Geotech (Slab Lifting & Void Fill) or Leak Seal for your job type.

2. Select the measuring system you want to use.

3. Fill out the required fields.

4. View the recommended material quantities.

Leak Seal Material Selection Guide (Choose a Leak Seal Product for Your Job)

1. Tap the three lines in the top left corner to display the application options. Choose Leak Seal Material Selection Guide.

2. Answer a series of Yes/No questions about your leak seal job.

3. Review the product recommendation screen (and/or click the Start Over button at the bottom to begin again).

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Polyurethane grouting is a complex process that involves numerous specifications and guidelines. However, amidst the vast amount of information, there are five fundamental rules that lie at the core of all successful polyurethane grouting projects. We will explore these rules, highlighting their significance in achieving desired outcomes.

Rule #1: Don’t Eat the Grout

On a serious note, this rule serves as a safety reminder to avoid accidents or potential health risks associated with ingesting grout materials. It may seem obvious, but it is crucial to emphasize that grout should never be ingested.

Rule #2: Protect Your Eyes

Ensuring eye protection is essential when working with polyurethane grout. Always wear appropriate safety gear and keep an eyewash nearby. This precautionary measure prevents grout particles or splashed drops from coming into contact with your eyes, safeguarding your vision and preventing injuries.

Rule #3: Avoid Premature Water Addition

One must refrain from adding water to the grout before pumping it. While experienced professionals might occasionally deviate from this rule, it generally stands as a reliable guideline, especially for those new to the field. By adhering to this rule, the grout maintains its intended consistency and properties, leading to optimal results.

Rule #4: Get the Grout in Right Location

Precise grout placement plays a crucial role in achieving successful outcomes. It is essential to accurately direct the grout to the desired location whether performing crack injections or high-flow grouting. High-flow grouting, especially, demands effective retention of the grout in place.

Rule #5: Allow Sufficient Set Time

The final rule stresses the importance of providing ample time for the grout to set. Once the grout reaches its intended location, it is crucial to avoid disturbances and allow the curing process to occur effectively. This rule is particularly significant in high-flow scenarios, where maintaining the grout in place poses a significant challenge.

As long as these rules are upheld, exploration and experimentation in grouting methods can be undertaken. This approach acknowledges the uniqueness of each job site and encourages problem-solving while adhering to the core principles of grouting.

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It’s crucial to determine if your project requires products that meet NSF/ANSI 61-5 standards for contact with drinking water. But what exactly are NSF/ANSI/CAN 61 standards? Our goal here is to provide a concise and comprehensive overview of why NSF approval is important for polyurethane geotech and leak seal materials.

What is the NSF (National Sanitation Foundation)?

The National Sanitation Foundation develops public health standards and certification programs that help protect the world’s food, water, consumer products, and environment. Their organization ensures that adequate testing is conducted for all products that will be used in or around drinking water from source to tap.

An NSF compliance brief reads: “NSF, an independent, private, not-for-profit, third-party certification organization founded in 1944, has developed numerous health-based certification programs and consensus standards including those that relate to drinking water…The purpose of its certification program is to promote public health and enrich the quality of life. Through its Council of Public Health and Health Advisory Board, which includes EPA health professionals, it obtains guidance in developing and maintaining programs and standards. NSF also partners with code councils to ensure ongoing compliance.”

Each product must undergo rigorous testing to receive NSF approval. The manufacturer's plant and quality assurance practices must pass a thorough inspection. Voluntarily undergoing such a rigorous certification process is invaluable to all parties involved.

The SDWA (Safe Water Drinking Act)

The Safe Water Drinking Act (SDWA) gives the EPA latitude to impose criminal and civil penalties on industries that are not in compliance. In 2014 enforcement efforts policing clean water netted $163 million in penalties and fines, 155 combined years of incarceration for sentenced defendants, and $16 million in court-ordered project clean-ups.

