Alchatek Blog

A municipal wastewater treatment facility in New York had catastrophic water loss in five interconnected tanks, including two Sequencing Batch Reactors (SBR) and a digester. One SBR alone lost 20–22 inches of water daily, threatening its compliance with environmental regulations and risking $25,000/day in regulatory fines. The facility’s partially buried concrete structure was built just five years prior, with cracks linked to defective cold joints and curing errors. Traditional demolition/replacement was estimated at $1.5M, but the client sought a less expensive and minimally invasive solution to avoid shutdowns. All County Spray Foam Solutions was brought in to do the job.

Initial Assessment

Technicians documented dozens of active leaks through crack networks at tank walls and floor transitions. Water migrated horizontally across tanks due to cold-joint defects in the buried structure. Larger cracks (up to ⅛") required stabilization to prevent material blowout during injection. A structural inspection confirmed no risk of wall collapse but highlighted the urgent need for crack sealing.

Proposed Solution

The engineering team selected Spetec AG200, an ultra-low-viscosity (3–4 cP) acrylic resin with NSF 61 certification for use in contact with potable water. Key advantages:

• Microscopic penetration: Fluid enough to fill hairline cracks without high-pressure injection.
• Flexible sealing: Creates elastic barriers tolerant of concrete movement.
• Cold operation: Reacts fully at substrate temperatures of 30–35°F.

The method avoided:

• Tank evacuation/excavation beneath the structure.
• Long-term downtime for concrete replacement.

Procedures

1. Crack Identification: Mapped moisture patterns and active leaks using towels/paper.
2. Port Drilling: Drilled 45° angles to intersect cracks, avoiding direct surface drilling.
3. Crack Stabilization: Used hydraulic cement to plug larger cracks, retaining oakum-soaked material.
4. Material Application:
   1. Injected Spetec AG200 at 1:12 to 3:00-minute gel times with accelerators.
   2. Monitored breakthrough (material appearing at adjacent ports).
   3. Verification: Confirmed leaks reduced to “moist areas” post-injection.

Results

The injection process, which used approximately 20 gallons of resin, sealed all major leaks within under a week. Post-repair inspections confirmed dry conditions. The approach averted months of tank shutdown, $1.5 million in replacement costs, and thousands more in potential fines.

Want more information on crack injection with polyurethane?

Master the Application.
Win the Work. Get Paid.

April 8th & 9th

If Paid in Full By EOD March 18th – $645
If Paid in Full March 19th or Later – $745
$50 Discount- Each Additional Participant 

Hello! I'm Gene McNaughton. I founded Geobear USA, where I built the business from the ground up and led its growth from 2020 through 2024.

During that time, I personally sold more than $4 million in residential and commercial foundation repair projects using geopolymer solutions, gaining firsthand experience in how these projects are found, evaluated, and won.

I also documented the entire sales system—from lead generation and site evaluations to presenting solutions and closing deals—turning the process behind those $4 million in personal sales into a repeatable framework contractors can use to grow their own businesses.

 Join me at Deep Lock® Training on April 8th & 9th to learn more... 

A Deeper Look

Complex products don’t require complex selling.
They require disciplined training.

When I was building Geobear, we sold geotechnical solutions.
Foundation stabilization.
Soil remediation.
Structural lifting.

Not exactly impulse buys.
Big-dollar decisions for homeowners, and none of it covered by insurance.  Cash money.

And here’s what I realized early:
It wasn’t the technical detail of the product that made selling difficult.
It was learning to explain it in language the buyers could understand.

90% of the people I worked with knew absolutely nothing about soil, settlement, clay soil issues, etc.

They knew that their house was settling/dropping, and the more it move the bigger the cracks on their walls and floor got.

Before I trained anyone, I mastered the sales process myself.

I refined:
How we screened leads.
How we converted opportunities into meetings.
How we ran discovery.
How we presented findings.
How we asked for the business.
How we increased average sales price.

Once my own conversions were strong, I documented every step.

Then I taught my team one principle:
“Just move the deal to the next step.”

Not:
“How much can we sell this for?”

But:
Do they have a real problem?
Can we solve it?
Is there urgency?
What’s the next step?

That mindset changed everything.

Here’s how I trained them:
First, they shadowed me.
They watched what “good” looked like.
Then we debriefed.
I let them critique me.
Then they ran the meeting.
I observed.
I coached immediately.

They repeated it until they mastered it.

No one moved to presentations until they could run a flawless first meeting.

No one presented pricing until they could present findings to me first.

No one closed until they practised closing multiple times internally.

Step by step.
Rep after rep.
Process before product.

Most companies throw new hires into the field and say,
“Go get ’em.”

