Alchatek Blog

Not all two-component polyurethane lifting and stabilizing foams are specifically designed for wet environments.  In most situations when you are injecting polyurethane foam into the ground, there is a high probability that the environment is going to be wet.  You need to be confident that the foam will react and retain the desired properties in these wet environments.  If the foam you are using is not specifically designed for wet environments, then you may be cheating yourself and your customer out of the best possible results.

All polyurethane foams are going to undergo a density change when introduced to water.  This is precisely because the isocyanate (A component) in polyurethane reacts faster with water than it reacts with the polyol (B component).  Some will undergo drastic changes and some minor changes.  It is important to feel confident that the foam you are using will only undergo minor changes.  The density of the foam is very important because density correlates to foam strength, and you are relying on that strength to support the structure you are lifting or the soil you are stabilizing.

All Alchemy-Spetec products are formulated to achieve minimum density changes when introduced to wet soil.

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

Over my many years of consulting with customers on jobs, I have pumped, shot, spilled, splashed, sprayed, poured and injected polyurethane foam into every imaginable type of concrete structure known to man. Most of it has ended up where it was supposed to go. But some of it did not.

Some of it ended up on my clothes, my skin, and my hair. That never bothered me (well, maybe the resin on that brand new button down shirt bothered me a little). What is really frustrating is when it stains the concrete you are trying to fix. Your job is to repair something for your customer, and if you are not careful, you can make it look worse than before.

A few years ago I asked our chemist to develop a water based solvent for cleaning out two component impingement style injection guns (such as our MixMaster Pro gun). I wanted the product to be water based so that it could be dispensed directly into the environment with no negative effects. I also needed it to be thick enough to push reacting foam out of the gun.

After I saw what he came up with, I realized it could probably be used as a barrier to prevent polyurethane from staining concrete. After a little testing and tweaking, I realized it would work.

AP Flush 125 is a concentrated product that you can mix with 3-5 parts water. It can be sprayed onto concrete, wood, metal, or plastic and creates a barrier layer that prevents polyurethane foam from sticking to and staining the surface. You can brush it on or spray it on with a pump up garden sprayer.

Our AP Lift customers spray it right out of the MixMaster Pro gun onto concrete surfaces as they are moving from injection point to injection point. They also saturate cracks and joints that foam may come out of. This has the dual protection of keeping stains off the concrete and helps reduce binding of the concrete that can impede the lifting process.

On hot, sunny days you may have to apply it again if the water evaporates out of the system, but overall it really works wonders. We have used it on lifting jobs, soil stabilization jobs, and leak seal jobs. Now the spray foam insulation contractors are starting to use it to protect surfaces adjacent to their work areas.

Next time you are using polyurethane foam on or near a surface you don’t want your foam to stick to or stain, try a pail of AP Flush 125. One pail of concentrate can give you up to 25 gallons of protection.

Want more in-depth info on procedures and products?

After three decades in this industry, I still find myself in awe of what polyurethane foam can do.  From sealing massive dam leaks to stabilizing airport runway slabs to lifting entire buildings – the feats contractors achieve with this stuff is astonishing.  Yet some people who are new to this technology have a hard time understanding how a mere “foam” can be ideal for these most demanding of applications.  Or maybe they wonder how safe it is. 

The irony is, whether you think you are “new” to this technology or not – you’ve been surrounded by polyurethane all your life.  Sometimes an understanding of the past can provide more confidence for moving forward into the future.  So if you can’t quite grasp how “foam” has been developed to the point that it can lift a building – or you wonder how safe it is – pay close attention to this story.

Dr. Otto Bayer first made polyurethane foam in Leverkusen, Germany in 1937.  Polyurethane was initially used as a cheap replacement for rubber.  Widespread use began in World War II, when many other materials became scarce.  Polyurethane use quickly spread as a key component in many products, from specialized paper to protective military garments to gloss finishes and protective coatings.

In the 1950s, many companies such as DuPont, BASF, Dow, and Union Carbide started producing polyurethane for an even wider variety of applications including adhesives, insulation and foam upholstery cushions.  In the 1960s the Bayer company (no relation to Dr. Otto Bayer) exhibited an all-plastic car, parts of which were made with polyurethane. 

In the early 1970s, the introduction of polyurethane skateboard wheels as a replacement for the old metal ones completely revolutionized the sport, as the new wheels allowed for high impact activities such as jumping off of ramps.  In the 1980s, the first mass produced plastic-body automobile – the Pontiac Fiero – was made with the use of polyurethane technology.

