Alchatek Blog

A Tennessee state correctional facility had a significant infrastructure failure when newly installed plumbing beneath a concrete slab malfunctioned. In an attempt to address the issue, the original contractor backfilled the entire plumbing system with concrete. When this approach proved unsuccessful, a second contractor was brought in to demolish the concrete and properly repair the plumbing systems. This process left a substantial void beneath the slab that required immediate filling to restore structural integrity and minimize facility downtime.

Initial Assessment

Following the plumbing repairs, engineers assessed a void measuring approximately 200 square feet in area and 4-5 feet in depth, totaling roughly 800-1,000 cubic feet of empty space beneath the concrete slab. The prison's security restrictions severely limited access to equipment, making traditional concrete replacement a challenging and time-consuming process. The facility required a solution that would minimize disruption to operations while providing structural support equivalent to the original concrete base.

Proposed Solution

Working with Alchatek, Mid-South Concrete Lifting recommended using  AP Fill 420, a two-component structural polyurethane foam, to fill the substantial void. This approach offered several critical advantages for the correctional facility environment. The material could be applied through a simple hose system, eliminating the need for heavy concrete trucks and mixing equipment that would be difficult to maneuver through security checkpoints. The foam's rapid curing time would significantly reduce the project timeline, and its structural properties would provide adequate load-bearing capacity for the slab above.

Procedures

1. Security clearance and equipment inspection were completed to bring polyurethane application equipment into the facility.
2. The void was accessed through existing openings created during the concrete removal process.
3. AP Fill 420 was applied using a free-shooting technique.
4. Material application was monitored to ensure complete filling and proper expansion throughout the space.

Results

The void filling was completed in 3 hours versus an estimated week for concrete replacement. AP Fill 420 polyurethane foam successfully filled the entire void space and provided adequate structural support. Prison officials expressed satisfaction with the efficiency and minimal operational disruption, leading the contractor to look at another similar project at a different state facility.

The polyurethane approach delivered 65-75% cost savings compared to traditional concrete replacement when accounting for materials, equipment, labor, and reduced facility disruption. The accelerated timeline also eliminated the extended security coordination costs typically associated with longer construction projects.

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Alchatek has streamlined its two-component production system according to lean manufacturing guidelines. These investments will ensure timely delivery of the high-quality products our customers depend on for their geotechnical projects.

• Material Handling System Automation: Our improved system speeds up material production while keeping quality levels high, ensuring a consistent supply of finished products to meet growing customer demand.
• Streamlined Filling Process: By redesigning workflows to minimize non-value-added activities, we’ve simplified operations, reducing cycle time and boosting team productivity. This translates to faster delivery and greater reliability for customers.
• Real-Time Process Monitoring: Advanced sensors provide continuous feedback on bulk tank material levels, enabling just-in-time inventory management. This keeps our production agile, ensuring customers get the products they need without delays.

These lean-driven investments reflect Alchatek’s dedication to customer satisfaction. By focusing on value stream optimization, we’re better equipped to deliver reliable, high-quality solutions to support your geotechnical projects efficiently and effectively.

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Fifteen, two‑unit condominium buildings exhibited differential settlement and interior slab movement from loose organics and voiding, risking structural performance and livability. Continuous occupancy required a rapid, low‑disruption remediation strategy that delivered durable lift and stabilization. The job was completed by foundation repair specialists at Helicon.

Initial Assessment

Investigations confirmed loose to very loose near‑surface soils, voids at 3–8 ft below the surface, and active settlement beneath slabs and footings under service loads; full replacement was not viable due to resident displacement, extended schedules, and higher cost risk.

Proposed Solution

The experts at Helicon selected AP Lift 430 for its hydro‑insensitivity, rapid reaction, and ~50 psi compressive strength to permeate, densify, and lift with minimal downtime.