That’s not training.
That’s hope.

Complex products don’t require smarter people.

They require:
A documented process.
Clear stage definitions.
Repetition.
Immediate coaching.

Mastery before advancement.
Selling isn't knowing everything about the product.

It’s knowing exactly what to do next.

If you had to audit your team today, which step of your sales process is weakest?

Let's discuss at Deep Lock® Training - April 8th & 9th, 2026!

Day 1: The 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. 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 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

(Discounted hotel rates available. Daily transport from hotel to event provided.)

Master the Application. Win the Work. Get Paid.

If Paid in Full By EOD March 18th – $645
If Paid in Full March 19th or Later – $745
$50 Discount- Each Additional Participant

About Gene McNaughton

Gene McNaughton is a nationally recognized sales trainer, author, and business growth expert who has spent more than two decades helping companies improve how they sell, communicate value, and win more business.

As the creator of The Sales EDGE, Gene has trained thousands of professionals on how to stand out in competitive markets by mastering the conversations that drive buying decisions.

Gene McNaughton also founded Geobear USA, where he built the business from the ground up and led its growth from 2020 through 2024.

During that time, Gene personally sold more than $4 million in residential and commercial foundation repair projects using geopolymer solutions, gaining firsthand experience in how these projects are found, evaluated, and won.

He also documented the entire sales system—from lead generation and site evaluations to presenting solutions and closing deals—turning the process behind those $4 million in personal sales into a repeatable framework contractors can use to grow their own businesses.

On Day 2 of the Deep Lock® Spring Training, Gene will lead a special session focused on the sales side of Deep Lock®—showing contractors how to identify opportunities, present solutions, and turn Deep Lock® projects into profitable work.

Day 1: The 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. 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 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.)

Master the Application. Win the Work. Get Paid.

If Paid in Full By EOD March 18th – $645
If Paid in Full March 19th or Later – $745
$50 Discount- Each Additional Participant

Day 1: The 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. 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 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 public park in New York had critical erosion issues at its waterfront staircase and adjacent beach, which were built over a landfill. Over the years, natural erosion pulled back sand, exposing uneven foundation areas and creating safety hazards for visitors. The partially buried concrete staircase exhibited significant subsidence and shifting soil, posing a threat to structural collapse. The New York City Parks Department required a rapid solution to stabilize the site before further degradation occurred.

Initial Assessment

The staircase and surrounding sand exhibited signs of differential settlement, likely due to uneven soil compaction and erosion. Technicians identified voids beneath the stairs and along the beachfront, with sand migration exacerbating instability. Traditional excavation or pier-and-casing methods were impractical due to limited access and the need to avoid displacing adjacent structures.

Proposed Solution

The team selected AP Fill 720 (a single-component polyurethane) for soil compaction/stabilization and AP 430 (a two-component foam) for structural void filling. AP Fill 720 addressed loose sand through permeation and consolidation, while AP Lift 430 filled critical voids beneath the staircase, providing lift and support.

Procedures

1. Stabilization Pattern: Injected AP Fill 720 every 4 feet at 6–8 feet depth to bond sand particles and prevent further migration.
2. Structural Foam Injection: Applied AP Lift 430 directly beneath the staircase’s granite slabs through strategic ports, filling void spaces with approximately 1 gallon per linear foot.
3. Final Treatment: Reserved excess AP Fill 720 to seal surface gaps around the staircase, preventing sand washout.

Results

The dual-material injection rapidly stabilized the waterfront staircase, eliminating soil migration and structural risk without closing the park. Compared to traditional heavy reconstruction, the approach cut costs by an estimated 97% and completed the work in under two weeks with minimal marine or community disruption. Post-repair inspections confirmed lasting results with no recurrence of erosion.

Want more information on stabilizing soil with polyurethane?

Master the Application. Win the Work. Get Paid.

If Paid in Full By EOD March 18th – $645
If Paid in Full March 19th or Later – $745
$50 Discount- Each Additional Participant

Day 1: The 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. 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 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.)

Initial Assessment

An Atlanta real estate company faced significant challenges with their large warehouse, where uneven concrete slabs ranged from 0.5 to 2.5 inches below level. This unevenness led to foundation instability, wall cracking, and compromised usability of the facility. A local slab lifting company was contracted to perform void filling and slab lifting to restore the warehouse floor.

Proposed Solution

The technicians recommended using AP Lift 475, a two-component polyurethane foam designed for lifting and stabilizing concrete slabs. This material was selected for its high strength, controlled expansion, and ability to effectively fill voids while lifting sunken slabs to the desired elevation. The approach included using a large concrete cutting machine to clear joints, ensuring precise preparation without extensive disruption to warehouse operations.

