Alchatek Blog

Mid South Concrete Lifting successfully executed an emergency repair operation at a Tennessee Valley Authority (TVA) lift station in New Johnsonville, Tennessee. What began as a new construction project quickly required an urgent repair when significant leakage was discovered at multiple joint locations immediately after installation. The contractor's rapid response and innovative solution prevented extensive water loss and potential environmental impacts.

Initial Assessment

The investigation began when facility managers discovered several critical issues:

• Structural weaknesses detected in multiple joint locations
• Massive water loss occurring within 24 hours of installation
• Thousands of gallons of water escaping through compromised joints
• Environmental concerns due to uncontrolled water discharge

The severity of the situation demanded emergency intervention to prevent continued water loss and potential damage to surrounding infrastructure.

Proposed Solution

After technical evaluation, Spetec PUR F400 was selected as the optimal solution due to its superior characteristics:

• Rapid-curing formulation for quick deployment
• Excellent adhesion properties for joint sealing
• Water-reactive chemistry suitable for wet conditions
• High structural strength for long-term durability
• Environmental compatibility for water infrastructure

Procedures

1. Complete dewatering of the lift station
2. Technical team rappelled into the structure
3. Systematic injection of Spetec F400 at all compromised joints
4. Progressive sealing to ensure complete joint stabilization

Results and Conclusion

The emergency repair proved successful on multiple fronts:

• Complete elimination of water loss through compromised joints
• Restoration of structural integrity to all sealed areas
• The system returned to full operational status within 24 hours
• Long-term solution achieved with minimal downtime
• Cost-effective resolution compared to alternative repair methods

The project demonstrated the effectiveness of chemical grout injection as a rapid response to critical infrastructure leaks. It successfully prevented ongoing water loss while providing a durable, long-term repair solution.

Want more information on sealing leaks with polyurethane?

Suburban Basement was hired to address significant voids beneath a slab foundation residence in Roseville, Michigan. The voids were suspected to have been caused by a compromised sewer line under the bathroom shower, resulting in extended leakage affecting a substantial portion of the home’s foundation. After plumbers discovered the issue, a local property restoration company managing the overall project engaged Suburban Basement.

Initial Assessment

The extent of the voids was assessed using 4-foot-tall plow markers as probes. The voids almost entirely engulfed these probes, indicating severe foundation undermining. The situation required a solution that could effectively fill large voids, bond with both soil and concrete, and perform well in wet environments.

Proposed Solution

Suburban Basement proposed using Alchatek's AP Lift 430 for the void filling. This material was chosen for its high expansion rate, making it cost-effective for large voids. Its ability to bond with soil and concrete, perform in wet conditions, and displace residual moisture from the plumbing leak made it ideal for this application.

Procedures

1. Drilled a systematic grid pattern of holes throughout the residence
2. Employed controlled injection shots to avoid excessive product usage and prevent lifting
3. Carefully filled all voids without causing any lifting of the foundation

Results

The project restored the foundation's integrity, filling all voids within a day. This efficient execution led to significant time and cost savings for all parties. The insurance company reduced relocation expenses, the restoration company delivered ahead of schedule, and the homeowners returned to their structurally sound homes earlier than expected. The outcome satisfied all stakeholders, demonstrating the effectiveness of the chosen solution in addressing complex foundation issues promptly and efficiently.

Want more information on geotechnical polyurethanes?

An old farmhouse with a wrap-around porch in Lake Orion, Michigan, presented a unique challenge. Beneath the porch lay an old cellar, initially used for coal storage but now serving only as a conduit for a well line into the residence. The primary concern was the inward buckling of the cellar walls, which posed a significant safety hazard. Many contractors suggested demolishing the porch and excavating the cellar, a solution that would have incurred substantial costs for both demolition and reconstruction.

Initial Assessment

Suburban Basement was engaged to address this issue. Upon evaluation, the team identified a more cost-effective and less invasive solution. The cellar, measuring 12 feet in length, 5 feet in height, and 5 feet in width, could be filled with foam to mitigate the risk of further wall collapse. This approach would spare the property owner the expensive and disruptive process of demolition and reconstruction.

Proposed Solution

The team proposed filling the cellar with Alchatek’s AP Lift 430 foam. This material was chosen for its extensive expansion rate, superior compressive strength, and lower application temperatures. These properties allowed for quicker application intervals while maintaining optimal temperatures between applications and minimizing ignition risks.

Procedures

1. Encapsulated the well line with sonotubes elevated above the cellar floor, ensuring future accessibility.
2. Installed OSB sheathing to define foam boundaries and prevent overflow.
3. Applied AP Lift 430 in layers, allowing cooling intervals between applications to optimize expansion and stability.
4. Coordinated with masons to prepare for CMU block installation at the containment boundary, ensuring seamless alignment with the existing foundation.

