Alchatek Blog

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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The owner of an apartment complex overlooking Stephen Foster Creek in Gainesville, Florida, faced a critical issue. The embankment below showed signs of erosion, creeping dangerously close to the structures. With each passing day, the unstable ground crept ever closer to the foundations of the residential structures, posing a significant threat to both the buildings and the safety of their inhabitants. The situation demanded immediate attention and a robust, long-term solution to safeguard the property and ensure the well-being of its residents. The predominantly sandy composition of the local soil posed a challenge for stabilization. Consequently, the geotech firm Stable Soils was called in to address this pressing concern.

Powerful Polymers

After conducting a thorough site assessment and carefully evaluating various potential solutions, the team at Stable Soils identified AP Soil 600 as the optimal polymer for this challenging project. This choice was strategic. AP Soil 600 features low viscosity, a crucial characteristic that allows it to effectively penetrate and permeate sandy soil. Moreover, its impressive strength after curing promised long-lasting stability for the embankment.

Painless Procedures

Injection points were established in a zigzag pattern, spaced 18 inches apart. The team drilled 10 feet below grade to reach the optimal depth for soil reinforcement. Low-pressure injection was key to the operation’s success. This approach prevented the chemical from fracturing the soil or moving in unintended directions. The injection rod was slowly extracted, allowing for precise distribution of the polymer. One gallon was applied every five minutes and every vertical foot. In total, a 240-foot row of soil stabilization resin was installed.

Rapid Results

The impact of this intervention was immediately apparent. During a subsequent heavy rain event, surrounding areas suffered minor washouts while the stabilized soil remained completely unaffected. The stark contrast in performance served as a powerful testament to the effectiveness of the AP Soil 600 polymer and the precision of its application. The apartment buildings, once precariously positioned near the eroding embankment, now stand secure and protected, their foundations no longer at risk from the relentless forces of erosion.

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Clearwater, Florida public works administrators faced a critical stormwater infrastructure issue. A junction box was leaking through multiple pipe penetrations, compromising system integrity. City officials invited infrastructure repair specialists Helicon to address the situation. This project showcases an innovative solution to a common urban infrastructure challenge, enhancing stormwater management capabilities for municipalities.

Powerful Polymers

Helicon chose AP Fill 700 as the primary repair material. This polymer offers several advantages for stormwater system repairs. Firstly, it's ideal for point grouting, allowing for precise application. Additionally, the polymer features a quick reaction time, enabling rapid repairs. Perhaps most importantly, AP Fill 700 excels at filling voids. These voids, created around the junction box due to ongoing leaks, needed to be addressed to ensure a comprehensive repair.

Painless Procedures

Injection rods were utilized to deliver the polymer solution. These rods were pushed down from the surface to the depth of the leak, ensuring targeted application. As the injections progressed, they served multiple purposes. The polymer filled existing voids, stabilized the surrounding roadbed, and effectively cut off the leaks. To ensure complete coverage, the injection rods were raised in stages. At each stage, additional injections were performed. This methodical approach guaranteed thorough treatment of the affected area.

Rapid Results

The repair operation proved remarkably efficient. In just two hours, the entire job was completed. More impressively, the leaks were sealed immediately upon application of the polymer. This rapid resolution minimized disruption to the city's infrastructure and daily operations. As a result of this swift and effective repair, city administrators expressed high satisfaction with the outcome. 

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A developer in Miami Beach faced a significant challenge during the construction of a high-rise. Water began seeping into the foundation excavation, threatening the project's progress. The situation demanded swift action and expert intervention. Florida Foundation Systems was called in to address this critical issue. Traditional sheet pile shoring wasn't feasible due to the proximity of neighboring properties. The risk of damage from sheet pile installation vibrations ruled out conventional methods. The project involved multiple sections of 15x15 foot caisson foundations, crucial for areas with unsuitable soil conditions for shallow foundations. The primary objective was clear: mitigate water intrusion effectively.

Powerful Polymers

Florida Foundation Systems turned to an innovative solution: AP Fill 700. This polymer boasts unique properties that make it ideal for the task at hand. Its low viscosity allows for easy application, while controllable set times with a catalyst provide flexibility in use. Furthermore, the high expansion capabilities of AP Fill 700 make it exceptionally effective in filling voids and creating robust barriers.