Procedures

1. Grid the interiors; mark piles, grout points, and quality control benchmarks.
2. Inject low‑mobility compaction grout to seal limestone and pre‑densify.
3. Install underpinning to ~36 ft, using predrill/sleeves to bypass clays.
4. Inject AP Lift 430 at 8/5/3 ft below land surface to lift slabs and encapsulate organics.
5. Monitor elevations/pressures; proof‑load and video‑verify.

Results

• Restored slab elevations and footing support with no resident displacement.
• Completion in days to weeks vs months for replacement.
• Approximately 80-90% cost savings versus full demolition/rebuild approaches.
• Durable, closed‑cell, water‑resistant stabilization for long‑term performance.

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In the fast-paced world of geotechnical contracting, having a team member who truly understands the grind of the field can make all the difference. That's why we're thrilled to introduce Antwon Butts, our newest Tech Support Technician on the Technical Services team. With a career built on the front lines, Antwon steps into this role ready to bridge the gap between product innovation and real-world application, helping contractors like you tackle everything from soil stabilization to complex grouting challenges with confidence.

Antwon's journey in the industry is a testament to his dedication and versatility. He most recently served as Production Manager here at Alchatek, where he honed his skills in manufacturing and quality control for polyurethane-based solutions—ensuring every batch meets the high standards demanded by demanding jobsites. Prior to that, as Lead Technician at Ground Consolidation Services, he led on-site operations for soil consolidation and injection projects, managing teams through high-stakes scenarios that required quick thinking and precise execution. Over more than a decade, these roles have equipped him with a deep well of practical knowledge, from equipment troubleshooting to optimizing workflows under pressure.

What sets Antwon apart is his ability to translate that hard-earned experience into actionable support for you. Whether you're dealing with void filling, concrete lifting, or emergency repairs, his expertise in a broad spectrum of tools, products, and techniques means faster resolutions and fewer headaches. As any seasoned contractor will tell you, field proficiency isn't just valuable—it's irreplaceable. With Antwon on board, our Technical Services team is even better positioned to be your go-to partner, turning potential pitfalls into seamless successes.

Antwon can be reached via phone at 470-925-1303.

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A south Georgia roadway developed a sinkhole over a double 48-inch RCP storm line about 10 feet deep, threatening lane safety and mobility. Replacement costs were prohibitive and would require extended closure and excavation.

Initial Assessment

The pipe exhibited joint leakage and surrounding soil loss, creating voids under pavement and shoulder with settlement risk across the travel path. Traditional open-cut replacement would demand deep shoring, traffic detours, and high restoration costs, making trenchless stabilization preferable. SiteMix Pressure Grouting LLC was called in to do the work.

Proposed Solution

The contractor selected AP Lift 475 for hydrophobic chemistry, industrial strength, and rapid set to encapsulate pipe exteriors, seal soil paths, and rebuild bearing capacity with minimal downtime.

Procedures

1. Lay out three rows on 3-foot centers around both barrels.
2. Inject at 6 lb per vertical foot to refusal for soil reconsolidation.
3. Pull the injection tubing vertically while injecting to form grout columns.
4. Encapsulate/seal pipe perimeter and monitor lift response.
5. Verify surface support and closure readiness.

Results

• Completed in one day with 1,400 lbs placed; roadway lifted and voids eliminated.
• Zero excavation and minimal traffic disruption during work.
• Approximately 95% cost savings compared to pipe replacement.

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A fire station access roadway developed cracking from subsurface voids caused by storm drain seam gaps that washed out soil during heavy rain, threatening daily emergency operations and pavement integrity. Geotech specialists from Helicon were brought in to assess the situation.

Initial Assessment

CCTV and probing identified voids up to several inches beneath the asphalt and open joints along the drain, allowing soil migration. Excavation replacement was rejected due to weeks-long closure risk, higher cost, and potential future seam misalignment, making trenchless permeation grouting the viable path.

Proposed Solution

AP Fill 700 was chosen for hydrophobic, single‑component injection with very low viscosity, and adjustable cure, enabling soil permeation, joint sealing, and formation of a water‑tight bearing layer for traffic.