Results

The foam-filling solution successfully stabilized the cellar walls, eliminating the collapse risk while preserving functionality. Compared to traditional approaches, this method saved the client approximately $25,000 and maintained the home’s historic features. Completed in just five days, the project significantly outpaced conventional methods. Homeowners were highly satisfied with the noninvasive approach, cost savings, and seamless integration with their property’s historic character, demonstrating the effectiveness of innovative techniques in addressing complex structural challenges in historic properties.

Want more information on geotechnical polyurethanes?

Suburban Basement was contracted to address a multifaceted water intrusion issue on a Rochester Hills, Michigan property. The basement had water ingress from both the furnace ductwork and the foundation. The ductwork, extending through the foundation wall into a garage-adjacent wall cavity, had sections below grade behind a garage curb. The root of the problem was water pooling under the back curb, caused by settled garage slabs from the main vehicle entrance.

Initial Assessment

The project was divided into two phases: first, addressing the leaking foundation and furnace ductwork, and second, void filling and concrete leveling of the garage floor and curb. The complexity arose from the undermined garage slabs and the need to prevent water intrusion while ensuring the safety of the furnace ductwork.

Proposed Solution

For the initial water intrusion, Suburban Basement proposed using Alchatek’s Spetec PUR Highfoamer for curtain grouting, given the limited accessibility and its fast reaction time. For the concrete leveling and void filling, AP Lift 430 was selected due to its expansion rate, soil stabilization capabilities, water displacement properties, and quick curing time for vehicle traffic.

Procedures

1. Applied curtain grout to the positive side of the wall to stop water intrusion and encapsulate the dual wall furnace ductwork
2. Commenced void filling and leveling at the garage curb, progressing toward the main vehicle entrance
3. Filled all voids beneath the garage curb and leveled the concrete across all areas of concern
4. Conducted water tests to ensure all leaks were addressed before proceeding to phase two
5. Performed void filling and concrete leveling, displacing significant amounts of water near the main vehicle entrance

Results

The project was completed successfully in two phases, with the curtain grouting finished within hours and the void filling and concrete leveling taking approximately half a day. All leaks were effectively stopped, and the concrete was successfully leveled. The homeowner expressed high satisfaction, notably as previous repair attempts had failed. Suburban Basement’s solution not only resolved the immediate water intrusion problems but also extended the lifespan of the garage concrete and driveway, providing a comprehensive fix to a complex issue.

Want more information on leak seal and slab lifting?

Management at a luxury hotel in Atlanta contacted geotech specialists Panhandle Seawall and Infrastructure after discovering significant voids beneath their swimming pool during routine maintenance. What began as a standard pool inspection quickly escalated into a serious structural emergency that threatened the integrity of part of the building. PSI was able to mobilize within days, providing temporary support until the foundation contractor could underpin the column footing and provide a permanent solution.

Initial Assessment

The investigation began when hotel maintenance staff noticed several concerning issues:

• Visible cracks developing in the pool structure.
• Accelerated water loss beyond normal evaporation.
• Significant increase in monthly water bills.
• Further investigation revealed an approximately 800 cubic foot void beneath the pool.
• A critical structural issue where a column footing was precariously supported only by the edge of a rock formation.

The severity of the situation led to a partial condemnation of the hotel structure, requiring immediate intervention to prevent potential catastrophic failure.

Proposed Solution

After careful evaluation by the project engineers, AP Lift 475 was selected as the optimal solution due to its superior characteristics:

• Higher density formulation for enhanced structural support.
• Superior bearing capacity to meet engineering requirements.
• Rapid deployment capabilities for emergency situations.

The project required approximately 300 gallons of material, deployed in three separate sets, to provide the necessary structural reinforcement.

Procedures

1. Safety Implementation

• Installation of proper ventilation systems.
• Deployment of temporary support beams.
• Setup of adequate lighting for the work area.

2. Grout Implementation

• Initial deployment of the Deep Lock® method to solidify underlying soil.
• Systematic void filling through carefully timed injection intervals.
• Continuous monitoring of material flow and structural response.
• Progressive filling to ensure complete void elimination and stabilization of footing.

Results and Conclusion

• The emergency shoring proved successful on multiple fronts:
• Complete stabilization of the compromised column footing.
• Establishment of solid connectivity between the underlying soil and structural elements.
• Prevention of further structural degradation.
• Removal of condemnation threat to the building.
• Restoration of structural integrity to engineering standards.

The project demonstrated the effectiveness of polyurethane void fill as a rapid response solution for critical structural emergencies, successfully averting potential building failure while providing a long-term stabilization solution.

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The owner of a gas manufacturing facility contacted a Georgia-based contractor regarding significant floor settlement issues, with a warehouse slab dropping approximately 3-4 inches. The settlement made issues for the forklift traversing in and out of the warehouse and posed a risk to the workers.

Initial Assessment

Upon arrival at the site, the team conducted a thorough investigation. Using a probe, voids were identified beneath the slab, with the probe sinking up to 2 feet in some areas. A Dynamic Cone Penetrometer test revealed large voids 2-4 feet below the slab.  Poor drainage was evident, with improper crowning causing water to flow towards the building instead of away from it. Interestingly, a layer of unusually hard clay was noticed outside the building, suggesting possible prior remediation attempts.

