Alchatek Blog

A dam at the outflow of Lake Lulu in Winter Haven, FL is small in size but plays a large role for the Southern Chain of Lakes: flood control for surrounding communities, water level management for recreational use, and local water supply support.

The dam is classified as a Significant Hazard Potential structure, meaning failure would not be expected to cause loss of life but could cause serious property damage, environmental harm, and community disruption. During the latest inspection, engineers identified structural and geotechnical issues requiring immediate stabilization to avoid further deterioration.

Initial Assessment

Emergency spillway. Cracks in end walls, holes on the upstream side, and a major void under the downstream apron caused by soil erosion. Without repair, water could flow beneath rather than over the spillway, leading to structural failure.

Main spillway. Multiple long cracks extending from crest to waterline, prior failed patchwork, vegetation growth in cracks, exposed aggregate, and joint separation.

Constructed in the 1940s, the dam has undergone various repairs over the decades, but age-related deterioration and recurring seepage have reduced its structural integrity. While long-term replacement is inevitable, immediate action was needed to stabilize the structure through hurricane season and allow time for engineering and funding of a full replacement.

Proposed Solution

Helicon developed a dual-phase stabilization program addressing both short-term safety and long-term planning needs, using two polyurethane products.

Spillway grouting. Crews injected Spetec GT500, a one-part hydrophilic chemical grout, into cracks, holes, and voids within the spillways to seal leaks, restore concrete integrity, and prevent soil migration.

Soil stabilization and erosion protection. Crews injected AP Fill 720, a hydrophobic grout, beneath concrete structures where erosion had carved out hidden voids, filling subsurface cavities, restoring the foundation, and blocking future water intrusion pathways.

Procedures

1. Inspected both spillways to locate cracks, holes, voids, and joint separation
2. Injected Spetec GT500 into cracks and holes in the emergency spillway end walls and upstream face
3. Injected Spetec GT500 into the main spillway cracks running crest to waterline
4. Injected AP Fill 720 beneath the concrete structures to fill erosion voids, including the void under the downstream apron
5. Confirmed subsurface support and sealed water intrusion pathways

Results

• Immediately stabilized both the emergency and main spillways
• Filled voids and restored subsurface support, protecting against further erosion
• Extended service life of the dam until full replacement can be designed and funded
• Ensured the structure can safely function through upcoming storm events

Want more information on sealing leaks with polyurethane?

Valley National Bank, in the heart of downtown Tampa, planned a major building expansion. The design called for a new elevator shaft, a structural element connecting multiple floors and relied upon daily by employees and clients.

Before construction could move forward, it was essential to confirm the foundation soil beneath the shaft could handle the load and vibration over the long term. In Tampa Bay's urban and coastal zones, unpredictable sandy soils pose serious risks for structures without proper stabilization. Valley National Bank turned to Helicon, Florida's trusted name in foundation repair, soil stabilization, and polyurethane grouting.

Initial Assessment

Helicon's site evaluation identified two hurdles.

Tight access. The shaft sat inside an existing, older building downtown. Narrow entryways, low overhead clearance, and the confined urban setting meant traditional foundation repair equipment would not fit. Helicon's polyurethane injection equipment is engineered for low-footprint, tight-access work where heavy machinery is not an option.

Sandy, unstable soils. The subsurface was primarily loose, granular sand, prone to shifting under heavy loads. Left unaddressed, it could cause uneven settling of the shaft, leading to operational problems and possible structural damage. The solution had to strengthen the sand without adding excessive weight, distribute load uniformly beneath the shaft footprint, and install without major disruption.

Proposed Solution 

Helicon selected AP Soil 600, a one-part, low-viscosity polyurethane permeation grout engineered for sandy soil stabilization. Low viscosity allows deep penetration into loose soils. The material is light relative to its strength, binds soil particles to reduce settlement risk, and resists water infiltration in Florida's wet climate. AP Soil 600 is widely used where high load-bearing capacity is required, including elevator shafts, bridge abutments, and commercial foundations.