Procedures

1. Established a grid pattern for injection points based on the extent of slab settlement on the warehouse floor.
2. Used a large concrete cutting machine to clear joints, ensuring unobstructed access for injections.
3. Drilled holes through the concrete slabs at predetermined injection points to access voids beneath.
4. Injected AP Lift 475 polyurethane foam into the drilled holes to fill voids and lift slabs, monitoring elevation in real-time to raise slabs up to 2.5 inches.
5. Performed multiple injection passes in areas with significant settlement to ensure even lifting.
6. Patched drilled holes to restore the surface integrity of the concrete slabs.

Results

The slab lifting project at the warehouse was a complete success. The application of AP Lift 475 effectively filled voids and raised all uneven slabs to a uniform level, eliminating foundation issues and wall cracking. The restored warehouse floor enhanced the facility’s functionality, enabling the real estate company to rent out the space, thereby maximizing its commercial potential.

Want more information on lifting slabs with polyurethane?

Initial Assessment

The management team at a corn syrup plant faced significant challenges with sinking concrete slabs supporting critical infrastructure, including water tanks and raw material tanks. The uneven slabs posed risks of tank instability and potential structural failure. A geotech contractor was engaged to perform void filling and stabilize the affected areas, ensuring a solid foundation for plant operations.

Proposed Solution

The technical team recommended using AP Lift 475, a two-component polyurethane foam that is ideal for void filling and slab stabilization. This material was selected for its high compressive strength, controlled expansion, and ability to effectively fill voids while providing robust support for heavy loads. The approach ensured minimal disruption, as it required no extensive excavation.

Procedures

1. Established a grid pattern to guide the placement of injection points in the affected areas beneath and around the water and raw material tanks.
2. Drilled holes through the concrete slabs at predetermined injection points to access the voids beneath.
3. Injected AP Lift 475 polyurethane foam into the drilled holes to fill voids and stabilize the soil beneath the slabs, ensuring comprehensive void coverage.
4. Patched drilled holes to restore the surface integrity of the concrete slabs.

Results

The void-filling project at the corn syrup plant was a success. The application of AP Lift 475 effectively filled all identified voids, stabilizing the concrete slabs and restoring a solid foundation. The stabilized areas now securely support the water and raw material tanks, eliminating concerns about sinking or tipping. The facility can resume full operations with confidence in the structural integrity of the tank foundations.

Want more information on geotech products?

An Atlanta contractor contacted Alchatek for assistance with a void filling job in the parking garage at Brookhaven City Hall. The bottom floor of the garage exhibited significant voids beneath the concrete slab, posing risks of settlement and structural instability.

Initial Assessment

An Alchatek support technician worked with the contractor to conduct a thorough assessment and implemented a targeted void-filling solution to restore stability.

Proposed Solution

Alchatek recommended using AP Lift 430 Fast, a high-performance polyurethane foam designed for rapid void filling and stabilization. This material was selected for its quick-setting properties, high compressive strength, and ability to effectively fill voids while providing robust support for the concrete slab. The approach ensured minimal disruption to the parking garage operations, as it required no extensive excavation.

Procedures

1. Established a grid pattern to guide the placement of injection points on the bottom floor of the parking garage.
2. Drilled holes through the concrete slab at strategically determined injection points to access the voids beneath.
3. Injected AP Lift 430 Fast polyurethane foam into the drilled holes, ensuring comprehensive void coverage from bottom to top.
4. Patched drilled holes to restore the surface integrity of the concrete slab.

Results

The void-filling project at the Brookhaven City Hall parking garage was a success. The application of AP Lift 430 Fast effectively filled all identified voids, eliminating the risk of further settlement. The stabilized concrete slab restored the structural integrity of the garage floor, ensuring a safe and functional environment for vehicles and pedestrians. The solution minimized operational downtime and avoided costly excavation, preserving the facility’s functionality.

Want more information on geotech products?

In this interview segment from Groundworks' Stability Matters podcast, Alchatek VP of Sales Andy Powell recounts a dramatic incident during a Florida water treatment plant expansion. A deep excavation for a large clear well structure suddenly flooded when a test pile fractured the underlying limestone bedrock about 30 feet below the excavation floor (50 feet below ground level). Water from an aquifer surged in at 300–500 gallons per minute, filling the site and stopping work entirely.

The bold fix: the "polyurethane bomb" technique. A two-inch pipe was drilled beside the leaking pile, and AP Fill 700 polyurethane resin with a fast catalyst was rapidly pumped in using high-flow diaphragm pumps.

Want more information on Alchatek products?