Procedures

1. Map defects and mark the injection grid along the pipe and pavement.
2. Drill ports; set packers to target joints and halo around pipe.
3. Inject AP Fill 700 to refusal, prioritizing seam sealing.
4. Permeate surrounding soils to fill voids and densify subgrade.
5. Monitor pressures/returns; adjust set times for water presence.
6. Verify with sounding/CCTV and traffic proof-load.

Results

• Restored structural support and sealed joints with zero operational downtime.
• Completion in days vs weeks.
• Approximately 95% cost savings compared to full excavation and pipe replacement.

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Attention Geotech Professionals!

Alchatek is exhibiting at the DFI 50 conference in Nashville.

Where: Gaylord Opryland Resort & Convention Center

When: October 20-23, 2025

Click Here for Registration Info

Visit us at Booth 227 to explore our advanced polymer solutions, including single and two-component polyurethanes for soil stabilization, groundwater control, and deep foundation support, addressing challenges like unstable slopes, soft ground, and deep excavation shoring for geotechnical projects.

Learn How Alchatek Helps You

At Booth 227, you can meet with our experts to learn how Alchatek empowers your geotechnical projects with cutting-edge technologies.

We support geotech professionals in three key ways:

• Innovative Polymer Solutions: Our advanced polyurethane grouts and foams provide robust solutions for curtain grouting, point grouting, and ground improvement, ensuring stability for slopes, excavations, and deep foundations.
• Expert Technical Support: We offer comprehensive training and ongoing assistance, leveraging our proven track record with industry leaders to optimize your project outcomes.
• Environmentally Safe Materials: Our NSF/ANSI/CAN 61-certified, chemically inert polymers ensure safety and compliance in sensitive environmental areas.

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A multi-level parking facility in downtown Los Angeles was experiencing significant water infiltration through its concrete ceiling. Building management had noticed increasing water staining and active leakage, particularly following rain events. The water migration around electrical conduits and light fixtures was most concerning, creating potential safety hazards with the electrical systems. Previous attempts to seal the ceiling using conventional surface treatments had failed to resolve the issue. With the structure serving high-end retail clients, the property management company required a solution to effectively stop the leaks while minimizing disruption to the facility's daily operations.

Initial Assessment

Inspection revealed that water was infiltrating through microscopic pathways in the concrete, with particularly noticeable intrusion around embedded conduits and penetrations. Engineers determined that concrete shrinkage had created tiny void spaces around these penetrations, some measuring only thousandths of an inch. Water was following these pathways, traveling along the outside of conduits and emerging at light fixtures and junction boxes installed in the ceiling. The ceiling showed distinctive water staining patterns radiating from these fixtures, confirming the migration pathway. Traditional polyurethane grouts would be too viscous to effectively penetrate these extremely small void spaces, requiring a material with exceptional flow characteristics.

Proposed Solution

Alchatek recommended using a specialized acrylic resin, Spetec AG 200. This material was selected specifically because of its extraordinarily low viscosity, significantly thinner than polyurethane alternatives, allowing it to travel through microfractures and voids that water could penetrate. Unlike thicker injection materials, acrylic resin can follow the same migration pathways as water, creating a waterproof barrier precisely where needed. The material's ability to travel long distances from injection points would minimize the number of injection ports required, reducing ceiling penetrations while ensuring complete sealing coverage around electrical conduits and other vulnerable areas.

Procedures

1. Technicians identified and mapped all water intrusion points in the ceiling, identifying migration patterns to determine optimal injection locations.
2. Strategic drilling and port installation were performed at intervals designed to intercept the water pathways, with particular focus on areas around electrical conduits.
3. Ports were installed in a pattern that would allow the low-viscosity material to flow along the same paths as the water infiltration.
4. Acrylic resin was injected through the ports, with continuous monitoring for material appearance at distant locations.
5. Injection continued at each port until the material was observed emerging from adjacent ports or known leak points, confirming pathway filling.
6. Engineers carefully monitored electrical systems throughout the process to ensure no disruption to the building's operations.