Procedures

1. Evaluated the site to confirm subsurface conditions beneath the planned shaft footprint
2. Designed a grid of 14 injection points beneath the footprint
3. Drilled each point to 5 to 6 feet, targeting the soil layers most at risk of movement
4. Injected AP Soil 600 through the grid, ensuring coverage without gaps
5. Permeated the sand, locking it into a dense, load-bearing mass
6. Confirmed uniform support across the foundation before vertical construction began

Results 

• Delivered a stable base for both the static weight of the shaft and the dynamic forces of daily elevator operation
• Eliminated voids and weak points, increasing soil density and shear strength
• Installed quickly and cleanly with minimal disruption
• Kept construction on schedule
• Treated the soil before vertical construction, heading off future settlement and repairs

Want more information on soil stabilization?

How Atlas Structural Expanded from Limited Commercial Work to Large-Scale Grout Projects

The Challenge

Atlas Structural already had a strong, stable business.

They were experienced, capable, and consistently performing excellent residential work and some commercial work.

But they had a plan. Specifically, they wanted to expand into large-scale projects in a big way.

To get there, they recognized the need to operate at a different level.

This meant:

• Taking on more complex scopes

• Positioning for larger, higher-margin projects

• Competing in a more demanding environment

The opportunity was clear. 

The next step was aligning their approach, tools, and positioning to consistently win that level of work.

What They Discovered

The limitation wasn’t demand.

The opportunity for larger commercial work was already there.

Larger commercial projects require:

• Advanced project evaluation 

• Expert technical positioning 

• The ability to clearly demonstrate scope and risk

Atlas recognized that competing at this level meant refining how they assessed, presented, and positioned their work.

This wasn’t about ability.

It was about operating at a higher level of precision and clarity.

With the right approach, they could confidently pursue—and win—the larger projects they were targeting.

The Shift

Through Alchatek support, Atlas Structural was introduced to new application capabilities and tools.

They received:

Application and product training 

Guidance on expanding into new types of work 

Hands-on experience using the Pagani DCP

But more importantly—

They learned how to use the DCP not just as a testing tool…

But as a sales tool.

This allowed them to:

Better diagnose site conditions 

Clearly communicate problems to customers 

Justify larger, more complex solutions

The Impact

The results were immediate and significant. Atlas Structural secured a bridge project that became:

The largest chemical grout project in their company’s history—5x larger than anything they had done before.

This wasn’t incremental growth.

It was a step change in the scale of work they could pursue and win.

What Changed

The biggest shift wasn’t just technical.

It was strategic.

They went from:

• Uncertain about bidding large commercial work → To confidently pursuing and winning it

They gained:

• A new level of confidence 

• A stronger way to evaluate and present projects 

• The ability to compete at a much higher level

The DCP became more than a tool—

It became a way to win work.

The Takeaway

This wasn’t about doing more of the same work.

It was about doing bigger work.

With the right tools and support, Atlas Structural didn’t just grow—

They broke through into a new level of commercial opportunity, winning projects 5x larger than anything they had done before. 

Break YOUR revenue ceiling. Consult with an Alchatek business growth expert.

Master the Application.

Win the Work.

Get Paid.

Registration Fee: $845
Each Additional Participant: 50% off ($422.50)
50% off deal expires end of day September 30.

Day 1: The Deep Lock® Application Process

Master the technical foundation that allows you to confidently diagnose, design, and deliver Deep Lock® projects safely and correctly.

On Day 1, you’ll gain expert instruction on site evaluation, material selection, rig setup, and injection strategy from Alchatek's Andy Powell and Colt Hullander — two seasoned industry veterans with decades of combined field experience. This is not just theory — you’ll learn the exact processes and decision-making frameworks that ensure predictable results, controlled risk, and successful project execution in both residential and commercial applications.

• How Deep Lock® works and when to specify it

• Site evaluation & diagnostics

• Material selection, rig setup, and safety essentials

• Injection patterns, pressure/flow control, and QA

• Step-by-step walkthroughs of real job scenarios

Day 2: The Deep Lock® Sales Process

Learn how to win more Deep Lock® deals — with more margin and at higher average sales prices.

