Alchatek Blog

Foundation foam is a trusted solution for engineers and contractors addressing soil stabilization and structural support challenges. This proven technology effectively tackles issues caused by unstable soil, from erosion to poor compaction. Over the years, it has established itself as an essential tool for maintaining the integrity of buildings, roads, and other infrastructure.

Why Soil Stability Matters

Unstable soil poses significant risks to structures built upon it. For instance, erosion, poor compaction, and freeze-thaw cycles can lead to settling, cracking, and even catastrophic failure. Moreover, these issues often occur deep beneath the surface, making them difficult to address using traditional methods. Therefore, reliable solutions are crucial for ensuring long-term structural integrity.

The Power of Foundation Foam

Foundation foam offers a dependable solution to these challenges. Unlike conventional methods, it can be injected deep into the soil without heavy excavation equipment, allowing for precise soil stabilization and compaction. Furthermore, the foam cures quickly. This rapid curing time significantly reduces project downtime and improves overall efficiency.

One-Component Standard Soil Stabilization

One-component foundation foam products offer durable and effective solutions for standard soil stabilization projects. These products are perfect for soil permeation, spreading through, and strengthening loose or unstable soil.

• AP Soil 600
• AP Fill 700
• AP Fill 720

Their ability to permeate soil makes them excellent choices for addressing issues like erosion, poor compaction, and water infiltration. As a result, these one-component foundation foam solutions can effectively stabilize soil without requiring extensive excavation or heavy machinery.

Two-Component Deep Lock® Stabilization

The Deep Lock® process utilizes two-component foundation foam products for deep soil issues. These include:

• AP Deep Lift 420
• AP Lift 430
• AP Lift 440
• AP Lift 475

The Deep Lock® process allows for soil stabilization at greater depths, thus making it particularly useful for large-scale projects or structures with significant foundation issues. Additionally, this method can achieve soil stabilization and compaction with minimal surface disruption.

Versatility in Application

One of the critical advantages of foundation foam is its versatility. It can be used in a variety of scenarios, including:

• Supporting settled buildings
• Enhancing soil density around pipes and tunnels
• Reinforcing bridge approach slabs
• Strengthening port and airport infrastructure

Foundation foam provides long-lasting support and protection against future settling or erosion in each application. Consequently, it has become a go-to solution for many construction and rehabilitation projects.

Comparing Foundation Foam to Traditional Methods

Compared to traditional soil stabilization methods, foundation foam stands out in several ways. For example, cement pressure grouting requires heavy equipment and can be messy and imprecise. Similarly, helical piers and push piers, while effective, are often more invasive and limited in their application.

In contrast, foundation foam is less invasive, faster to install, and addresses underlying soil issues more comprehensively. Moreover, it can be combined with other methods for even more effective results. Therefore, it offers a more flexible and efficient solution for many soil stabilization projects.

Environmental Considerations

An important aspect of foundation foam is its environmental safety. Alchatek foundation foams are NSF-certified to strict ecological standards. This certification ensures that the cured foam won't negatively impact groundwater quality. As a result, these foundation foams are a responsible choice for projects in environmentally sensitive areas. This rigorous environmental compliance further enhances their appeal as a trusted soil stabilization solution.

Long-Term Benefits

The long-term benefits of foundation foam are substantial. Once cured, the foam creates a stable, water-resistant barrier lasting decades. This longevity translates to reduced maintenance costs and improved structural integrity over time. As a result, property owners can enjoy peace of mind knowing their investments are protected for years to come.

A Solid Foundation for the Future

Consistently providing an effective solution to soil issues, foundation foam has proven instrumental in ensuring the longevity and safety of buildings and infrastructure worldwide. With its track record of success, foundation foam continues to be a go-to choice for construction and rehabilitation projects of all sizes. This time-tested technology remains at the forefront of creating stable and resilient structures for the present and future.

Want more information on stabilizing soil with foundation foam?

Are you a geotechnical contractor facing challenges with unreliable lifting foam that leads to costly callbacks? You can significantly reduce these issues by choosing quality lifting foam from a manufacturer focused on slab lifting applications. The right solution makes all the difference in achieving consistent, successful results.

The Painful Costs of Job Callbacks

The financial impact can be severe when callbacks occur due to subpar lifting foam. You can lose revenue when you have to redo jobs without additional payment. Meanwhile, new project starts may be delayed, creating a ripple effect throughout the schedule. As a result, resource allocation becomes inefficient, further straining the business.

