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Case Study - Emergency Leak Repair at Lift Station

Posted by Kreg Thornley on Apr 30, 2025 10:00:00 AM

1. Banner - Emergency Leak Repair at Lift Station

2. Body - Emergency Leak Repair at Lift StationMid 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?

Download an Info-Packed Leak Seal Brochure!

Topics: All Posts, Seal Leaks

Case Study - Void Remediation Under Slab Foundation

Posted by Landon Feese on Apr 23, 2025 10:00:00 AM

Banner - Void Remediation Under Slab Foundation

Body - Void Remediation Under Slab FoundationSuburban 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?

Download the Info-Packed Geotech Product Catalog!

Topics: All Posts, Fill Voids

Case Study - Void Fill for Historic Preservation

Posted by Landon Feese on Apr 9, 2025 10:00:00 AM

Banner - Void Fill for Historic Preservation

Body - Void Fill for Historic PreservationAn 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?

Download the Info-Packed Geotech Product Catalog!

Topics: All Posts, Fill Voids

Case Study - Stopping Water Intrusion and Leveling Concrete

Posted by Landon Feese on Mar 26, 2025 10:00:00 AM

Banner - Stopping Water Intrusion and Leveling Concrete

Body - Stopping Water Intrusion and Leveling ConcreteSuburban 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?

Download an Info-Packed Leak Seal Brochure!

Download an Info-Packed Slab Lift Brochure!

Topics: All Posts, Lift Slabs, Seal Leaks

Case Study - Warehouse Slab Leveling

Posted by Landon Feese on Mar 5, 2025 10:00:00 AM

Banner-Warehouse-Slab-Leveling

Body-Warehouse-Slab-LevelingThe 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.

image-png-Nov-01-2024-01-47-59-8883-PM

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?

Download an Info-Packed Slab Lift Brochure!

Topics: All Posts, Lift Slabs, Stabilize Soil, Fill Voids

Reminder - Register for Alchatek 2025 Spring Geotech Training

Posted by Kreg Thornley on Feb 26, 2025 9:23:49 AM

Banner - Register for 2025 Spring Geotech Training v2

Body - Register for 2025 Spring Geotech Training v2Essential 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.

Click Here to Register NOW!

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.

Click Here to Register NOW!

Topics: All Posts, Lift Slabs, Stabilize Soil, Business Tips, Fill Voids, Deep Lock, Training, Municipal Resources, Events

Reminder - Register for Alchatek 2025 Spring Geotech Training

Posted by Kreg Thornley on Feb 20, 2025 10:01:44 AM

Banner - Register for 2025 Spring Geotech Training v2

Body - Register for 2025 Spring Geotech Training v2Essential 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.

Click Here to Register NOW!

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.

Click Here to Register NOW!

Topics: All Posts, Lift Slabs, Stabilize Soil, Business Tips, Fill Voids, Deep Lock, Training, Municipal Resources, Events

Case Study - Lifting Sunken Steps at a Mixed-Use Complex

Posted by Kreg Thornley on Feb 12, 2025 10:00:00 AM

Banner - Lifting Sunken Steps at a Mixed-Use Complex

Body - Lifting Sunken Steps at a Mixed-Use ComplexA 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?

Download an Info-Packed Slab Lift Brochure!

Topics: All Posts, Lift Slabs

Register for Alchatek 2025 Spring Geotech Training

Posted by Kreg Thornley on Feb 3, 2025 10:00:00 AM

Banner - Register for 2025 Spring Geotech Training

Body - Register for 2025 Spring Geotech TrainingEssential 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.

Click Here to Register NOW!

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.

Click Here to Register NOW!

Topics: All Posts, Lift Slabs, Stabilize Soil, Business Tips, Fill Voids, Deep Lock, Training, Municipal Resources, Events

Case Study - Solar Field Soil Stabilization

Posted by Andy Powell on Jan 29, 2025 1:18:32 PM

Banner-Solar Field Soil Stabilization

Body - Quality Lifting Foam Equals Less Job CallbacksAt a new solar field installation in North Florida, there were areas of bad soil where the H piles were not passing the loading and pull testing.  Solar panels lay at an angle, and if a strong wind is coming from one direction, it can try to “lift” the panel and pile.  Conversely, a strong wind coming from the opposite direction creates a downward force and can drive the supporting pile into the soil.