On Day 2, you’ll gain proven sales frameworks from Gene McNaughton, Sales Expert and author, who built Geobear USA from the ground up and generated over $4 million in Deep Lock® residential and commercial sales. This session goes beyond theory — you’ll learn the exact strategies, positioning, and closing techniques used to consistently secure high-value projects.

• How to find Deep Lock® opportunities

• Site evaluation & client qualification

• Estimating, scopes, and pricing essentials

• Proposal presentation, negotiation, and contracting

• Step-by-step walkthroughs of the lead to payment cycle

(Hotel rates available soon. Info sent upon registration. Daily transport from hotel to event provided.)

A seawall rarely fails all at once. It starts small, a hairline crack near the waterline, a soft spot in the yard, a slight lean nobody notices until the pavers start pulling apart. The price of the fix grows every day you wait, because the damage behind the wall keeps progressing even when the surface looks stable. 

What a Failing Seawall Actually Costs

There's no single number that fits every seawall repair, but the relative cost structure is predictable, and it's worth understanding before you call anyone.

Targeted repair, filling the voids and stabilizing the soil behind the wall, is by far the least expensive path when caught early. Patch-and-repeat cosmetic fixes look cheap on any single invoice, but they don't stop the underlying erosion, so the cost adds up every time you have to call someone back. Full demolition and replacement sits well above both, often by a wide margin, because it involves permitting, heavy equipment, and rebuilding the structure from the ground up rather than restoring what's already there.

That gap between options is significant enough to change how a homeowner should think about a small crack today: fixing it now, while it's still a targeted repair, is not a close call against waiting until it becomes a replacement.

Exact costs vary by region, wall material, soil conditions, and severity. A trained contractor can give you an accurate number after a site evaluation.

The Root Cause: Why Seawalls Fail From the Inside Out

Most seawall problems don't start at the wall. They start behind it.

As water levels rise and fall against the wall, whether from tides, wave action, storm surge, or seasonal water table changes, water pushes through cracks, joints, and defects on the way in and pulls sand and soil out with it on the way out. Over time, this cycle hollows out voids behind the wall that nobody can see from the surface. Heavy rain speeds it up. Clogged weep holes and vents make it worse, trapping pressure that has nowhere to go except through the wall itself.

By the time a sinkhole appears in the yard or a section of wall visibly leans, the soil loss behind it is usually already extensive. Wall age, soil type, drainage, and storm exposure all affect how fast this moves, which is why two similar-looking walls can be at very different stages of failure.

Do Nothing, Patch It, Replace It, or Repair It Right

The instinct with a small crack or minor void is often to wait. But seawall damage compounds. A problem that starts as a localized void becomes a larger stability issue as soil continues to migrate.

The right path depends on how far the damage has progressed and whether the wall itself is still structurally sound. A proper site evaluation, not a guess from the yard, should always come first.

Why the Right Contractor and the Right Material Matter

Not every repair method is right for every wall, and this is where a lot of homeowners get burned. Some contractors default to aggressive, rigid two-component foams because they're fast and inexpensive to install. On the wrong wall, especially one with limited structural capacity or a lot of existing movement, that rigidity and expansion force can do more harm than good. In some documented cases, an overly aggressive two-component fill has blown a wall completely out rather than stabilized it.

Alchatek factory-trained contractors are taught to match the material to the wall, using flexible, hydrophobic single-component resins for void fill and soil stabilization in most residential applications, reserving higher-density two-component products for situations where they're actually appropriate. Some of these resins are certified to NSF/ANSI 61 for contact with potable water, a specific, third-party-verified standard covering leaching and health effects, though that certification speaks to potable water contact and doesn't by itself confirm performance or safety in a saltwater or marine setting. Confirm the specific certification for any product on its technical data sheet.

This is exactly why the contractor matters as much as the product. Filling a void and sealing the points of soil loss is only part of the job. Choosing a resin that fits the wall's condition, the soil, and the water environment is the rest of it, and that judgment comes from training and experience, not from a price quote.