Because so many of those defined contaminants are pertinent to even the most basic construction projects – turbidity from soil runoff, leaching from PVC pipes, potentially harmful and corrosive chemicals, and more – understanding and adhering to the law is particularly important for industry stakeholders. Contractors and engineers must be able to confidently choose vendors whose products and services won’t become the source or cause of drinking water contamination either in the short or long term. Having products that may come into contact with drinking water certified to NSF/ANSI/CAN 61 (approved for contact with drinking water), ensures compliance with the SDWA.

Alchatek NSF Approved Products and Solutions

Alchatek's NSF-certified materials are evaluated and lab-tested, and the production facilities are inspected and annually audited for re-testing to maintain certification. 

The following products have received the official NSF seal of approval for contact with drinking water:

• AP Lift 430
• AP Lift 475
• AP Soil 600
• AP Fill 700
• AP Fill 720
• Spetec PUR F400
• Spetec PUR GT500
• Spetec PUR HighFoamer
• Spetec PUR H100
• Spetec PUR H200
• Spetec AG200

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In this article, we’re comparing the use of epoxies and polyurethanes for waterproofing. This is not a battle of good versus evil, but rather a discussion about their differences and when to use each type of material.

A Brief History

Epoxies and polyurethanes are both old technologies, with epoxies making their way into the construction market about a decade before polyurethanes. The term “chemical grouting” often refers to epoxy, much like how “soda” is used as a generic term for carbonated drinks.

Why Epoxy?

When you’re asked to waterproof with epoxy, it’s essential to ask why. Are you merely waterproofing, or are you also doing a structural repair? Epoxies are strong, about three to four times stronger than the concrete you put them in. They will waterproof that crack, but when movement occurs, you’ll likely see mirror cracking about a foot over on either side. When you have mirror cracking, your water problem will return.

The Case for Polyurethane

If you’re just looking to waterproof, polyurethane is almost always going to be the better choice. Polyurethanes are flexible, allowing the wall to move and breathe as it needs to while stopping the water from coming in. It’s simple that way.

Wet Environments and Polyurethanes

One other point worth noting is that polyurethanes can be installed in wet environments. That’s typically when you have the leak. Epoxies, on the other hand, don’t like to be installed in wet situations. Remember, it’s not about which one is better overall, but about which one is better for your specific situation. As always, feel free to contact us with any questions about epoxy vs polyurethane for waterproofing or for assistance with your waterproofing project.

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“At what pressure am I going to inject the grout?” This question is not only common but also crucial on leak seal jobs, as it directly impacts the quality of your work. The answer, however, is not as straightforward as one might hope. The optimal pressure for injection is as low as possible. However, the exact pressure cannot be determined until the injection process begins.

Hairline Cracks

When dealing with urethane and hairline cracks, the pressure required is generally on the high end. This is where the technical expertise comes into play. If the pressure is too high, there is a risk of spalling the concrete, which can lead to further damage. To mitigate this risk, one might consider switching to an acrylate-type product. Acrylate, being almost as thin as water, penetrates hairline cracks more effectively, thereby reducing the risk of spalling.

Process of Injection

As a rule of thumb, the process begins by connecting to the port, whether for crack injection or curtain grouting. The ball valve is opened while the pump is off. Once the pump is turned on, the pressure is gradually increased until a steady flow rate is achieved. This process requires a keen eye and a steady hand, reinforcing the importance of technical expertise in this field.

The Concept of Exploratory Grouting

The in world of crack injection, there is a concept known as exploratory grouting. This process involves intentionally creating one small crack to understand the wall’s resistance. Typically, walls start cracking around 1500 PSI, although this can vary, with some walls withstanding up to 2200 PSI. This exploratory process is essential for understanding the wall’s capacity and planning the injection process accordingly.

Marking the Pressure

It is recommended to mark the pressure at which the wall cracks using a wax pencil on the pump. This marking serves as a reminder of the wall’s capacity. Remember, you get one free crack for exploratory purposes. Any cracks after that are on you. 

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