This post is part of the Alchemy-Spetec Contractor Lens series, featuring views, news & case studies written by our customers. This article, written by John Knieper of SiteMix Pressure Grouting LLC, provides an overview of a repair job on a detention pond wall footer. If you're an Alchemy-Spetec customer and you'd like to discuss writing content for our blog, please send an email to marketing@alchemy-spetec.com today!

A general contractor working with a homeowners association reached out to SiteMix Pressure Grouting, LLC about a detention pond wall that was leaking along the footer in several places. A detention pond is designed to collect rainwater and then let it drain slowly in a controlled manner. But in this case, water was washing out quickly in an uncontrolled manner in multiple spots under the footing.

Powerful Polymers

To rapidly address the problem the technicians at SiteMix chose AP Fill 720 soil repair material. This single component, closed cell, hydrophobic, water-reactive, solvent and phthalate-free, low viscosity polyurethane foam has a high expansion rate and is ideal for filling voids. In this case, AP Fill 720 was the perfect choice for filling the soil voids underneath the footer created by water erosion.

Painless Procedures

First, the crew injected AP Fill 720 along 150 feet of the wall, installing approximately one gallon underneath the footing every two feet. Next, they installed another 75 gallons spot treating larger voids.

Rapid Results

The job was completed in only 2 days. The detention pond wall was ready for use immediately upon completion of the work. The general contractor and the homeowners association manager were very happy with the results.

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Alchemy-Spetec is proud to donate a portion of all proceeds to the Volunteer Florida Foundation's Hurricane Ian relief efforts through the end of 2023. Join us in supporting our neighbors in Florida, who were affected by Hurricane Ian.

From the Volunteer Florida website:

The Florida Disaster Fund is the State of Florida’s official private fund established to assist Florida’s communities as they respond to and recover during times of emergency or disaster. In partnership with the public sector, private sector, and other non-governmental organizations, the Florida Disaster Fund supports response and recovery activities.

Donations to the Florida Disaster Fund are made to the Volunteer Florida Foundation, a 501(c)(3) charitable organization (EIN# 01-0973168), and are tax-deductible. Up to 3%, however, no more than $30,000 is typically taken from each donation to cover administrative costs, including but not limited to staff salary, indirect costs, and credit card and bank transaction fees. However, for Hurricane Ian, all administrative and credit card fees have been waived so that 100% of every donation can be used to help Floridians recover.

Causes of Unstable Soil

Poor compaction, water erosion, broken pipes, and organic material in the soil can all lead to the settling of a foundation or a roadway. Traditional methods of soil stabilization can strengthen the soil directly under concrete and structures, but they do not address instability at deeper levels. Other methods of addressing deep soil issues require heavy equipment, extended downtime, and collateral property damage. These situations create problems for property owners as well as opportunities for the elite contractors that know how to fix them.

Deep Soil Stabilization

Introducing the Deep Lock process! Alchemy-Spetec offers a unique combination of high-quality structural polymers (AP Deep Lift 420, AP Lift 430, AP Lift 440 & AP Lift 475) along with the equipment and training needed to address deep soil issues. Now you can achieve soil stabilization and compaction on large projects with the smallest footprint and least amount of heavy equipment required. The Deep Lock process is powerful, painless, and rapid. Deep Lock gets to the root of the problems in the soil, it stabilizes the soil at all levels and accomplishes this with minimal imposition or downtime to the property owner.

Want more information about the Deep Lock process?

The Crack Injection Process

Crack injection is a precision-focused leak seal approach for smaller cracks or joints. Contractors repair these defects by drilling holes into the wall and inserting injection ports at an angle to intersect the crack inside the wall. Next, they inject polyurethane grout directly into the center of the crack through the ports. The resin rapidly reacts with water to form a flexible watertight seal. 

This process also protects the rebar inside the wall. Water intrusion through the cracks can lead to rebar corrosion and concrete spalling. Rusting rebar can expand six to ten times the original volume of the steel. This creates internal pressure on the concrete. While concrete is very strong in compression, it has a low tensile strength, and the expanding rebar will cause it to crack. When polyurethane resin is injected under pressure, it can encapsulate rebar and slow down the corrosion process.