Find a Trained Contractor Before You Have a Bigger Problem

Small cracks, soft spots in the yard, or a wall section that's slightly out of alignment are worth a professional look now, not after the next storm. An Alchatek factory-trained contractor can evaluate the site and recommend a repair matched to your wall's condition, rather than a one-size-fits-all fix.

Continue Reading

• Common Causes of Seawall Failure
• Signs a Seawall Is in Need of Repair
• Residential Seawall Repair

Seeing Signs of Trouble?

Small cracks, soft spots in the yard, or a wall section that's slightly out of alignment are worth a professional look now, not after the next storm. Talk to an Alchatek specialist at (404) 618-0438, or find a trained contractor near you.

 Want more information on geotech products and equipment?

Register by end of day August 31: $645

Register September 1 or later: $845

That’s a $200 savings per attendee just for registering before the deadline.

Additional participants receive a $50 discount.

OCTOBER 6–7, 2026

Want to master Deep Lock® and learn how to turn that expertise into more profitable projects?

▶️ First, watch the video to hear directly from past training participants about what they learned, the new technology and equipment they discovered, and how the training helped prepare them to take on more opportunities.

Then join us at Alchatek HQ in Tucker, Georgia, for two intensive days of Deep Lock® training.

DAY 1: MASTER THE APPLICATION

• Site evaluation and diagnostics

• Material selection and rig setup

• Injection strategy and safety

• Real-world job scenarios

Training with application experts Andy Powell and Colt Hullander

DAY 2: WIN THE WORK

• Finding Deep Lock® opportunities

• Pricing projects

• Presenting proposals

• Closing deals

• Managing the sales process from lead to payment

Sales training with Gene McNaughton

SAVE $200 WHEN YOU REGISTER EARLY

Register and pay in full by August 31: $645

Register September 1 or later: $845

That’s $200 in savings for the same training and the same experts.

Plus, each additional participant receives another $50 discount.

Master the Application. Win the Work. Get Paid.

A long crack running through the floor of a high-traffic medical supply warehouse in Memphis signaled a problem below the slab. With forklift traffic and heavy racked storage running daily, and the building staying operational throughout, the team needed to know what was happening underground before choosing a repair method.

Initial Assessment

Ground penetrating radar (GPR) scans identified voided areas roughly 10 to 20 inches below the slab, confirming the crack wasn't just surface wear. Soil had shifted or washed out beneath the concrete, leaving sections of the slab unsupported. Removing and replacing the affected concrete would have meant disrupting warehouse traffic, adding downtime, and extending the repair window well beyond what the facility could accommodate on a live operating schedule.

Proposed Solution

Mid-South Concrete Lifting selected AP Lift 475, a two-component, high-density structural polyurethane, to fill the voids beneath the slab without removing any concrete. The product's expansion behavior, reacting to fill irregular void shapes rather than settling flat, made it a fit for reaching uneven cavities and re-establishing contact with the underside of the slab. This approach kept the facility in service throughout the repair.

Procedures

• Located the crack and mapped suspected void zones
• Staggered injection points along both sides of the crack
• Covered approximately 450 linear feet
• Drilled injection holes through the slab
• Injected polyurethane to fill the voids
• Monitored slab response throughout injection

Results

• Completed the project in two days
• Minimized disruption to warehouse operations
• Filled voids without slab replacement
• Improved support beneath forklift traffic areas

What This Means for Similar Projects

Void fill worked here because the slab itself was in good enough condition to stay in service and the underlying issue was a void rather than a structural failure in the concrete. That won't hold true on every job. Deteriorated or delaminated concrete, active water intrusion, poor bearing soil, or a drainage source that's still feeding the erosion can all change which repair approach actually makes sense. GPR or another subsurface assessment is generally the step that determines that, not the crack itself.

As a general point of reference, industrywide, full removal and replacement of an industrial slab tends to run well above void fill injection on a cost basis once demolition, disposal, and downtime are factored in. That gap varies by region, access, traffic control requirements, and the extent of the voiding, so it's not a number to lean on without a site-specific estimate.

The Role of a Technical Partner

This job was completed by Mid-South Concrete Lifting, a contractor experienced in polyurethane slab lifting and void fill work. On projects like this, Alchatek's role is providing the product knowledge and technical backup that help a contractor match the right polyurethane system to the void size, load, and site conditions, and staying available for tech support once the crew is on-site.