Impact on Business Reputation

Low-quality foam products can severely damage customer relationships. Negative online reviews may start appearing, which can hurt your lead-generation efforts. Property managers and other repeat customers may look elsewhere for future projects. Moreover, the likelihood of receiving valuable referrals decreases substantially. In this competitive industry, maintaining a solid reputation is essential for long-term success.

Benefits of a Specialized Manufacturer

Choosing a manufacturer focusing exclusively on polyurethane for slab lifting makes a notable difference. Specialized manufacturers maintain rigorous quality control standards throughout the production process. Furthermore, this dedicated approach ensures that you receive consistent results with every application. This approach provides better outcomes than relying on a general foam manufacturer who could be producing everything from spray foam insulation to material for couch cushions.

Quality Lifting Foam: The Foundation of Success

Reliable quality lifting foam leads to satisfied customers and more substantial business growth. With proper materials and consistent results, contractors can build lasting relationships with repeat customers while maintaining a solid reputation in the industry. 

Want more information on quality lifting foam?

Winter weather creates unique challenges for polyurethane slab lifting operations. As temperatures drop, proper equipment care becomes essential for successful projects. Here are vital tips to keep your rig running smoothly during cold weather and properly stored at season's end.

Cold Weather Operation Essentials 

Operating in cold conditions requires specialized heating equipment. The proper function of the pump's A/B preheaters and the hose heater is the biggest factor for pumping in cold weather. Without these heaters, the material cannot warm up or stay warm. Additionally, heated hoses with copper coils or internal wiring keep material flowing smoothly through the system.

Temperature Management Strategies 

Maintaining the correct material temperature is crucial for optimal performance. Therefore, barrel temperatures should stay between 70° and 80° Fahrenheit. During winter months, achieving these temperatures takes longer due to overnight cold. Consequently, keeping barrel heaters running overnight can help maintain proper temperatures. Most importantly, regular material recirculation ensures consistent heating throughout the system.

Winter Storage and Maintenance 

Proper end-of-season maintenance protects your investment. Flush the pump system thoroughly with Alchatek Pump Flush until all iso discoloration disappears. Run the end of the hose through cheesecloth to catch crystallized iso particles. Finally, fill the system with Alchatek Pump Saver 195 for long-term storage. For detailed step-by-step instructions, contact the Alchatek support team at 404-618-0438.

Safety First: Winter Precautions 

Safe winter operations require proper protective equipment. Start with appropriate goggles and a respirator. Furthermore, always work in well-ventilated areas to ensure adequate air circulation.

Expert Support When You Need It 

Cold weather operations can present unexpected challenges. Contact Alchatek's technical support team at 404-618-0438 for specific questions or detailed guidance.

Want more information on geotech products and equipment?

Water leaks in concrete slabs can be a severe issue for property owners. These leaks occur when water from the ground seeps through cracks or gaps in the concrete foundation, leading to moisture problems inside the building. If not addressed promptly, these upward-moving leaks can lead to structural issues, damage flooring materials, and create an environment conducive to unhealthy mold growth. Curtain grouting with polyurethane is a proven technique for effectively fixing water leaks in concrete slabs. This method creates a barrier beneath the slab, preventing water from penetrating upwards and resolving the issue at its source.

The Curtain Grouting Solution

Curtain grouting is a well-established and highly effective method for addressing water leaks in concrete slabs. The process begins with drilling small holes through the concrete slab in a precise diamond grid pattern. Technicians then inject polyurethane grout into each hole, overlapping injections like shingles on a roof to ensure comprehensive coverage. Upon contact with water from the leak, the grout expands and forms a solid, watertight barrier beneath the slab. This durable seal effectively prevents further water intrusion, resolving the leak at its source.

Advantages of Curtain Grouting

This technique can address multiple leaks simultaneously, providing a comprehensive solution. Additionally, it delivers long-lasting results, ensuring the integrity of your slab for years to come. The process requires minimal equipment and causes less disruption compared to other methods. Moreover, the materials used in curtain grouting are environmentally safe and NSF-certified to meet strict environmental standards.

The Critical Role of Professional Expertise

Fixing a water leak in a concrete slab is not a task for DIY enthusiasts. Due to the complexity of the process, professional expertise is crucial. Experienced contractors possess specialized equipment and materials necessary for effective curtain grouting. Their expertise allows for accurate diagnosis of the leak's extent and location. Proper curtain grouting application requires precise techniques that professionals have honed through years of experience. Furthermore, experienced contractors provide comprehensive repairs that address not just the symptoms but the root cause of the leak.