Today polyurethanes can be found in an infinite amount of products including furniture, clothing, shoes, beds, moldings, etc.

In the 1960s, 3M Company in the U.S. and Takanaka in Japan both introduced polyurethane grouts.  3M’s product was called Elastromeric Sewer Grouting Compound.  As the name indicates, it was intended for use in underground utilities.  Takanaka’s product was called Takanaka Aqua-Reactive Chemical Soil Stabilizer (TACSS).  As the name indicates, it was intended for use in soil stabilization projects.  In the early 1980s, DeNeef obtained the rights to TACSS and began distributing polyurethane grout worldwide.  By the mid 1980s, there were almost a dozen manufacturers of polyurethane grouts.  I got my start pumping 3M 5600 to seal cracks in the Atlanta subway system back in 1985.  I was amazed at what it could do back then, and I am still amazed at what our products do today.  3M exited the business many years ago.

In the last few decades, polyurethane grouting has become a widely accepted method for sealing leaks, stabilizing soil and lifting slabs.  Many innovations have been made, including closed cell hydrophobic polyurethanes and the use of two-component foams in geotechnical engineering.  Polyurethane’s advantages over the old school approach of cement grout repair is covered thoroughly in our blog post Polyurethane vs. Cement for Slab Jacking.

Want more in-depth info on polyurethane and chemical grouting?

As I said previously in my blog post Stop Erosion Through Your Seawall with Polyurethane:

When it comes to seawalls, there is a lot more to learn than meets the eye. Seawalls are like living, breathing things: especially in the way that they are designed to function. But like all living breathing things, they have a finite lifespan. For many of them, it's a mere 20 – 30 years. Depending on where you live, replacing a seawall can cost anywhere from $150 to $500 per foot. That's enough for some homeowners to choose to move instead of rebuilding their seawalls. Today however, signs of seawall distress can be solved before they get too bad through the application of polyurethane grouts to seal leaks, fill voids, and stabilize the surrounding soils.

Here's a glimpse of polyurethane seawall repair in action. Hang 'Em High Charters in Key Colony Beach, Florida discovered massive voids inside their seawall. Watch closely as they are repaired with AP Lift 475 foam...

Want more info on polyurethane seawall repair?

In a recent media interview, I was quoted as follows: “Ultimately, the customer is the property owner, somebody who’s got a problem. Even though we’re selling to contractors, we kind of all have to be on the same page.” That view has motivated us to pay close attention to what contractors, engineers AND property owners are most concerned about regarding the use of polyurethane. Over the years, we’ve noticed three main questions that arise over and over again:

1. Are the polymers strong enough?
2. Are they easy to install?
3. How quickly can the job be finished?

So we’re going to take a look at each of these three core issues in detail…

Powerful Polymers

Concrete Leveling Foams

In my blog post Slab Jacking With Polyurethane Foam – How Strong is Strong Enough?, I point out that the National Home Builders Association and the International Building Code list stiff clay as having a 4,000 lbs per square foot load bearing capacity and crystalline bedrock as having 12,000 lbs per square foot capacity. Our lifting foams have load bearing capacities of 7,200 to 14,000 lbs per square foot after curing in a free rise state. 

When Alchemy-Spetec foams cure in a confined state underground, that bearing capacity has been known to be even stronger. Testing data in the lab shows that our lifting foams will increase in compressive strength: In a space confined 25% by volume there will be an increase of 31% in psi and in a space confined by 75% there will be a 79% increase in the psi.

The Alchemy-Spetec lifting foams are used to level airport slabs supporting jumbo jets, heavy equipment, building slabs supporting tremendous loads, and even railway slabs supporting the heaviest freight trains.

Leak Seal Resins

Alchemy-Spetec leak seal resins have been used in many applications, including shutting down a 2-million gallon per day leak at a water treatment plant. The leak was reduced from 1,700 gallons per minute to just 10 gallons per minute (attributed to the many vintage valves and fittings that are still present at the plant). They are also used in other applications such as curtain wall grouting.