If you're weighing void fill, slab lift, or another repair method for a project you're looking at, Alchatek's tech support team can walk through the site conditions with you before you commit to an approach.

Want more information on geotech products?

For contractors, winning more work often comes down to more than simply offering the right service. The way value is communicated, questions are asked, and recommendations are presented can have a major impact on whether a prospect moves forward. On August 27 at 12:00 PM Eastern, sales consultant Gene McNaughton will lead a contractor-focused Sales Excellence webinar designed to help contractors sharpen those conversations and improve their ability to close more opportunities.

During the 45-minute live session, Gene will share four practical strategies contractors can use to strengthen their sales approach, build more confidence with prospects, and improve close rates. The session is designed to be immediately useful, with ideas that can be applied to real-world sales conversations rather than broad theory. Attendees will also have the opportunity to participate in a live Q&A and ask questions about the specific sales challenges they face.

Whether you are looking to improve your own sales performance or give your team a stronger framework for turning more opportunities into signed work, this webinar is built to provide actionable takeaways.

Space is limited to 30–50 attendees, so early registration is encouraged.

For DOT maintenance teams, municipalities, public works departments, bridge maintenance engineers, and the contractors who perform concrete lifting, void filling, and soil stabilization work — what an unstable approach slab really costs, and why the bump is rarely the actual problem.

A bridge approach slab does not fail all at once. It shows up as a bump, then a dip, then a crack along the joint where the slab meets the deck. Crews patch it, grind it smooth, and move on. A few months later, the same spot is back on the list.

That cycle is why this problem is easy to underestimate. Each patch looks cheap on its own. It's the repeated mobilizations, the lane closures, and the eventual heavier repair that add up. Most of that cost has nothing to do with the asphalt on top. It's driven by what's happening in the soil underneath.

The Real Cost Driver Isn't the Patch

A single patch is inexpensive. What's expensive is the pattern: mobilizing a crew, setting traffic control, closing a lane, and grinding or filling the same joint — repeatedly, at the same location, because the cause was never addressed. Traffic control and mobilization alone often cost more than the patch material itself, and that overhead repeats with every visit.

Left long enough, the condition can progress from the slab into the structure itself. At that point, repair moves into abutment or wing wall territory, where structural work runs $500–$1,200 per square foot.

Actual costs vary by region, traffic control requirements, agency specifications, slab condition, drainage, soil conditions, access, and severity.

This gradual progression is the point: money spent patching the same location, over and over, without resolving the underlying condition — until it's no longer just a slab problem.

The Bump Is the Symptom. The Void Is the Problem.

An approach slab bridges two systems that behave very differently. The bridge itself sits on a foundation — an abutment, piles, drilled shafts, footings bearing on stable material. The approach slab sits on compacted fill and native soil. Those two systems settle at different rates, and that difference is where the trouble starts.

Common causes include:

• Fill settlement — backfill behind the abutment consolidates over time, especially if it wasn't compacted to spec.
• Erosion and soil loss — water finds a path under the slab or through a failed joint and carries fines out, leaving a void.
• Failed drainage — deck drains or approach drainage that no longer function concentrate water exactly where it does the most damage.
• Voids beneath the slab — once soil is lost, the slab spans open space instead of bearing on support, and traffic loading accelerates the cracking.

None of this is visible from the driving surface. What's visible is the bump — the downstream symptom of a support problem that started below grade.

Why Repeated Patching Doesn't Fix It

Asphalt patching and grinding improve ride quality fast, which is why they're usually the first response. But if there's a void or ongoing erosion beneath the slab, the patch sits on the same unsupported base that caused the original settlement. Traffic keeps flexing the slab over the void, the patch cracks again, and the crew returns on a schedule that tends to compress rather than stretch out.

Where Polyurethane Injection Fits

When the cause is loss of support — a void, settled fill, or eroded soil — polyurethane injection addresses that condition directly, without full slab removal. Small-diameter ports are drilled through the slab or pavement, and high-density polyurethane resin is pumped beneath it. The material expands to fill the void, densify loose soil, and in appropriate cases lift the slab enough to close the joint differential.

