Alchatek Blog

Administrators at Orange County, Florida Public Works had a pressing issue. Settlement was occurring along a quarter-mile stretch of a three-lane roadway. The culprit? Loose, sandy soils combined with a high water table. Before repaving could begin, stabilizing the supporting soil was crucial. This case study explores how the problem was addressed and resolved. This project showcases innovative solutions for common infrastructure challenges in areas with problematic soil conditions.

Powerful Polymers

AP Fill 700 was selected as the repair material for this project. Its low viscosity allowed for effective soil permeation, and its curing strength promised to create a permanent soil mass. These properties made AP Fill 700 the perfect choice for stabilizing the loose soil beneath the roadway. The selection of this material demonstrated the importance of choosing the right product for specific geotechnical challenges. AP Fill 700's unique characteristics ensured a robust and long-lasting solution.

Painless Procedures

A methodical approach was essential for this project. First, a large grid pattern for injections was carefully planned out. Each injection point was spaced five feet apart, and the depth of each injection reached approximately 15 feet. At each point, one gallon of material was injected per vertical foot. This systematic process ensured thorough coverage and stabilization of the problematic soil. The precise spacing and depth of injections were critical factors in the project's success. By following this detailed procedure, the team could address the soil instability comprehensively.

Rapid Results

This massive project was completed in about a week. As a result, the once-loose soil was successfully stabilized. The municipality now had a solid foundation to repave the quarter-mile stretch of road. In the end, Orange County Public Works had effectively addressed the settlement issue. The roadway was now ready for safe, long-lasting resurfacing. This efficient resolution solved the immediate problem and prevented potential future issues. The success of this project demonstrated the effectiveness of proactive infrastructure maintenance and the value of employing advanced soil stabilization techniques.

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A critical safety issue arose at a large paper manufacturing plant. Large voids up to 18 inches deep were discovered beneath concrete slabs supporting heavy water pumps. This hazardous condition put both employees and equipment at risk. SiteMix Pressure Grouting, LLC was called in to fill the voids and secure the slabs. 

Powerful Polymers

The technicians chose AP Lift 475 for the job. This material offers strong load-bearing capacity and cures quickly, minimizing plant downtime. Fast-curing was essential for a swift return to full operation, making AP Lift 475 the ideal solution for this repair task.

Painless Procedures

The repair began with the drilling of 3/4-inch holes. Workers drilled these holes roughly every 3 feet across the affected area. Then, they injected the repair material into each hole until the substance flowed beneath the slab from one drilled hole to the next. This method provided comprehensive coverage of the voids beneath the slabs, ensuring no areas remained untreated.

Rapid Results

The entire repair took only one day to complete. After the work, the slabs were securely stabilized, and the pump equipment and workers were safe. The paper manufacturing company expressed satisfaction with the outcome. Due to the quick turnaround time, minimal disruption occurred. Most importantly, eliminating the dangerous voids created a safer work environment.

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Many property owners face the frustrating issue of sinking concrete slabs. This problem not only affects the appearance of the property but also poses safety risks. Fortunately, modern solutions can effectively address sinking concrete without the need for complete replacement. Let's explore the causes of this common problem and discuss innovative repair methods.

Why Does Concrete Sink?

Several factors contribute to concrete settlement. First, erosion can wash away soil beneath the slab. Second, poor soil compaction during initial construction may lead to instability. Finally, biological decay of buried organic matter can create voids. As a result, the ground beneath the concrete becomes unstable, causing the slab to sink.

The Dangers of Ignoring Sinking Concrete

Failing to address sinking concrete can lead to serious consequences. For instance, uneven surfaces may cause trip hazards, potentially resulting in injuries and liability issues. Moreover, sunken slabs can damage vehicles and expensive structures. In extreme cases, a neglected settlement might even lead to sinkhole formation.

Traditional vs. Modern Repair Methods

Replacing the Slab

Historically, replacing the entire slab was a common solution. However, this approach is messy, time-consuming, and expensive. Additionally, it often involves significant disruption to the surrounding area.

Mudjacking

Another traditional method is mudjacking, which involves pumping a cement-based slurry under the slab. While effective in the short term, the injected material may crack or erode over time, leading to future issues. Furthermore, this technique requires large drill holes and disruptive heavy equipment.

Polyurethane Foam for Lifting Sinking Concrete

In recent years, polyurethane foam lifting has emerged as the preferred method for repairing sinking concrete. This innovative technique offers numerous advantages over traditional approaches.