Results

The injection program successfully sealed the water infiltration pathways throughout the parking structure ceiling. Post-treatment monitoring through several significant rain events confirmed that all previously active leaks had been eliminated, with no further water migration observed around electrical fixtures. Most importantly, the acrylic resin's exceptional flow characteristics allowed for complete sealing with minimal disruption to the facility's operation. The property management company avoided spending an estimated $80,000-$100,000 that more invasive remediation methods would have required, while eliminating potential liability from water contact with electrical systems. The parking facility remained operational throughout the repair process, avoiding revenue loss that would have resulted from traditional ceiling replacement or excavation of the deck above.

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The property manager for a multi-level parking garage contacted Pavecon regarding persistent water infiltration in an elevator pit. The facility engaged Allana Buick & Bers, Inc. to develop a remediation strategy. Water leakage in elevator pits poses risks to equipment, safety, and can lead to service disruptions.

Initial Assessment

Inspection revealed multiple water entry points in the concrete walls of the elevator pit. The recurring water infiltration threatened the elevator system's integrity and created potential safety issues. Traditional repair methods would require extensive excavation and significantly disrupt parking facility operations, making them impractical and costly. The assessment determined that an effective solution was needed to address active leaks and provide long-term waterproofing without frequent maintenance.

Proposed Solution

The team selected a specialized polyurethane injection system (Spetec PUR F400) for the elevator pit leakage. This product effectively seals active water leaks in concrete structures by creating a waterproof barrier without extensive excavation. The method required only brief elevator shutdown periods rather than extended facility closures and could be applied even with active water infiltration.

Procedures

1. Thoroughly cleaned repair areas to remove dirt, debris, and loose concrete that could compromise adhesion.
2. Drilled through the concrete wall at strategic locations to access water infiltration pathways.
3. Installed injection ports (zerk fittings) into each drilled hole to facilitate polymer application.
4. Injected water when necessary to properly activate the polyurethane foam reaction.
5. Polyurethane injection material was applied through installed ports, allowing it to expand and fill voids.
6. Performed sequential injection following a pattern to ensure complete coverage of affected areas.
7. Removed injection ports and patched drill holes with hydraulic cement after the injection process.
8. Performed final inspection to verify cessation of all leaks.

Results

The polyurethane injection process successfully sealed all water infiltration points in the elevator pit, creating a waterproof barrier. The repair was completed within the scheduled timeframe, minimizing elevator system downtime. The project addressed approximately 17 linear feet of repair work.

After several substantial rain events, the elevator pit remained completely dry, confirming the solution's effectiveness. The property manager expressed satisfaction with the results, subsequently requesting additional services at other facilities and providing positive recommendations.

This solution demonstrated significant cost advantages over traditional methods, saving an estimated 60-70% compared to conventional waterproofing approaches while preventing potential damage to electrical and mechanical components.

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MixMaster Gun Cleaner 160 is the latest innovation designed to streamline maintenance for contractors using the MixMaster Pro gun for concrete slab lifting. This powerful liquid ISO and polyurethane remover simplifies the cleaning process, ensuring your equipment stays in top condition with minimal effort. Packaged for convenience and engineered for efficiency, this cleaner delivers rapid results, enabling professionals to focus on the job rather than on time-consuming maintenance. 

Features

• Packaged in a convenient 5-Gallon pail.
• Dispensing gun and pump included with purchase of the full kit.

Benefits

• Larger quantity than brake cleaner.
• As easy to apply as brake cleaner.

MixMaster Gun Cleaner 160 from Alchatek is more than just a cleaning solution—it’s a productivity booster for contractors who value efficiency and reliability. By offering a larger quantity and ease of application comparable to brake cleaner, this product ensures your MixMaster Pro gun remains free of stubborn ISO and polyurethane residue, reducing downtime and maintenance costs. Pair it with Alchatek’s industry-leading polyurethane foams and equipment for a seamless, high-performance slab lifting experience.

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