Fixing Water Leaks in Concrete Slabs

Water leaks in concrete slabs seriously threaten your home's structural integrity. Understanding the problem and seeking professional help promptly are critical steps in addressing these issues effectively. When performed by experienced contractors, curtain grouting offers a reliable and time-tested solution to fix water leaks in concrete slabs. You can ensure your home's long-term stability and safety by taking swift action and relying on professional expertise.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on curtain grouting?

A critical infrastructure issue emerged on a four-lane road near downtown San Francisco. Soil erosion caused a bridge approach slab to settle 2.5 to 3 inches over time. The affected area had an asphalt surface with a thin sleeper slab underneath. California Department of Transportation (Caltrans) engineers initially advocated for complete replacement. The situation changed when Bay Area Underpinning entered the scene. Together with Alchatek, they presented an alternative solution: Deep Lock® soil stabilization and concrete leveling. After careful consideration, the DOT engineers agreed to try this innovative approach. This method promised to minimize traffic disruption and significantly reduce costs compared to full replacement, which would have required closing the entire roadway and replacing a 40x12 foot area of asphalt and sleeper slab.

Powerful Polymers

The project team chose AP Lift 475 as the repair material. This substance offers impressive compressive strength while maintaining good expansion properties. Once injected, the material spreads out effectively, filling voids in the annular space within the soil. This combination of strength and expansion makes AP Lift 475 ideal for stabilizing and leveling the settled bridge approach slab. The material's ability to penetrate and fill voids addresses the underlying cause of the settlement, providing a more comprehensive solution than - for example - simply adding a new surface layer.

Painless Procedures

Before starting the repair, DOT engineers conducted thorough soil testing. They performed soil borings to determine soil types and characteristics at various depths. This crucial step provided insights into the subsurface conditions contributing to the settlement. Additionally, they used a DCP (Dynamic Cone Penetrometer) test to identify areas of weak soil density. Armed with this information, the contractor developed an optimal application plan.

The team installed injection tubes on four-foot centers at six- and 10-foot depths. They injected about 40 pounds of material per tube, using 10-15-second shots. This measured approach allowed for controlled material distribution. Throughout the process, the team carefully monitored the slab lift using a rotary laser and zip-level altimeter. These precise instruments ensured even raising of the slab to the desired level, preventing any potential issues from uneven lifting.

Rapid Results

The modular approach to repair minimized traffic disruption, a critical factor for this busy thoroughfare. At any given time, only two out of four lanes remained closed. Consequently, traffic continued to flow throughout the project, preventing gridlock in the area. The team completed the entire leveling process in just four eight-hour shifts, a remarkably short timeframe for such a significant repair. Compared to full replacement, the method significantly cut labor requirements, traffic disruption, and financial costs. Moreover, the repair addressed the root cause of the problem by stabilizing the eroded soil beneath the roadway.

Unlike simply adding an asphalt layer for leveling, which would have provided only a temporary fix, this solution offers long-lasting results. By directly treating the underlying issue, the team greatly reduced the likelihood of recurrence. The success of this project offers a blueprint for similar infrastructure challenges. It showcases how modern materials and techniques can provide cost-effective, efficient, and durable solutions to complex engineering problems. 

Want more information on Deep Lock® soil stabilization and slab lifting?

Polyurethane slab lifting effectively restores sunken concrete surfaces. This process relies on specialized slab jacking equipment, enabling contractors to perform precise and efficient repairs. This overview will explore the fundamental tools for successful polyurethane slab lifting operations.

Slab Jacking Equipment Rigs

Firstly, let's consider the most popular slab lifting rig options. V-nose trailers (16-20 feet) and Box Truck Build-Outs (16-28 feet) are the most common choices for polyurethane contractors. These rigs provide ample space for storing and transporting essential equipment and materials to various job sites. The flexibility of these mobile setups allows contractors to easily adapt to different project scales and locations.

Slab Lifting Pumps

Moving on to slab lifting pumps, PMC plural component hydraulic proportioners play a crucial role in polyurethane slab jacking. These reliable pumps are designed to inject two-component structural foams effectively. Additionally, they utilize relays and circuit breakers instead of circuit boards, thus enhancing reliability and reducing maintenance issues. The rugged construction of these pumps ensures they can withstand the demanding conditions often encountered in concrete leveling projects.

