Nowhere on earth are they building more railroad lines than in the People’s Republic of China. The most populous nation in the world is developing rapidly and with it comes a need for more and more freight and passenger rail - and the demand for higher and higher speeds. Unfortunately, these high speeds cannot be achieved on rail that is sinking and settling in various places, especially in tunnels. This slows down people and commerce and is also a concern for safety. The culprit is groundwater, soil consolidation, and in some cases poor compaction. This is the type of environment where AP Lift 475 has done some of its best work.

Powerful Polymer

AP Lift 475 is a two component, hydrophobic, structural lifting polymer designed for airport, highway, and railroad applications. It can be used to stabilize structures, fill voids, and lift slabs supporting tremendous loads. The real beauty of it is the ability to be traffic ready for a train or a jumbo jet in less than one hour. A few years ago, it was put to the test in tunnels in the mountains of China.

Painless Procedure

With rails sitting on double concrete slabs (the top slab was 1 meter thick, the bottom 30 cm) a plan was developed to bring the low spots back into tolerance by injecting AP Lift 475 underneath both slabs through extra-long injection packers.

Monitoring with laser levels, the low spots in the rail were lifted back to the original grade. AP Lift 475 performed as advertised. The railroad track was raised and supported, while at the same time the ground water was displaced, literally jetting out of relief holes as it sought a place to escape.

Rapid Result

Working in 4 hour windows where the rail traffic is shut down at night, crews lifted low spots in these tunnels quickly and efficiently.  At 5 AM equipment and personnel had to be clear of the tracks and 15 minutes later the trains would rumble through.  Vibration monitoring by railway engineers showed a smoother ride and the people and commerce of China were allowed to move once again at a frenetic pace.

Want More In-Depth Info on Concrete Leveling Polyjacking Products?

County inspectors found a depression in the road due to an underground sewer line that wasn’t sealed at a heavily trafficked roadway intersection in Orange County, Florida.  Water and eroding soil were infiltrating the sewer line causing the road to slowly settle.  The resulting voids around the drainage structures had the potential to grow larger, eventually resulting in a complete cave-in of the roadway.  In this particular case, there was a patch of asphalt 12’ x 25’ that was settling and officials feared a cave-in would occur.  A point repair was done from within the leaky pipe to stop the infiltration but they feared it was only a matter of time before the road gave way. It was going to be very difficult and inconvenient to dig up this roadway, fill the void, re-compact, and re-pave due to the high volume of traffic, the adjoining rail crossing, as well as several major utilities running through the area.  Not to mention that the area would have to be completely shut down to accommodate all of the equipment required for such a repair.

Powerful Polymer

Orange County approached us to see if we could come up with a powerful, painless and rapid solution for their maintenance crew using chemical grouting to fill the voids and stabilize the roadway. We devised a solution for them using the versatility of AP Fill 700 as both a permeation and void filling grout.

Painless Procedure

We advised their crew to lay out a grid on the settling asphalt area and set up injection points to drive pipes down to the 13’ depth where leaking had occurred and where the loose soil zone was located. They monitored the pipes while injecting material at a rate of 2 gallons per vertical foot through the open manhole to identify additional leaks that had been missed during the first point repair. As expected when foam was observed coming in through a leaking joint it quickly sealed off the leak at the same time it was stabilizing the soil.

Rapid Result

To keep the lane closure down to a bare minimum of time, the project was successfully completed on two separate Saturdays.  The voids were filled, the loose soil was solidified, and only minor asphalt patching was required to make that area smooth for traffic again.

Want in-depth info on soil stabilization products?

On top of a hill northeast of Chattanooga, Tennessee sits a clearwell that belongs to Eastside Utilities. Built in the 1940’s on a former Army post, this clearwell consists of twin 2-million gallon tanks used for treating surface water to turn it into drinking water. The problem was that less than half of the water coming into the clearwells was making it out the other side. Although this water treatment plant has undergone several upgrades in its 70+ year lifespan, the ground beneath it has been subject to settling and consolidation. The tanks had shifted slightly and in doing so, loosened some of the joints and the water stops contained within. Measurements indicated that the clearwells were losing 1,700 gallons per minute through various leaks; well over 2-million gallons per day. A short drive downhill from the property revealed various gullies and small creeks created by water running down the hillside.