Strength and Durability

Polyurethane foam features impressive strength, often surpassing that of bedrock. Once injected, the foam continues to gain strength, providing long-lasting support for the repaired slab. As a result, this solution offers exceptional durability compared to other methods.

Minimally Invasive Process

Unlike mudjacking or replacement, foam lifting requires only small drill holes. Consequently, this method causes minimal damage to the existing slab and surrounding area. The lightweight equipment used also reduces the risk of disruption and further soil compaction.

Rapid Results

One of the most significant advantages of polyurethane foam lifting is its speed. The foam cures to 90% strength in just 15 minutes. Therefore, repaired areas can often be used the same day, minimizing disruption to daily activities.

Environmentally Friendly

Alchatek offers polyurethane lifting foams that are NSF-certified to meet strict environmental standards. These products won't leach harmful chemicals into the soil or groundwater. As a result, property owners can feel confident in choosing contractors who offer this eco-friendly solution.

The Foam Lifting Process

The concrete lifting process using polyurethane foam is straightforward and efficient. First, technicians drill small holes in the slab. Next, they inject the foam through these holes. As the foam expands, it fills voids and gently lifts the slab. Finally, the holes are patched, and any cracks are sealed.

Choosing a Professional for Sinking Concrete Repair

When dealing with sinking concrete, it's crucial to hire experienced professionals. Skilled technicians can assess the situation accurately and determine the best course of action. Moreover, they have access to high-quality materials and specialized equipment necessary for effective repairs.

Restoring Your Property's Safety and Value

Addressing sinking concrete promptly can prevent further damage and costly repairs. Property owners can quickly and efficiently restore their concrete surfaces by choosing modern foam lifting techniques. This not only enhances safety but also improves the overall value and appearance of the property.

Fill out this form or call 404-618-0438 for a contractor referral today!

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A cooling tower lift station under construction in Iuka, Mississippi, had a significant water leak problem. The facility was losing approximately 1,000 gallons of water daily. The source and destination of the leak were unknown. A solution was implemented using concrete sealing techniques. Leak seal experts at Mid-South Concrete Lifting were called in to perform the repairs.

Powerful Polymers

The technicians chose Spetec PUR F400 for the repair. This polyurethane-based material has a closed-cell structure that seals cracks and joints. It remains flexible after curing, which allows for structural shifts. The material is NSF-certified, meeting environmental standards for water-related applications.

Painless Procedures

Due to the leak's unknown location, a comprehensive approach was necessary. The team injected the solution into all of the control joints and treated any visible hairline cracks within the concrete. The entire process was completed in two days, minimizing operational disruption.

Rapid Results

The treatment showed noticeable effects in the control joints. After the procedure, the company refilled the pit. The results met their expectations. Construction at the facility resumed without further delays. The solution effectively addressed the water loss issue while maintaining the structural integrity of the cooling tower lift station.

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In Salt Lake City, Utah, a historic brick structure built in 1893 showed signs of foundation settlement. The building's sandstone foundation presented a challenge. Traditional stabilization methods like installing helical piers could potentially cause further damage. Rhino Foundation Systems proposed a solution using polyurethane foam to stabilize the foundation. This case study examines how this approach addressed the building's foundation problems.

Powerful Polymers

The technicians selected AP Lift 430 polyurethane foam for the project. This foam was chosen for its ideal soil stabilization and structural support properties. The plan involved injecting the foam beneath the footings to provide a stable support platform. This method would achieve the desired stabilization without requiring extensive excavation.

Painless Procedures

The project began with a detailed site assessment to understand the extent of the settlement and soil conditions. Following this, the team designed a plan to install 63 deep foam injections under the foundation, ensuring comprehensive coverage and stabilization. Specialized equipment was then used to perform these deep injections, with the foam strategically placed to improve the soil and stabilize the foundation.

Rapid Results

The project delivered several key benefits. Deep foam injections improved the soil and provided a strong platform for the foundation, ensuring effective stabilization. The non-invasive process precluded the need for extensive excavation, preserving the structure and minimizing disruption. Notably, the project was completed in just two days, significantly reducing downtime and disturbance to the area. Finally, the polyurethane foam injections offered a cost-effective solution compared to traditional stabilization methods, making it an economically viable option for similar foundation challenges.