Proposed Solution

AP Lift 430 was chosen for this project, providing an excellent injectable polyurethane grout solution. With its impressive 22x expansion capability and 7,200 psf compressive strength, it’s ideal for warehouse slabs that support heavy equipment. The grout’s hydrophobic properties ensure long-term stability by blocking water infiltration that could otherwise lead to void formation.

Procedures

1. Deep Injection (Void Fill)

• 32 injection points were established in a grid pattern (16 on each side) at 4 ft apart.
• At each point, the team injected 15-20 pounds of material at about 5 feet depth.
• A slight lift (approximately 1/16 inch) during this phase indicated successful void filling.

2. Slab Lifting

• Additional holes were drilled next to the wall, 3 feet from the wall, and 9 feet from the wall (6 feet from the first row).
• Injection began from the holes nearest to the wall and moved outward.
• Multiple passes were made, with some areas requiring 3-4 injections.
• Gradual lifting was employed to prevent slab cracking.
• Dial indicators were used to ensure even lifting across the warehouse floor.

Results

The project successfully stabilized the warehouse floor and restored it to its proper level. Effective void-filling addressed the underlying instability, providing a solid foundation for the slab. Success was evident in the restored functionality of the warehouse space and the elimination of safety hazards posed by the uneven floor. The property manager was pleased with the work and requested additional slab lifting services for their other facilities.

Want more information on lifting slabs with polyurethane?

Essential Details

Dates/Pricing (Discount Deadline Extended!)

Geotechnical Masterclass: March 25th - 27th, 2025

$695.00
This is special pricing for all who register before the end of the day, March 2nd. $745 March 3rd and later. ($50 discount for each additional participant.)

Location

Atlanta, GA

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.

Essential Details

Dates/Pricing

Geotechnical Masterclass: March 25th - 27th, 2025

$695.00
This is special pricing for all who register before the end of the day, February 25th. $745 February 26th and later. ($50 discount for each additional participant.)

Location

Atlanta, GA

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.

A concrete staircase in a prominent mixed-use complex in Atlanta needed urgent repairs due to a set of 75-foot-long sunken steps. This issue posed a significant trip hazard, potentially compromising visitor safety. The problem stemmed from a combination of factors working together over time. Water infiltration through expansion cracks had created voids beneath the stairs, weakening their foundation. Compounding this issue was the natural tendency of separate concrete pieces to expand and contract, moving independently. This movement was particularly problematic as it caused the steps to separate from the adjacent sidewalk. Over time, the repeated cycles of expansion and contraction, coupled with the underlying voids, led to the steps sinking and rolling, creating a hazardous situation. 

Local experts from Engineered Restorations were called in to tackle this tricky situation. The team faced the challenge of addressing safety concerns while preserving the structural integrity of the staircase.

Powerful Polymers

AP Lift 430 was selected as the repair material for this restoration project. This polyurethane foam has expansive properties that are suitable for lifting sunken structures. Once cured, AP Lift 430 provides support for long-term stability, aligning with the project's requirements.

Painless Procedures

The repair process began with an assessment of the trip hazard. This allowed the team to determine the extent of the problem and plan their approach. Next, backer rods between the steps and sidewalk were removed to prepare the area for treatment. Alchatek Surface Guard 125 was applied around the injection area to prevent any excess polyurethane from bonding to the concrete. Protective sheets were placed to shield nearby glass surfaces.

The team drilled holes through the 8-inch concrete steps to reach the underlying soil. Soil probes revealed firm underlying conditions. The team then implemented their injection strategy. They created an initial foam layer slowly, injecting it just once every ten seconds. This gradual approach prevented existing hairline cracks from expanding during the lifting process. The team continued to inject AP Fill 430 until the steps were level. Finally, they redrilled and applied a second injection layer beneath the first to fill any voids created in the process. New backer rods were then installed.

To enhance the longevity of the repair, the team took an additional crucial step. They sealed the expansion joints with silicone, creating an optimal water barrier. This silicone sealant is flexible, accommodating future expansion and contraction. This extra measure was designed to protect the structure from water infiltration and movement, addressing the root causes of the original problem. 

Rapid Results

In just four hours, the steps were restored to a level position, aligning with the adjacent walkway. This efficient repair method addressed the immediate safety issue while extending the structure's lifespan. By lifting the existing steps rather than replacing them, the property owner avoided substantial expenses associated with demolition, new materials, and extended labor time for a complete replacement. This approach ultimately provided significant cost savings.

Want more information on concrete leveling with polyurethane?

Essential Details

Dates/Pricing

Geotechnical Masterclass: March 25th - 27th, 2025

$695.00
This is special pricing for all who register before the end of day, February 25th. $745 February 26th and later. ($50 discount for each additional participant.)

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.