Crack Injection Case Studies

• Water Treatment Plant Losing Two Million Gallons Per Day Due to Leaks
• Sealing Leaks in a Church Wall to Stop Costly Flooding of Elevator Pit
• Saving a Luxury Penthouse Suite from Costly Water Damage (Just in Time!)
• Leaks in Wastewater Treatment Plant Sealed to Prevent Environmental Contamination
• Contractor Seals Leaks in Quenching Tanks for Aluminum Manufacturer
• Leak Seal in Water Treatment Plant Pump Station Manhole
• Specialty Waterproofing at Hydroelectric Dam
• Sealing Hairline Concrete Cracks with Acrylic Injection Resin

Want more information on polyurethane crack injection?

The Curtain Grouting Process

There are negative-side leak seal solutions, in which contractors apply surface treatments to the face of a wall to stop leaks. However, this is merely a band-aid approach. The water pressure coming through the cracks from behind the wall can still blow this band-aid repair right off. Contractors using positive-side solutions like curtain grouting can stop multiple leaks in a structure at one time.

In this process, holes are drilled through a structure in a diamond pattern. Next, expansive leak seal grout is injected through the structure, sealing leaks and filling soil voids on the other side. The grout quickly reacts with the water and cures to form a curtain wall made of a resin/soil mixture that seals the leak permanently. This is a positive-side waterproofing solution applied from the negative side.

Curtain Grouting Case Studies

• Massive Underground Leak in Aquifer Shut Down
• Protecting Drinking Water from Potential Flood Contamination
• Repairing a Leaky Pipe & Sinkhole on a Residential Property

Want more information on polyurethane curtain grouting?

The Polyurethane Soil Stabilization Process

Weak soil under any structure or slab increases the risk of settling and structural damage. Excavating next to a building can weaken the soil that supports the foundation, potentially causing structural damage. Eroding soil can create sinkholes under roads and damage existing infrastructure. In some cases, this erosion is caused by water leaking into pipes and manholes and carrying soil with it. Regardless of the cause, loose soil will result in structural damage over time.

Contractors use Alchemy-Spetec soil stabilization polymers to fill voids and solidify the soil, thus preventing additional structural damage. These polymers are also used to reinforce excavation areas next to existing buildings. The contractor drives pipes in a grid pattern and injects soil stabilization resins to strengthen the soil and protect nearby structures. 

Polyurethane Soil Stabilization Case Studies

• Deep Soil Stabilization at Shopping Center
• Gravel Wall Stabilization
• Deep Soil Stabilization with Polyurethane
• Soil Stabilization at Busy Intersection
• Stabilizing a Foundation to Save a Valuable Two-Story House
• Deep Soil Stabilization at Residential Property
• Protecting a Building Foundation Next to an Excavation Site

Want more info on polyurethane soil stabilization?

The Concrete Leveling Process

Surface erosion, water damage, shrinking from heavy loads, or void spaces in the soil can all cause commercial, industrial, and residential slabs to sink or, in worst-case scenarios, collapse completely. Even without catastrophic collapse, slightly uneven concrete can cause expensive damage to property, vehicles, and factory equipment - not to mention personal injury.

Polyurethane concrete leveling is often the most cost-efficient and durable solution to this problem. A technician simply drills 3/8-inch holes through the concrete surface. Then, injects one of the Alchemy-Spetec concrete leveling polymers with the MixMaster Pro slab lifting gun. As the foam expands, pressure on the underside causes the concrete to lift to its original level position. The slab is ready for traffic 15 minutes after installation. The repair is waterproof and strong enough to support virtually any structure.

Concrete Leveling Case Studies

• Slab Lift for Chinese Railway
• Slab Lifting at a High School in Buffalo, New York
• Contractor Successfully Completes Unique & Challenging Driveway Lift
• Leveling Sunken Slabs in a Pole Barn
• Slab Lift at Seed Sorting Plant

Want more information on polyurethane concrete leveling?

Alchemy-Spetec offers one-hour CE/PDH accredited presentations on polyurethane concrete repair. Presentation topics offered include Leak Seal, Geotech, and Seawall Repair. Here is a detailed overview... 

Leak Seal Presentation

The Specialty Waterproofing with Chemical Grouts presentation covers sealing leaks in structures with the use of polyurethane chemical grout injection materials and techniques. 

• Chemical Grouting Primer
  • History
  • Safety
  • Characteristics
• Utilization & Applications
  • Identifying Applications
  • Selecting a Chemical Grout
  • Epoxy & Hydraulic Cement
• Installation Techniques
  • Crack and Joint Injection
  • Curtain Grouting
  • Oakum Soakum
  • Equipment Overview

Alchemy-Spetec's one-hour CE/PDH accredited Leak Seal presentation is perfect for engineers looking for information on innovative and proven leak seal repair methods for sealing leaks in structures, inflow/infiltration mitigation, and more.