MixMaster Pro Slab Lifting Gun

Furthermore, the MixMaster Pro slab lifting gun is manufactured explicitly for concrete leveling. It's built to handle high back pressure and has a durable stainless steel construction. Moreover, its integrated rebuildable check valves protect the whip hose, lowering replacement costs. The gun's mechanical actuation system eliminates the need for side seals or O-rings in the mixing block, further simplifying maintenance and increasing reliability.

PolyBadger Mobile Lifting System

The PolyBadger lifting system is an excellent option for contractors seeking a compact solution. Its auto-calibrator ensures precise component ratios, thereby preventing mix-up issues. Notably, this system can fit in a pickup truck, making it highly portable for various job sites. The PolyBadger's versatility makes it ideal for both beginning slab lifting contractors who want to start with a smaller, more affordable unit and experienced professionals looking to add a compact system to their arsenal for hard-to-reach locations.

Jack Attack Manual Slab Lifting System

The Jack Attack system proves invaluable when dealing with small to medium slabs. This leverage device, featuring a triangular steel frame and an 8000 lb jack, allows for accurate slab positioning during polyurethane injection. As a result, it significantly simplifies complex repairs. The system's design enables a single operator to manipulate slabs efficiently, reducing labor requirements and improving overall project efficiency.

Dynamic Cone Penetrometer for Soil Testing

Assessing soil strength before beginning polyurethane injection can be crucial. The Dynamic Cone Penetrometer (DCP) offers a portable solution. Consequently, the data gathered helps develop effective injection plans and accurately estimate material usage. Many municipalities and agencies recognize DCP testing as a valid method for soil strength assessment, potentially opening up additional revenue streams for contractors.

Stain Prevention with AP Surface Guard 125

Lastly, many contractors use AP Surface Guard 125 to prevent staining during slab jacking. This water-based barrier protects concrete surfaces from polyurethane resin stains. Additionally, it serves as a flushing agent for cleaning the MixMaster gun block, thus offering a dual-purpose, environmentally friendly solution. Its biodegradable nature aligns with growing environmental concerns in the construction industry.

Polyurethane Slab Jacking Equipment

In conclusion, as slab jacking equipment continues to evolve, polyurethane contractors gain access to more efficient and precise tools for concrete repair. Professionals can deliver high-quality results by understanding and utilizing these specialized tools while optimizing their operations across various projects. The ongoing development of slab jacking equipment underscores the industry's commitment to improving concrete restoration techniques and outcomes.

Want more information on slab lifting products and equipment?

Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $745.00

Location

Atlanta, GA

Discount

$50 discount for each additional participant.

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.

Atlanta geotech contractors Lift It Rite were contacted by Deas Construction regarding the settlement of parking lot pavement behind the loading docks at a manufacturing plant in Norcross, GA.  The following observations were made during this first visit:

• An area of concrete slab pavement, approximately 75’ x 25’, surrounding a crane and a steel rack showed signs of settlement. 
• Holes drilled in random spots within the 75’ x 25’ area revealed voids up to 24” directly beneath the slab.
• Manual probing of the soil indicated it was quite soft.

Calculations were made for filling the voids and lifting the slab using high-density polyurethane, the DOT's product for highway stabilization and bridge approach slab leveling.  However, it was agreed that further investigation into this settlement's cause was warranted before proposing the void fill and lift.  Ground Consolidation Services of Tucker, GA, was asked to come in and do some GPR (ground-penetrating radar) readings and DCP (dynamic cone penetrometer) testing to determine the compaction of the soil.  Results indicated the following:

• Confirmation of voids beneath the concrete slab.  When core holes were drilled to accommodate the DCP cone, the cores fell into the voids under the slab.
• GPR readings are difficult in clayey soils, but shallow subsurface voids were detected, especially around the 12’ diameter brick manhole.
• Penetrometer results, measured in blow counts, indicated very soft soils down to 28’ in some places.
• Very soft soil was detected around the 12’ diameter brick manhole.

At this point, it was determined that the root cause of the slabs' and voids' settlement must be an infrastructure infiltration issue. Lift It Rite technicians met with Deas Construction on-site for a third visit to inspect the interior of the infrastructure.