Painless Procedures

The team targeted a specific zone for injection: 14 to 20 feet deep into a limestone base. First, they drilled holes and inserted pipes. Next, injections began at the 20-foot mark, creating a plug at the limestone base to block water intrusion. The process continued in a precise grid pattern across the entire area. Accuracy was paramount in this operation. One gallon of polymer was used per vertical foot. As the rods were slowly extracted, the team continued pumping at this rate. Consequently, the resin filled all the limestone fissures, ensuring comprehensive coverage and maximum effectiveness.

Rapid Results

The entire repair process was completed in less than a week. In that short time, all water intrusion was completely mitigated. Both the developer and general contractor expressed full satisfaction with the results. This swift resolution allowed the high-rise project to proceed without further delays. The success of this innovative approach not only solved the immediate problem but also prevented potential future issues, demonstrating the power of specialized expertise in complex construction projects.

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Executives at a prominent shipbuilding company discovered a significant problem at one of their largest shipyards. Soil was migrating from the landward side of the bulkheads into the water, resulting in erosion and compromising the stability of the dock slabs. The shipbuilding company enlisted Helms PolyFoam, a local specialist in soil stabilization and concrete repair, to address the issue. Helms PolyFoam collaborated with Alchatek to develop a comprehensive repair plan. Their strategy focused on two key solutions: joint sealing and slab stabilization, designed to reinforce the bulkheads and fill voids beneath the concrete slabs.

Powerful Polymers

For soil erosion prevention and stabilization, the contractor selected AP Fill 720, a highly expansive geotechnical polyurethane foam known for its effectiveness in sealing leaks and reinforcing loose soil. To address the large voids beneath the slabs and ensure their stability, they opted for AP Lift 475, a high-density geotechnical polyurethane foam designed for concrete leveling, void filling, and soil stabilization.

Painless Procedures

To combat soil loss, AP Fill 720 was injected at 24-inch intervals along the wall. This spacing allowed the material to flow and connect between injection points, forming a grout wall that stabilized the loose soil. The process created a water-impermeable barrier, securing existing soil and mitigating loose soil along an 8-10 foot test section of the wall. At each point, a 1/2-inch steel tube was inserted to a depth of approximately 30 feet.

For slab stabilization and void filling, AP Lift 475 was injected beneath the concrete in a zigzag pattern. Using 3/8-inch holes and 1/2-inch steel tubes, the resin was introduced into the soil. As it expanded, it compressed the soil, filled voids, and generated positive pressure on the slab.

Rapid Results

The joint sealing and slab stabilization methods yielded excellent results. They effectively reinforced the wall, stopped soil erosion, and halted void formation. The structural polyurethane resins used proved to be a durable and efficient fix.

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The Bowline is an iconic 16-story apartment development located in the Wickham suburb of Newcastle, Australia. There is a secant pile constructed wall system in the basement of this new building. However, an issue arose during the drilling process, where the overlaps were not interlocked correctly, resulting in voids and substantial leaks. This situation posed a risk of sinkhole formation under the main road, the light rail system, and neighboring properties. Furthermore, it led to the accumulation of a substantial water pool within the construction site, impeding further excavation efforts. Geotech contractors The Injection Experts AU were called in to solve the problem.

Powerful Polymers

The following materials were chosen for the project: AP Fill 720 was selected for full curtain injection behind the secant pile wall system to stabilize and seal the voids and leaks. Oakum was chosen to plug large voids and gushing leaks due to its ability to quickly stop high-flow water intrusion when soaked in resin. Spetec AG200 was chosen for injecting minor leaks because of its ability to penetrate and seal hairline cracks.

Painless Procedures

AP Fill 720 was pumped through an Alchatek PolyShark pump into 1.1m x 13mm injection rods. This was done to fill the voids left by escaping sand and water and to create a waterproof barrier on the back side of the secant piles. Oakum, soaked in resin, was packed into voids and large holes. This measure aimed to slow down the ingress of sand and water into the basement while excavation and injection processes were ongoing. Spetec AG200 was injected through 13mm packers to seal any fine hairline cracks and to provide touch-up sealing around the injection rods.