If a soil boring or dynamic cone penetrometer (DCP) test indicates weaker soils at greater depth, those layers can be targeted first with polyurethane injected several feet into the ground using Alchatek's Deep Lock® process — addressing the soil density issue driving the settlement before the slab itself is lifted.

This isn't a fit for every situation. It addresses void and soil support — not a structurally deficient slab, a failed expansion joint, or drainage that's actively delivering water to the site. Site conditions, soil type, drainage, and the extent of the void all factor into whether injection is appropriate.

Why Contractors and Agencies Work With Alchatek

Alchatek manufactures high-strength polyurethane systems for void filling, soil stabilization, and concrete lifting on roadway, bridge, and transportation infrastructure. For contractors working under DOT or municipal specifications, that means products engineered for wet conditions, rapid cure, and traffic-ready turnaround, backed by technical support from a team familiar with public infrastructure estimating and application questions.

The right approach depends on the cause of the settlement, the soil conditions, and the condition of the slab — not a one-size-fits-all fix.

Related Reading

• 5 Warning Signs a Structure May Need Slab Lifting or Stabilization
• A Trusted Polyurethane Soil Stabilization Resource for Engineers
• AP Fill 700 – Polyurethane for Pipe Repair

Talk to a Specialist

If an approach slab on your system is showing repeated settlement, the first step is understanding what's happening beneath it. Call an Alchatek specialist at (404) 618-0438, or find a trained contractor near you.

The structural repair range in this article is confirmed via Alchatek's Cost Reference Library. Actual costs vary by site conditions, region, traffic control requirements, agency requirements, slab condition, drainage, soil conditions, access, and severity of settlement.

Want more information on soil stabilization?

Learn More About Coastal Structure Failure

Landon Feese | Applications Engineer
Online PDH Session — August 26 | 12:00 PM ET

• Diagnosing soil loss behind seawalls, bulkheads, and retaining walls
• Comparing repair methods by cost, downtime, and site access
• Fit criteria and limits for chemical grouting in the tidal zone

Includes coastal project examples and measured outcomes. 50-minute session plus live Q&A.

Reserve Your Seat →

The Wall Isn't What Fails First

Every tide that moves past a seawall or bulkhead takes a little more soil with it than it brought in. That process runs for years before anyone notices, because the wall itself usually holds its shape long after the ground behind it has hollowed out.

By the time a panel cracks, a cap shifts, or a section of walkway drops, the structure isn't announcing a new problem. It's reporting one that's already been running unseen since long before the first inspection flagged it.

That gap between when a coastal structure starts failing and when it looks like it's failing is where budgets get blown. Engineers and contractors who can read the early signs are working with a fraction of the cost, and a fraction of the disruption, of the crew who gets the call after a section of shoreline has already opened up.

What This Session Covers

Landon Feese, Applications Engineer at Alchatek, will walk through how to read the early signs of soil loss behind coastal structures and how to evaluate the repair options once it's confirmed.

The session is built around three practical questions engineers and contractors face on nearly every coastal job:

How do you confirm soil loss behind a wall you can't see behind? Landon will cover the diagnostic approach for evaluating voids and undermining behind seawalls, bulkheads, and retaining walls, including what separates a cosmetic crack from a structural warning sign.

How do the repair options actually compare? Once soil loss is confirmed, the choice usually comes down to excavation and replacement, mechanical anchoring, or chemical grouting. The session breaks these down by real cost, downtime, and how much site access each one demands, so you can make that call before it becomes an emergency decision.

Where does chemical grouting work, and where doesn't it? Tidal zones are unforgiving on materials and methods. Landon will lay out the fit criteria and limits for using chemical grouting in this environment, including where it's the right call and where it isn't.

Who Should Attend

This session is built for engineers, marine contractors, and municipal staff responsible for evaluating or maintaining seawalls, bulkheads, and waterfront retaining structures. If you've ever had to explain to a property owner or a board why a wall that "looked fine" needed emergency repair, this session is for you.