Geotech Presentation

The Geotechnical Applications for Polyurethane presentation explains three types of concrete leveling and soil stabilization materials and applications. 

• Single Component Polyurethane Grout Applications
• Two-Component Polyurethane Grout Applications
• Acrylic Grout Applications

Alchemy-Spetec's one-hour CE/PDH accredited Geotech presentation is perfect for engineers looking for information on innovative and proven geotechnical repair methods for lifting concrete, soil stabilization, excavation support, controlling erosion, and more. 

Seawall Repair Network Presentation

The Seawall Stabilization and Preservation through Permeation Presentation explains and demonstrates how Seawall Repair Network contractors use polyurethane injection resin and surface-applied preservation solutions to stabilize and preserve seawalls and bulkheads. (Seawall Repair Network is a division of Alchemy-Spetec.)

• The Causes of Seawall Failure
• Stabilizing a Seawall
• Preserving a Seawall
• Stabilization & Preservation Through Permeation

Alchemy-Spetec's one-hour CE/PDH accredited Seawall Repair Network presentation is ideal for engineers who are interested in designing superior seawall/bulkhead rehabilitation and preservation solutions. This type of environmentally friendly permanent soil stabilization and seawall preservation can be applied to all types of waterfront infrastructure.

Want info on scheduling a presentation?

The John Day Dam is located in the state of Oregon on the Columbia River. In 2020 the Army Corps of Engineers put a repair job out to bid to address a variety of situations, including leaks that were occurring in a number of the galleries (openings or passageways within the dam). The general contractor that won the bid brought Spokane, Washington’s Talisman Construction Services in for the leak seal portion of the job.

Powerful Polymers

The Army Corp of Engineers specified a flexible polyurethane for the specialty waterproofing due to the fact that it would be injected into dynamic joints and cracks (joints and cracks that contract and expand with weather conditions).

The technicians from Talisman Construction Services chose Spetec PUR F400 from Alchemy-Spetec. This product features 100% elongation. If you install a rigid product in a dynamic joint or crack is will fail at the first movement. In addition to its flexible nature, Spetec PUR F400 is also hydrophobic. Hydrophobic polyurethanes have excellent chemical resistance and superior longevity. In addition, Spetec F400 features a field adjustable set time (when you have cold water, with varying volumes, this is essential so you can either penetrate small cracks with a slower set time or shut down gushing leaks with a faster set time).

The Bureau of Reclamation and the Army Corp of Engineers have approved Spetec PUR F400 for use on their structures. This durable repair material has been successfully installed in many of their dams and locks.

Painless Procedures

One of the classic rules of grouting cracks and joints is to pull off the crack or joint half the thickness of the wall and drill at a 45° angle. However, when you get over 3’ thick it is not necessary to pull off the crack or joint more than 1.5’. The crew followed these guidelines when injecting the resin.

On thicker structures leaking cold water at high volumes, it is imperative to be able to adjust the set times in the field. Gen ACC is the accelerator for Spetec PUR F400 and is added at a ratio of 1% all the way up to 10%. The more you add the quicker the product polymerizes. The crew adjusted the set times according to properties of each leak.

They also soaked AP Oakum in Spetec PUR F400, and packed it into the wider cracks and high volume leaks. Depending on the situation, the oakum is sometimes packed in before the injection or packed in simultaneously as a second crew member fills the void with the first crew member is injecting the resin.

Rapid Results

Within a matter of days, the leaks in the galleries were successfully remediated. The general contractor was then able to move on to other parts of their project, on budget and on schedule.

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Alchemy-Spetec HQ in Tucker, GA

THIS EVENT HAS BEEN CANCELLED

$745 Registration Fee
$665 for each additional participant from
the same company.

Get ready for a thorough education in Slab Lifting, Soil Stabilization, the Alchemy-Spetec Deep Lift® process, equipment, and applications. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Tuesday, October 4th

• Geotech Product Line Overview
• Geotech Applications & Case Studies
• MixMaster Pro Slab Lifting Gun
• Slab Lift Rig Demonstration

Wednesday, October 5th

• Pump Demos & Training
• PolyShark® / Soil Stabilization
• Deep Lift® 
• Ground Penetrating Radar

Thursday, March 31st

• PolyBadger® Mobile Slab Lifting System
• Estimating Material for Jobs

THIS EVENT HAS BEEN CANCELLED