Rapid Results

The repair efforts were ultimately a success. Through the strategic use of polyurethane grouting methods, the voids and leaks in the secant pile wall system were effectively sealed. This meticulous process not only waterproofed the basement area but also mitigated the risk of sinkholes forming under the nearby road, light rail, and neighboring lots. As a result, the project was able to proceed safely without further excavation issues, marking a triumphant conclusion to a challenging endeavor.

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Beneath the seemingly solid surface of concrete slabs lurks a hidden threat that can compromise the integrity of an entire structure: voids in the supporting soil. Fortunately, polyurethane void fill foam offers an effective solution for identifying and repairing these issues, helping maintain the stability and safety of valuable property.

Detecting Potential Voids

Recognizing potential problems early is key to preventative maintenance. Watch for these telltale signs:

• Cracks in the concrete surface
• A hollow, drum-like sound when walking or tapping on the slab
• Noticeable dips or uneven areas in the concrete

Catching these indicators early can save significant time and money. Swift action typically results in simpler repairs and prevents small issues from escalating. Moreover, addressing problems promptly helps maintain the structural integrity of the concrete. By staying vigilant, property owners can often avoid more extensive and costly interventions down the line.

How Void Fill Foam Works

Polyurethane void fill foam offers several benefits:

• Adapts to various cavity shapes
• Resists shrinkage and settling
• Cures quickly, minimizing downtime

These versatile properties make polyurethane void fill foam an ideal solution for both residential and commercial applications, while also ensuring its effectiveness across a wide range of soil conditions and project requirements.

Risks of Ignoring Voids

Neglecting gaps beneath concrete slabs can lead to significant problems:

• Structural instability
• Increased accident risk
• More extensive and costly repairs if left untreated

Therefore, addressing these issues promptly helps protect both property investments and the safety of those using the space.

The Application Process

Applying void fill foam is relatively straightforward when done by professionals. The process typically involves:

1. Identifying problem areas through inspection
2. Drilling small access holes in the concrete
3. Injecting the foam beneath the slab
4. Allowing the material to expand and cure

This method usually causes minimal disruption. As a result, the repaired area can often be used again within hours.

Ensuring Long-Term Slab Stability

In conclusion, void fill foam represents an important tool in concrete repair. Its ability to stabilize structures efficiently makes it valuable for property maintenance. Thus, by hiring a qualified contractor, owners can ensure the durability and safety of their concrete slabs for years to come.

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

Want more information on stabilizing soil with polyurethane?

Engineering soil with polyurethane, an innovative and increasingly popular approach, encompasses both soil stabilization and concrete leveling techniques that offer minimally invasive solutions for a wide range of geotechnical and construction applications. These techniques involve injecting expandable polyurethane foam into problematic soils to fill voids, compact loose particles, and create a stable foundation, addressing instability and enhancing structural support. Engineers and property owners now have access to a solution known for its efficiency, versatility, and long-lasting results.

Engineering Soil: Stabilization with Polyurethane

Various factors can cause soil instability, including erosion from poor drainage, inadequately compacted fill dirt, freezing and thawing cycles, and the decay of buried organic material. If left unaddressed, these issues can lead to foundation settling, cracking, and other structural problems that compromise a building's integrity and safety. However, the polyurethane injection process fills voids, permeates and binds loose soil particles, and creates a stable, solid base for structures.

Engineering Soil: Concrete Leveling with Polyurethane

Moreover, polyurethane concrete leveling is an effective method for lifting sunken slabs. When concrete settles due to unstable soil conditions, technicians inject expandable polyurethane beneath the affected area. First, they drill small, strategically placed holes in the slab. Then, they inject the polyurethane. As the foam expands, it fills voids beneath the slab and lifts it to the desired elevation. Additionally, it compresses the surrounding soil, providing a stable base for the newly leveled slab.

Advantages of Polyurethane

Furthermore, polyurethane offers several advantages compared to other soil stabilization materials. For instance, the application process is minimally invasive, requiring only small injection holes. Additionally, the material expands and cures quickly, resulting in fast, long-lasting repairs. Moreover, polyurethane foams feature high compressive strengths, making them suitable for supporting a wide variety of structures.