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The management team at a community pool in Midvale, Utah, faced a significant challenge. A water leak had saturated the silty soil beneath the structure, causing uneven settlement and safety hazards. To address this issue, they brought in geotechnical specialists from Rhino Foundation Systems, who proposed an innovative solution as an alternative to tearing out and replacing the pool. This approach not only promised to stabilize the pool but also lift it back to its proper position.

Powerful Polymers

The key to this solution was Alchatek's AP Lift 440 polyurethane foam. This powerful polymer was chosen for its soil stabilization, load-bearing, and lifting capabilities. Deep soil injections were planned to address the underlying issues. The foam's expanding properties would displace water and stabilize the soil base. This method offered a non-invasive alternative to traditional approaches like helical piles.

Painless Procedures

The process began with a thorough site assessment. The technicians analyzed soil saturation and settlement patterns. Based on this data, a 3-foot by 5-foot injection grid was designed. Next, holes were drilled through the bottom of the pool, and injection rods were installed. AP Lift 440 was injected beneath the structure. As a result, the expanding foam displaced water and stabilized the soil base. Following this, the pool was lifted by 3.5 inches. Finally, the pool deck was adjusted to match the new level.

Rapid Results

The pool was successfully stabilized and leveled with minimal disruption. Moreover, there was no need for extensive excavation. This method proved to be both effective and efficient. The foam injections effectively displaced water and stabilized the soil. Additionally, the lifting process was precise, raising the pool by exactly 3.5 inches. Perhaps most importantly, this solution was cost-effective. It proved quicker and more economical than complete pool replacement.

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Manhole infiltration can pose serious risks to nearby structures. In a recent case, water infiltration pulled soil into a manhole, eroded the ground beneath a walkway in front of a residence, and threatened to compromise the home's foundation. Specialists from SiteMix Pressure Grouting, LLC were called in to perform repairs to address this urgent situation.

Powerful Polymers

Two key products were selected for the job. First, AP Fill 700 was chosen to stabilize the soil around the manhole and seal the leaks. This product features low viscosity, making it ideal for permeating soil and sealing thin cracks. Additionally, it activates with moisture, which is perfect for damp environments like this one. Secondly, AP Lift 430 was selected to stabilize the house's footing. This high-density product cures quickly. Furthermore, it excels at filling voids and stabilizing soil near structures due to its high load-bearing capacity.

Painless Procedures

The repair process began with stabilizing the soil around the manhole. To achieve this, injection rods were driven into the ground around the structure. Then, AP Fill 700 was injected to seal the leaks and stabilize the surrounding soil. Next, the team focused on the large void areas around the house's footing. Once again, injection rods were utilized. This time, AP Lift 430 was injected to fill the voids and secure the foundation.

Rapid Results

The repair project yielded impressive outcomes. First and foremost, the manhole was successfully sealed. In addition, the surrounding soil was stabilized, preventing further erosion. The walkway, previously at risk, was now secure. Importantly, the voids adjacent to the house were filled, protecting the foundation. Remarkably, all these tasks were completed in less than a day. Finally, the repaired area was prepared for the county to add backfill around the newly stabilized manhole. This swift and effective solution ensured the safety of both the property and its residents.

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A power outage at a high-rise condo building recently demonstrated the importance of proper underground power line installation. Soil settlement caused the power lines in the duct banks to shear off, cutting electricity to the entire building. Ironically, concrete poured over the lines to "protect" them had contributed to the settlement. With power cut off from the entire building, ownership was paying thousands per hour for emergency generators. A quick, durable repair was essential. Geotechnical experts from SiteMix Pressure Grouting, LLC tackled the problem using innovative techniques and materials.

Powerful Polymers

AP Lift 475, a high-strength polymer, was crucial for this stabilization project. Its placement near the condo's footing made this material the perfect choice. AP Lift 475 provides exceptional load-bearing capacity, which is ideal for supporting large structures. The polymer's robust properties ensure long-term support for the repaired power lines. Moreover, its strength offers a reliable foundation for the electrical system, preventing future settlement issues.

Painless Procedures

The repair process began with careful excavation. In order to access the crushed duct banks 12 feet below grade, the workers removed soil and concrete next to the building. Next, the geotech team installed 15-foot injection rods into the soil below the duct banks for deep soil stabilization, a technique also known as Deep Lock®. The team methodically created a grid pattern with 12 injection points, each spaced about 3 feet apart. This systematic approach ensures thorough soil treatment throughout the affected area. The specialists achieved comprehensive stabilization by injecting the polymer at multiple points, addressing all potential weak spots in the soil structure.