Powerful Polymer

An Alchemy-Spetec certified installer was called in to utilize Spetec PUR GT500, an NSF /ANSI 61 approved product for contact with drinking water, to seal the leaks.  This single component polyurethane resin is designed to penetrate and seal off leaks in cracks, joints, and pipe penetrations.  As a hydrophilic polyurethane, it chases down water and gets into the microstructure of the concrete, forming a flexible seal and a tenacious bond with the wet concrete.

Painless Procedure

Due to the amount of water escaping, all of the joints around the perimeter walls were suspect as well as the roof support columns throughout each clearwell that penetrated through the floor.  The contractor drilled holes to intersect the leaking joints around the perimeter of the clearwell and along all interior joints.  Injection ports were installed and Spetec PUR GT500 was pumped into each one to create an injected membrane within the joints and beneath the clearwell.

Rapid Result

After three days of injection the work was done and the site was cleaned up.  Monitoring after the Spetec PUR GT500 was installed indicated that the leak had been reduced from 1,700 gallons per minute to 10 gallons per minute.  The small number of remaining leaks were attributed to the many vintage valves and fittings that are still present at the plant.

Want in-depth info on polyurethane leak seal injection?

In our continuous effort to make sure you have the technical knowledge to succeed, we’ll explain how to select the appropriate slab lifting polyurethane.

Use the Right Supplier

First and foremost, you want to be sure you’re working with the right supplier.  For niche work like polyurethane slab lifting, you need a company that specializes in polymer concrete repair materials.  Some larger polyurethane manufacturers make everything under the sun in addition to lifting foam, such as mattress foam, carpet padding foam, etc.  Your materials would be manufactured quarterly at most.  Technical support, if it exists, is unfocused and lacking in detailed expertise.  Don’t set yourself up for failure by going this route.

The right supplier will be a specialized polymer manufacturer with a laser-like focus on producing the best slab lifting foam possible.  Even better, they should offer dedicated tech support from professionals with field experience on actual slab lifting jobs.  Set yourself up for success with the absolute best supplier partner you can find.

If a Specification Exists, Read it!

If you’re working on a larger job involving an engineering firm, make sure you read the specs!  (If the Department of Transportation is involved, they will also have one available.)  For experienced contractors, this is just basic common sense obviously.

Foam for Filling Voids

An empty void underneath a slab needs to be filled with a lighter density foam that has an excellent expansion rate yet still ahs the structural strength for the application.

Different Foams for Different Lifting Jobs

The foam you choose for lifting will depend greatly on the size of the slab and the amount of weight it typically bears.

• Residential Jobs
  Driveways, walkways, garage floors and the like can usually be lifted with 3 lb density foam such as AP Lift 430.

• Common Commercial/Industrial Jobs
  Warehouse floors, concrete retail floors, larger concrete parking slabs and the like will require 4 lb density foam such as AP Lift 440.

• Maximum Weight Bearing Slabs
  Airport runways, railroad slabs, transformer pads, factory floors with heavy equipment, grain silo slabs and the like will require 4.75 density foam such as AP Lift 475.
  

Foam Designed for Wet Environments is Essential

At LEAST 90% of the time, water is the underlying cause of slab problems.  On most jobs, the soil will contain at least some infiltration.  So ALWAYS make sure your foam is designed for environments with moisture in the soil.  Many companies offer resins that will NOT work in wet environments or will require a lot more material to get the job done.  Why pay good money for a product that won’t work 90% of the time?  Every Alchemy-Spetec lifting foam is designed to work in wet environments.

NSF Approval is a Must

NSF approval is ESSENTIAL for doing work near waterfronts, food processing operations, water treatment plants, etc. 

This single designation ensures compliance with the Safe Water Drinking Act (SDWA) and guarantees peace of mind for in-the-field stakeholders on construction projects of almost any scope and size.

The SDWA gives the EPA latitude to impose criminal and civil penalties on industries 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.

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.

Alchemy-Spetec is one of only TWO companies in the world with NSF approved lifting foam.

We’ve Got Your Back

If you’re still not sure what the right choice is for an upcoming job, then not to worry – we’re here for you!  Our staff has the expertise both in the lab and in the field.  We can help you make the right decision.  Just give us a call!

Want in-depth info on slab lifting polyurethane and procedures?

Reminder!  Book your personalized meeting with an Alchemy-Spetec rep at World of Concrete!

Alchemy-Spetec will be at World of Concrete 2019!  Drop by to see us at Booth # O40551 in the Silver Lots (same location we were in last year).