Soil Stabilization Resins

Unstable, eroded, or loose soil around infrastructure can result in settlement and damage to the structure. Voids can be filled, seawalls remediated, soil consolidated, and water migration halted by injecting the soil with Alchemy-Spetec soil stabilization resins. In my blog post Soil Stabilization Products Prevent Cave In Beneath Busy Intersection, I profiled a powerful example of AP Fill 700 in action. Inspectors in Orange County, Florida found a depression in the middle of a busy intersection that was due to an underground sewer line that wasn’t sealed. 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. 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. We devised a solution for their crew to use the versatility of AP Fill 700 as both a permeation and void filling grout.  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.

Orange County Utilities Supervisor Paul Morrison has been enthusiastic about AP 700 since the first time he tried it out on a severe manhole leak, when he had this to say…

“Based on our extensive prior experience, we expected to use at least five to ten pails to stop this leak. With Alchemy-Spetec material we were able to do the job with 1/10th of that amount. Their product will save our crews a lot of time and labor, and save the taxpayers of Orange County a lot of money.”

AP Soil 600 is one of the most versatile permeation grouting products on the market. It can be characterized by its single component, moisture activated, hydrophobic, and low viscosity qualities. It can fortify sandy soil to strengths approaching 2,000 psi.

Painless Procedures

As I never fail to point out, application procedures for Alchemy-Spetec products are relatively painless. The installation process is very clean compared to replacing the structure or repairing with cement grout.  Polyurethane is lighter than cement, so it doesn’t sink. Alchemy-Spetec products do not shrink after installation. The closed cell structure makes these resins impermeable. 

Rapid Results

Application of polyurethane is usually less expensive than replacement. Polyurethane concrete repair is also less time consuming. Any structure repaired with Alchemy-Spetec products is usually ready for use 45 minutes after application.

There you have it – the three most critical issues for contractors, engineers and property owners regarding polyurethane concrete repair. By staying focused on these concerns we constantly remind ourselves WHY we do what we do. We do it for YOU.

Want in-depth info on polyurethane infrastructure repair resins?

As a technical consultant, I often assist customers when they're put to the test with difficult jobs. That's why we go out of our way to provide the powerful polymers and painless procedures they need to achieve the rapid results those projects require. For an in-depth dive into what we mean by powerful, painless and rapid - see this blog post I wrote awhile back. Then watch the video below to see powerful polymers, painless procedures, and rapid results in action... 

Want more in-depth info on Alchemy-Spetec products?

Poor compaction, water erosion, broken pipes, and organic material in the soil can all lead to settling of a foundation or a roadway.  Traditional slab lifting can bring concrete and structures back into place but it doesn’t necessarily address the underlying issue or guarantee a long term fix.  Other methods of addressing deep soil issues require heavy equipment, extended down time, 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.

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.

For a detailed explanation of the process, watch the animated video below... 

 Want more information on the Deep Lift process?

According to the Guinness Book of World Records, the honey badger is the world's most fearless animal. With ultra-thick skin and top of the line fighting instincts, this creature is not to be messed with. It boldly goes where similar animals consistently fear to tread. 

Let's take a deep dive into why Alchemy-Spetec's smallest slab lifting system, The PolyBadger, is named after this incredible animal. As Alchemy-Spetec regional manager Andy Powell mentions in this previous blog post...

"The Alchemy-Spetec PolyBadger lifting system is tough and compact. This system is an affordable entry-level slab lifting option for new contractors, as well as an extremely portable addition to the experienced contractor’s arsenal. The PolyBadger is a lot less expensive than your standard 20-foot trailer rig. The setup is simple and requires minimal equipment. The entire system can easily fit in the back of a pickup truck!"

Like the Honey Badger, the PolyBadger lifting system is both Tough and Compact

The PolyBadger slab lifting system is durably built and designed to go where other lifting systems simply cannot venture. Here's a quick rundown...

• The PolyBadger is smaller in size than most of the competition, at 30" wide and 48" long. Now that's what you call portable!
• This is one of the few systems powered through a common 120-volt wall outlet (vs the usual 240-volt requirement). Compatibility with common wall outlets exponentially increases your location possibilities.
• Essential elements (heaters, electronics, auto calibrator) are self-contained and protected in the cabinet for extra portability.  
• The cabinet is constructed from powder coated carbon steel and the frame is constructed from carbon steel box tubing. 
• The entire system is very maneuverable, resting on two swivel and two fixed 6-inch pneumatic castor wheels.  The wheels are are filled with light weight polyurethane instead of air, so they don't go flat. 
• The hose is built to last with a Teflon core and a stainless-steel braid. The system can operate with up to 200 feet of hose.