Consult an Experienced Professional

To ensure successful soil stabilization, collaborating with experienced professionals who specialize in polyurethane injection is essential. For property owners, working with skilled contractors who possess the knowledge, equipment, and expertise to execute the stabilization process effectively is crucial. By partnering with a reputable contractor, property owners can achieve lasting soil stability and protect their structures.

Similarly, engineers may require the assistance of an experienced consultant when designing specifications for geotechnical projects. Alchatek's consultants provide valuable insights into material selection, injection techniques, and quality control measures. By engaging with a knowledgeable consultant, engineers can ensure that projects are designed and executed to the highest standards, thus maximizing the benefits of polyurethane applications.

In conclusion, Alchatek, a leading manufacturer of polyurethane repair materials, offers innovative solutions and technical support for property owners and engineers alike.

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

Want more information on soil stabilization and slab lifting?

Alchatek is a leading polyurethane grout manufacturer specializing in solutions for lifting slabs, stabilizing soil, and sealing leaks. Additionally, we offer expert technical support with decades of industry experience. Consequently, this helps clients build their businesses and complete crucial jobs successfully.

Cutting-Edge Products and Solutions

We take pride in providing advanced construction technologies that meet clients' needs and exceed expectations. Furthermore, Alchatek is a customer-oriented company manufacturing products in the USA, with a growing network of sales and service resources. We offer a wide range of polyurethane grout products and solutions as a trusted partner.

Specialized Divisions for Specific Needs

Our company is organized into three specialized divisions in order to better serve customers:

• Leak Seal Division: This division offers a complete line of products for sealing hairline leaks, gushing leaks, and multi-leak surfaces. These solutions prevent water ingress through concrete infrastructure like parking garages, culverts, basements, foundations, and sewer manholes.
• Geotechnical Division: This division offers a complete line of single-component products for soil stabilization and two-component products for concrete lifting, void filling, and infrastructure stabilization.
• Seawall Repair Network®: We operate the only national network of certified contractors for waterfront barrier repair, preservation, and protection. Seawall Repair Network® proprietary methods employ environmentally friendly, marine-safe materials, providing a non-destructive seawall repair solution at 80% less cost than replacement.

Unparalleled Technical and Marketing Support

Our industry-leading technical support team averages decades of experience and is incredibly responsive. Moreover, our marketing department supports qualified customers with product illustrations, customized brochures, truck graphics, educational videos, and guidance on strategies like online lead capture and internet advertising.

A Polyurethane Grout Manufacturer Focused on Customer Success

At Alchatek, commitment to customer success is deeply ingrained in our company culture. Likewise, our entire team understands the relationship between your success and ours. Therefore, we go to great lengths to assist customers and ensure their polyurethane grout projects succeed.

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The Jack Attack and the PolyBadger are practical tools designed to adjust and level concrete surfaces. These concrete lifting devices enhance the efficiency of slab lifting tasks, making them suitable for a wide range of situations. Their user-friendly features efficiently streamline the concrete lifting process.

Jack Attack Leverage Device

The Jack Attack features a triangular steel frame to leverage small to medium-sized slabs while lifting or stabilizing with polyurethane. An integrated 8,000-pound jack applies force to rotate and level the slab. This user-friendly device is easy for one person to operate.

PolyBadger Mobile Lifting System

The PolyBadger offers a cost-effective alternative to conventional 20-foot polyurethane slab lifting trailer rigs. Its setup is straightforward, requiring minimal equipment. The entire system is remarkably compact, fitting effortlessly into the back of a pickup truck, making it a convenient and practical choice.

Simplified Material Handling

The PolyBadger avoids the need to handle and dispose of the large 50-gallon drums typically used in polyurethane slab lifting. Instead, it uses smaller, disposable 10-gallon sets that are easier to manage.

Enhancing Productivity

Featuring few moving parts, the PolyBadger reduces maintenance needs and downtime, thereby increasing job site productivity. Its straightforward design simplifies use compared to other systems.

Concrete Slab Lifting Devices

The Jack Attack System and the PolyBadger enhance the efficiency and outcomes of concrete lifting tasks. These tools streamline operations and ensure smooth, professional results.

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