There will be a LOT to see and do at our booth this year: 

• See the Polybadger Lifting System in action. 
• Learn about preventative waterstop products. 
• Get in-depth instruction on using and cleaning the MixMaster Pro slab lifting gun. 
• View leak seal and curtain grouting displays. 
• Mix foam samples at our live mixing station. 
• Learn about the Deep Lift process. 
• Tour a fully stocked slab lifting rig (you can even take it home with you if you're ready to buy!)

Respecting YOUR time is important to us.  So, in addition to the action-packed list above, you can schedule a one-on-one consultation with your regional rep for personalized product or equipment demos, tips and advice on building your business, etc.

Want a personlized one-on-one meeting at World of Concrete?

When it comes to custom slab lifting rigs of all shapes and sizes, Alchemy-Spetec is your one-stop shop!  Want to see a 16-foot V-Nose rig, stocked with top of the line slab lifting equipment and gear?  We'll give you a personal tour at World of Concrete 2019!  Drop by to see us at Booth # O40551 in the Silver Lots (same location we were in last year).

There will be a LOT to see and do at our booth this year: 

• See the Polybadger Lifting System in action. 
• Learn about preventative waterstop products. 
• Get in-depth instruction on using and cleaning the MixMaster Pro slab lifting gun. 
• View leak seal and curtain grouting displays. 
• Mix foam samples at our live mixing station. 
• Learn about the Deep Lift process. 

Respecting YOUR time is important to us.  So, in addition to the action-packed list above, you can schedule a one-on-one consultation with your regional rep for personalized product or equipment demos, tips and advice on building your business, etc.

Want a personlized one-on-one meeting at World of Concrete? 

Alchemy-Spetec offers a unique combination of high quality structural lifting foams along with the equipment and training needed to address deep soil issues. Now you can achieve soil densification and lifting on large projects with the smallest footprint and least amount of heavy equipment required.

The Deep Lift™ process is powerful, painless, and rapid. Deep Lift™ gets to the root of the problems in the soil, it brings the structure back to level, and accomplishes this with minimal imposition or downtime to the property owner.

Alchemy-Spetec will be at World of Concrete 2019!  You can learn more about the Deep Lift™ process at our exhibit space.  Drop by to see us at Booth # O40551 in the Silver Lots (same location we were in last year).

There will be a LOT to see and do at our booth this year: 

• See the Polybadger Lifting System in action. 
• Learn about preventative waterstop products. 
• Get in-depth instruction on using and cleaning the MixMaster Pro slab lifting gun. 
• View leak seal and curtain grouting displays. 
• Mix foam samples at our live mixing station. 
• Tour a fully stocked slab lifting rig.

Want more information on the Deep Lift™ process?

See first-hand how chemical grouts react and set up when mixed at our Live Mixing Station at World of Concrete 2019! 

Drop by to see us at Booth # O40551 in the Silver Lots (same location we were in last year). 

There will be a LOT to see and do at our booth this year: 

• See the Polybadger Lifting System in action. 
• Learn about preventative waterstop products. 
• View leak seal and curtain grouting displays. 
• Get in-depth instruction on using and cleaning the MixMaster Pro slab lifting gun. 
• Learn about the Deep Lift process. 
• Tour a fully stocked slab lifting rig.

Want to schedule a one-on-one consultation with a rep at World of Concrete?

Leaking concrete structures can be permanently repaired with concrete crack injection by using a water activated flexible foam. Pressure injection of these liquid polyurethane resins forces the material into leaking cracks, joints, and other defects. After the polyurethane crack injection is complete, the polyurethane resin rapidly reacts with water to form a flexible, watertight seal.

Curtain wall grouting is a leak seal method that is often required when cracks cannot be identified, when walls are made of material that does not respond well to crack injection (such as masonry, stone and CMU), and when previous leak seal methods have failed. Curtain wall grouting is the process of injecting water reactive resin behind the leaking wall in a widespread grid pattern. The water on the other side mixes with the grout and cures to a solid mass covering the surface of the wall on the other side.

See crack injection and curtain wall grouting displays at World of Concrete 2019!  Drop by to see us at Booth # O40551 in the Silver Lots (same location we were in last year). 

There will be a LOT to see and do at our booth this year: 

• See the Polybadger Lifting System in action. 
• Learn about preventative waterstop products. 
• Get in-depth instruction on using and cleaning the MixMaster Pro slab lifting gun. 
• Mix foam samples at our live mixing station. 
• Learn about the Deep Lift process. 
• Tour a fully stocked slab lifting rig.

Want to schedule a one-on-one consultation with a rep at World of Concrete?

Want more information on our Leak Seal products?