One last very important point:

Honey badgers are also mentally tough. They've been known to build stools with rocks in order to get over walls even break through locks on food freezers! Nothing stops them! The PolyBadger system's auto calibrator provides similar qualities to keep it going through thick and thin. As Andy Powell mentions in this previous blog post...

"The genius of the PolyBadger is the auto calibrator. It keeps the flow of A-side and B-side slab lifting material on ratio, eliminating the possibility of crossover clogging in the gun or the whip hose. The two low-pressure transfer pumps and auto calibrator are literally the only moving parts in the whole system. That means less downtime, less maintenance, and more productivity on the job."

Want more information on the Alchemy-Spetec PolyBadger lifting system?

Salt corrosion, tidal action, currents, boat wakes, storm surges and sometimes hurricanes all deliver a constant beating on the seawall. Contrary to popular opinion, many of the forces also come from the side of the wall facing the land. Did you realize that rainfall/storm events create more hydrostatic pressure than rising and falling tides? Every time it rains or the irrigation system runs, and every time the tide goes out; all of the groundwater above the waterline needs a place to vent or equalize. Massive pressure can build up if that water is trapped, making it impossible for it to drain into the sea or storm water system. That is a recipe for disaster which can easily be avoided with proper surveillance. Let's take a look at some of the external signs a seawall is in need of repair... 

Small Sinkholes Near the Wall

In landscaped areas, evidence of soil erosion is often quite obvious.  In this photo you can see that there is a small sinkhole developing at the inside corner of the seawall.  Some types of grass will actually keep larger sinkhole from being seen.  So check thoroughly.

Voids Near the Edge of the Wall

Obvious settling soil should have gotten the property owner’s attention in this case.  Too often, they ignore the warning signs until something more catastrophic occurs.

Cracking Concrete

Here, ground penetrating radar revealed loose soil zones beneath this concrete apron outside of a fish processing facility.  The steel sheet pile walls were losing soil and huge voids had developed.  Evidence of cracking concrete was not enough to get their attention as is often the case.  However, when a Lull forklift went through the slab, everything but foot traffic was prohibited from being on the apron.

Damage to Structures Up to 100 Feet Away

Capillary pathways of leakage can be found over 100 feet away from the visible leak, depending on the soil matrix.  The back of this pool deck had dropped about 6” already as the yard slumped towards the leaking seawall.

Causes of Seawall Damage – An Overview

Correct construction of a seawall will include a drainage system to handle the bulk of the water that comes from rain in addition to check valves, weep holes, or seams to handle the daily influx and outflow from tide and wave action. Although these systems are designed to retain the soil behind the seawall, over time the materials degrade or can be disturbed by settling.

This is a direct symptom of normal wear and tear from the natural environment and is unavoidable. The result is a loss of soil and the inevitable sinkholes and / or low spots that will occur along the wall. Other times, the weep holes and vents become clogged and the water has no way to escape except to force its way down and out from underneath the base of the wall. When this occurs there will again be sinkholes and sometimes wall failure.

Conclusion

When signs of sinking ground are observed, you can almost be sure there are voids below that are that are not seen from the above the surface easily and are indeed dangerous. Sometimes these voids can extend below an adjacent patio, dock, or pool deck, causing those to sink and crack as well. The key to keeping those problems at bay is to actively anticipate them.

If you live along the water, it is always going to be man against nature. That seawall is keeping your property from damage and from disappearing altogether. The key to extending the life of your seawall is the advanced polyurethane technology from Alchemy-Spetec. For more on the repair process itself, read An In-Depth Look at Polyurethane Seawall Repair. It's fast; clean, easy to install, and most of all, effective.

Want more in-depth info on polyurethane seawall repair?

In the previous post, An In-Depth Look at Polyurethane Seawall Repair – Part 1, we looked at causes of seawall deterioration, typical evidence of deterioration to look out for near seawalls, and the three most common seawall repair options: excavation, cement grout repair and polyurethane repair.

Now we’re going to take a deep dive into the qualities, applications and advantages AP Fill 700 – the Alchemy-Spetec product most typically used for seawall repair. We’ll also share a case study on a seawall crisis at an upscale marina that was resolved by contractors using AP Fill 700.

AP Fill 700 Advantages

AP Fill 700 is a single component, water activated, hydrophobic, low viscosity, closed cell polyurethane injection resin. In addition to seawalls, it’s a proven polyurethane concrete crack sealant for all types of structures. From our experience advising contractors, we’ve found it to be the most cost effective method for repairing seawalls.