Powerful Polymers

The general contractor contacted the grouting specialists at Stable Soils and asked if they could use cement grout to try and lock the piles into place. Because of the tight confines between rows of piles, the specialist suggested a polyurethane permeation grout, Alchatek's AP Soil 600. The required installation equipment is more compact and it is a lot cleaner to install than cement. AP Soil 600 is moisture-activated (the same as Gorilla Glue), but it only takes about 5% moisture in the soil to make it react.  AP Soil 600 is heavier than water by design, and it is also hydrophobic.  As it soaks in, it pushes through the moisture and displaces it.  Once it cures, the sand is locked together. As the AP Soil 600 soaks into the damp sand, it reacts and produces carbon dioxide.  The CO² creates a swelling effect, driving the resin further into the sandy soil.

Painless Procedures

Around 20 test piles were installed at the solar field.  AP Soil 600 was injected right against the steel at a depth between 3 and 4 feet.  About 1/3 of the piles received 1-1/2 gallons.  Another third received 1 gallon, and the final third was injected with 3/4 of a gallon.  All of the piles passed the pull testing and compression testing.  The project was awarded, and around 4000 piles were injected in total.  It was a complete success.

Fast forward to 2022 at a massive solar field installation in Ft. Green, Florida.  Like many solar fields, it was not necessarily on the best land.  The site was a filled-in phosphate mine, so the soil was layered with bands of clay, sand, and mine tailings. Once again, there were sections of the solar field where the piles were not passing the pull testing, load testing, and lateral testing.

Polyurethane grouting was proposed but the manufacturer of the components wanted the proposed material to go through more vetting.  Primarily they wanted to know if the polyurethane grout would last for the 25-year service lifespan of the solar field.  Job histories, accelerated testing results, and chemical resistance data was provided, to their satisfaction.

For this project, the owners wanted to get engineers involved in the grouting portion of the installation.  Mathers Engineering was in charge, and they contracted Madrid Engineering to handle the soil testing. Testing showed that there were layers of clay and sand (referred to as zebra striping), so the grout was targeted in the sandy areas.  The thought was that the permeated sand would be locked in between layers of clay, thus improving both compression and pull strength. 

For this installation, the same three different volumes of AP Soil 600 were tested.  Once again, only 3/4 of a gallon was deemed sufficient to pass the testing, so that was what was used.  5000 piles were injected on this project, about 90% of them with AP Soil 600.  There were some areas of organic soils, and for those, AP Fill 700 was injected and tested successfully.  AP Fill 700 has over 30X expansion and works well at improving organic soils.  The work was completed in the Spring of 2022, and the solar field went into service.

Rapid Results

In the Fall of 2022, disaster struck Ft. Green, a location unfortunately positioned directly in the path of a Category 3 hurricane. The storm’s ferocity was evident as it swept through, leaving behind a trail of destruction in its wake. Trees were toppled, and the solar field, designed to endure winds exceeding 100 MPH, faced unprecedented damage. The wind from the hurricane’s eyewall proved too powerful, driving piles of solar panels into the ground. Despite their robust design, many panels were shredded, and a significant number of the piles suffered movement, highlighting the sheer force of nature’s fury.

Out of 5000 piles injected, only 9 showed any sign of movement.  The polyurethane grout was put to the test and passed with flying colors.  Currently, this field is going through the insurance claim process, but the testing for the repair method has already been completed.  The embedded piles were jacked back up to level and then grouted in place with AP Soil 600.  All of them passed the test; now, the field is waiting for the insurance to be worked out so the rest of the damaged piles can be glued back into place. AP Soil 600 carries the NSF / ANSI 61 rating.  It is safe for contact with potable water, and in this application, it will not leach any chemicals into the soil or groundwater.

Want more information on stabilizing soil with polyurethane?

Download an Info-Packed Soil Stabilization Brochure!

Topics: All Posts, Stabilize Soil