Rapid Results

The entire project was completed in less than two days. Once the soil was stabilized, electricians safely reinstalled power lines through new duct banks into the building. The duct banks were then covered with well-compacted backfill. The condo ownership could finally stop the costly generator payments. Most importantly, the repair provided a permanent solution to prevent future power line issues. This quick, effective intervention minimized disruption for residents while ensuring long-term stability for the building's power supply.

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Ground Penetrating Radar (GPR) has revolutionized soil stabilization and concrete leveling projects. This non-invasive technology provides crucial subsurface information without disturbing the ground. Consequently, contractors and engineers can make more informed decisions about soil stabilization and concrete leveling techniques. Furthermore, Ground Penetrating Radar for soil stabilization and concrete leveling is vastly improving project outcomes. Let's explore how this technology is making a difference.

Alchatek's Deep Look GPR System

The Deep Look GPR System employs advanced technology for superior results. Notably, it features multi-frequency antennas, covering a wider bandwidth than conventional systems requiring multiple antennas. As a result, this approach allows for both detailed near-surface imaging and deeper sub-surface imaging. Thus, the Deep Look GPR unit streamlines the data collection process.

Advantages of Ground Penetrating Radar

GPR offers several benefits for soil stabilization projects:

• Non-invasive assessment: First and foremost, GPR provides valuable data without disturbing the site.
• Comprehensive imaging: Additionally, it detects soil layers, voids, buried objects, and groundwater levels.
• Enhanced safety: Moreover, by identifying subsurface hazards, GPR improves worker safety. Consequently, these advantages enable more accurate soil assessment, leading to better application strategies.

GPR in Action: From Raw Data to Insights

Raw GPR data provides valuable insights into subsurface conditions. Specifically, high-resolution images reveal intricate details about soil composition and structure. For instance, GPR can detect individual shallow rebars and even the spacing between surface tiles. Undoubtedly, this level of detail is crucial for soil stabilization and concrete leveling projects, as it helps identify potential weak points or areas requiring special attention.

Ground Penetrating Radar for Soil Stabilization and Concrete Leveling

In conclusion, Ground Penetrating Radar has proven to be an invaluable tool for soil stabilization and concrete leveling projects. Its noninvasive nature allows for comprehensive site assessment without disturbance, while high-resolution imaging provides crucial insights into subsurface conditions. Furthermore, GPR enhances safety by identifying hidden hazards, reduces costs by minimizing exploratory drilling, and improves project outcomes through more informed decision-making. Overall, from initial site surveys to quality control and ongoing monitoring, GPR's versatility and accuracy make it a powerful tool for modern geotechnical work.

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A broadband provider in Alpharetta, Georgia, contacted a local leak seal contractor after discovering water infiltration through a crawl space wall during heavy rainstorms. Over time, cracks had developed, allowing not only water but also sediment to enter, creating substantial voids outside the fissures upon inspection. Given the sensitivity and high value of the equipment housed within the facility, eliminating all potential leaks in the crawl space became a top priority.

Powerful Polymers

The technicians chose Alchatek’s Spetec PUR HighFoamer to address this leak. This highly expansive polyurethane grout creates a robust, waterproof barrier, effectively sealing a wide variety of leaks without extensive excavation. Spetec PUR HighFoamer’s remarkable expansion capacity (40x-50x) ensures comprehensive coverage and a tight seal, making it ideal for projects requiring minimal downtime. Its NSF 61 certification guarantees safety for potable water applications, positioning this product as a versatile and cost-effective choice for leak sealing projects across various industries.

Painless Procedures

The repair process consisted of three efficient steps. First, the crew drilled through the concrete wall, installing zerk fittings into each hole for subsequent injections. Next, they used an electric airless sprayer to inject water into each fitting, ensuring proper activation of the foam. Finally, they injected Spetec PUR HighFoamer through these fittings. This created a curtain wall of polyurethane foam that effectively sealed the cracks, prevented further water ingress, and filled voids in the soil substrate.

Rapid Results

Within 24 hours, the technicians successfully sealed all leaks in the underlying crawl space. This injection process was completed in a fraction of the time required for a full membrane replacement. Months after the repair, following several heavy rainstorms, the facility manager confirmed that the crawl space has remained completely dry, with no recurrence of leaks.

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