Alchatek Blog

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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In the field of concrete leveling, reliable tools are essential for achieving accurate and efficient results. The MiniMaster Low-Pressure Gun, developed by Alchatek, serves as a robust component of the PolyBadger Mobile Slab Lifting System.

This system is engineered for portability and ease of use, making it suitable for both emerging contractors and established professionals engaged in slab lifting operations.

The MiniMaster Low-Pressure Gun facilitates the precise injection of polyurethane materials, supporting the stabilization and leveling of concrete surfaces with minimal setup requirements.

Features

• Metal construction.
• Safety lock.
• Compatible with standard static mixers.

Benefits

• Easy to clean and reuse.
• Prevents accidental material discharge.
• Ensures seamless integration with existing equipment.

The MiniMaster Low-Pressure Gun, when integrated with the PolyBadger Mobile Slab Lifting System, provides a dependable solution for demanding slab lifting projects. Its durable design and safety features contribute to reduced operational risks and improved efficiency.

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Overview

If you’re battling A-side crystallization or clogged gun screens or injectors, the A-Side In-Line Filter is  essential. Installed between the hose and the slab lifting gun, it filters isocyanate, the A-side material prone to crystallization from moisture or poor storage. The filter traps solid chunks, sediment, and contaminants, preventing clogs, ensuring smooth flow, and maintaining foam quality. By protecting components like the mixing chamber, it extends equipment life and reduces maintenance costs.

Purpose and Function

Filters A-side Material: 
The A-side material, isocyanate, is prone to crystallization when exposed to moisture or improper storage conditions. Crystallized particles can form solid chunks that clog hoses, nozzles, or gun components, leading to uneven application, equipment damage, or downtime.

Prevents Clogs: 
The inline filter traps these solid particles (crystallization chunks, sediment, or other contaminants) before the material reaches the slab lifting gun, ensuring smooth flow and consistent foam quality.

Extends Equipment Life:
By reducing the risk of clogs and damage to sensitive components like the mixing chamber or gun filters, the inline filter helps prolong the lifespan of the equipment and minimizes maintenance costs.

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A persistent water infiltration was observed in a below-grade tunnel in Houston, TX. Staining on the sheetrock ceiling indicated the leak originated at the joint between the tunnel shell and the building wall, specifically at the interface with the flashing. The tunnel was situated on the negative pressure side of the structure, resulting in recurring water intrusion issues. The property management team sought technical advice to resolve the leak without extensive demolition or disruption to the building’s operations.

Initial Assessment

Visual inspection confirmed that water was entering through the wall/flashing joint and migrating into the tunnel ceiling. The stains and moisture patterns suggested a continuous leak path exacerbated by negative hydrostatic pressure. The location and nature of the leak made traditional surface repairs ineffective, as water was entering from behind the structure and not from an exposed face.

Proposed Solution

Alchatek recommended injecting the joint between the tunnel shell and the building wall with Spetec PUR F400, a hydrophobic polyurethane grout. This product was chosen for its ability to react with water and expand, effectively sealing active leaks even under negative pressure. The material’s low viscosity allows it to penetrate tight joints and bond with both concrete and steel, creating a durable, watertight seal. The recommended installation method involved using a Titan 440 electric injection pump, ensuring the grout was injected until the joint could no longer accept any more material.

Procedures

1. The team identified the leaking joint at the wall/flashing interface as the primary injection target.
2. Injection ports were installed along the joint to provide access for the polyurethane grout.
3. Spetec PUR F400 was injected using an electric injection pump, with technicians monitoring for material refusal and observing for any signs of milky fluid or foam, which indicated grout migration.
4. Injection continued until the joint was fully saturated and would not accept additional material, ensuring complete sealing of the leak path.
5. The process required no pre-pumping or removal of water from the joint, as the hydrophobic grout was designed to react in wet conditions.

Results

The polyurethane injection successfully sealed the leak at the tunnel shell/building wall joint. Post-repair observations showed no further water staining or active intrusion in the tunnel ceiling, and the tunnel remained dry even during subsequent rain events. The method enabled targeted remediation with minimal disruption to building occupants and eliminated the need for costly demolition or exterior excavation. The use of Spetec PUR F400 provided a cost benefit of 96% compared to traditional invasive repair methods. The property management team was satisfied with the outcome and the efficiency of the repair process.

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