Here are some of the advantages it has over other polyurethanes:

Lowest viscosity on market

AP Fill 700 has a viscosity of 110 to 130 cps. This allows for getting into thin cracks.

Closed cell, 0% permeability

The closed cell structure of this foam allows for ZERO percent permeability. No compromising of the repair material to worry about.

Adjustable set time

Adding various amounts of catalyst to adjust the set time allows for custom application of the material to address the specific nature of the seawall problem. A longer set time allows for the material to permeate and soak in around the structure before setting up. A shorter set time makes the material set up more immediately, which may be appropriate when there are large voids to fill or gushing leaks to stop.

Single component

This particular product does not require a “B” side to react with before setting up. This allows for simple, efficient installation.

Phthalate free

Some companies use phthalates in their polyurethanes. Because of their environmentally unfriendly nature, it’s not even legal to manufacture phthalates in the United States. Companies using them have to import them from overseas. Needless to say, AP Fill 700 does NOT contain phthalates – a known marine pollutant.

Approved for contact w/ drinking water

As mentioned in the previous post in this series, AP Fill 700 has been NSF certified for contact with drinking water. So, obviously installation in recreational or commercial bodies of water is no problem from an environmental perspective. Read more about NSF certification in the blog post Alchemy-Spetec's NSF Certification Spells Environmental Protection.

High bonding characteristics

Once AP 700 is installed, it’s NOT coming off. The adhesive qualities are unparalleled. This contributes to the vast advantage polyurethane has over cement grout when it comes to durability.

More about AP Fill 700

This material is designed to be efficiently delivered into all sized gaps and eroded depressions. It reacts with water or moisture in the soil and expands to fill the voids. It’s compatible with any seawall material: concrete, steel, vinyl, etc. And it permeates the most sandy of soils to form a solid, strong, watertight mass. It sets in less than 10 minutes. By being impermeable to water once in place, the likelihood of future erosion is vastly diminished. 

AP Fill 700 Applications

In addition to seawall repair, there are many other general applications for AP Fill 700. Here a few to keep in mind…

• Cutting off low and high flow leaks
• Concrete void / crack filling for all structures
• Cutting off underground water flows
• Soil stabilization
• Filling voids under concrete slabs
• Encapsulating contaminated soils

Durability

Leading experts in the polyurethane industry predict that this material lasts for hundreds of years once installed. Polyurethane is made from similar materials as plastic. There’s a reason why people campaign against the dumping of plastic waste in the middle of the ocean: it will be there forever. The edge of the ocean, properly installed as part of a seawall repair, is a much better place for it. And, yes, it tends to last forever.

Powerful

If needed, AP Fill 700 can quickly shut down leaks of thousands of gallons per minute. Rapid expansion makes it great for filling voids, wide cracks, pipe joints, pipe penetrations. Originally developed over 30 years ago, and continuously improved since, this technology has one of the longest histories of success in the field among uses of polyurethane foams

Efficient Installation

Results are immediately clear due to the visible exiting of sea water when the foam is injected. The low viscosity allows it to be injected into hairline, expansion joints and smaller cracks as well. AP Fill 700 is field proven in “curtain grouting” (earthen dam seepage protection), and consolidating loose soils.

Case Study

Let’s close out this two part series with a look at polyurethane seawall repair in action…

Situation

Owners of an upscale marina in Riviera Beach Florida noticed cracking in the slabs outside of their main boathouse. They also noticed that the slab had settled in several areas. The slabs in question were subject to heavy dynamic loads as a large forklift traversed the area, bringing 40' motor yachts in and out of the boathouse. Contractors came in and did a site evaluation, drilling holes to probe beneath the slab and also a sub surface investigation of the seawall to see if soils were being lost.

Solution

Most of the joints in the seawall were leaking sandy soil out - resulting in a void beneath the concrete slabs, which then cracked and settled. AP Fill 700 was specified to seal the concrete panel joints. It was injected behind the panels in the area of the joints, both vertically through the concrete, and horizontally from the water side of the panels. Proper venting was then installed to relieve hydrostatic pressure.

Results

The sandy soils have been stopped from escaping from behind the seawall. The concrete slabs were then lifted back into place with a combination of helical piles and AP Lift 475. There are no longer any voids beneath the slab so it is not flexing and cracking any longer. This marina was saved from a much larger, more catastrophic failure.

Want more info on polyurethane seawall repair?