Entry was made into a new manhole uphill beside the employee parking lot.  This manhole was connected to the 12’ diameter brick manhole (located in the area of settling) by a 72” corrugated metal pipe (CMP).  The CMP runs parallel to the back of the facility where the loading docks are located.  It is about 16’ deep (below grade of concrete) to the invert of the CMP.  Observations were as follows:

• The CMP was in decent shape until you got closer to the area of the concrete slab settlement.
• There were two major breaches in the CMP at the joints.  Soil was observed coming through the breaches.  These breaches were within the 75’ x 25’ rectangle of sunken concrete.
• The inside of the 12’ diameter brick manhole was in pretty good shape except for the base itself, which was pitted and had voids underneath.

A summary of the testing and the walkthrough/site evaluation indicated that the failure of the 72” CMP culvert joints led to major soil erosion, which in turn led to settlement and undermining of the concrete. Additionally, the base of the 12” diameter brick manhole was pitted and broken, leading to more soil infiltration and settlement around the base.

Powerful Polymers

Lift It Rite employed a variety of specialized materials to address the complex issues at the site. AP Fill 700, manufactured by Alchatek, played a crucial role in sealing pipe joints and deep soil stabilization. This NSF/ANSI 61-approved polyurethane resin features a low viscosity for soil permeation and an impressive 30x expansion factor. Its ability to react with moisture creates a squeezing and compaction effect in the soil, making it ideal for sealing infiltration in stormwater and sewer systems and stabilizing roadways.

Lift It Rite used Alchatek’s AP Lift 475 high-density polyurethane foam for concrete lifting and void filling. This two-component system expands 15x its original volume, creating a strong, watertight support structure. The team used a PMC PHX-40 plural component proportioner capable of 4 gallons per minute output to apply this material. For the CIPP point repairs, Pelican Underground was called in to install fiberglass and felt composite liner impregnated with epoxy resin. This combination creates a structural repair that restores the pipe’s original strength. Lastly, AW Cook supplied a polymer-modified concrete patching material to rebuild and provide a new wearable surface for the brick manhole base.

Painless Procedures

A proposal was made for a three-step repair:

• Lifting and void-filling the concrete slabs with high-density polyurethane.
• Permeation and pressure grouting of the soils with single-component geotechnical hydrophobic polyurethane resin.
• CIPP point repairs of the two breaches in the CMP and concrete repair for the 12’ diameter brick manhole base.

The proposal was accepted, and the work was done during September and October 2021.  The sequence of the work and details were as follows:

CMP (Corrugated Metal Pipe) Joint Injections and Soil Stabilization

Because of the amount of soil coming in through the failing CMP joints, Lift It Rite technicians decided it would be best to seal and encapsulate the joints with expanding polyurethane foam to create a temporary patch until the CIPP point repair contractor could mobilize.  This would stop the undermining of the concrete by eliminating the erosion pathways. 

The technicians went down through the 12’ diameter manhole and proceeded up the 72” CMP culvert to the failed joints.  At four locations, AP Fill 700 was injected in a clock pattern at the failed joints.  Injection holes were drilled through the wall of the CMP approximately 12” offset from the joint.  The resin was pumped until reacting polyurethane foam refused back through the joint breaches and sealed them off.  Once all the joints were sealed, the soil stabilization could proceed.

Two CMP pipe breaches and a brick manhole with infiltration issues occurred within a 75’ x 25’ area. DCP testing detected loose soil down to 28’ below grade. This CMP culvert had a constant flow of water through it, so the surrounding soils were wet and soft, and the soil infiltration into the CMP compounded this. The grout plan would involve permeation/compaction injections to stabilize this block of soil 75’ x 25’ x 28’ deep.

GCS performed additional GPR scanning before the soil stabilization grouting, and Ground Penetrating Radar Services came by to locate the water main and fire hydrant piping.

A grid pattern was laid out with approximately 3-5 foot spacing. Some spacing varied due to obstructions like the steel racks, etc. ABC Concrete Cutting was called in to core the 2” holes to accommodate the next step: forming the holes for the pressure grouting. Over 100 holes were cored in the 72’ x 25’ area.

Geotechnical Contractor GeoLab was called in to use Direct Push technology to form the grout holes with their Geoprobe machine.  Because of the clayey soils present, it was possible to press the holes using a 1-3/4” pressing tool and then extract the probe, leaving a 1-3/4” to 28’ deep hole pressed into the soil.  2” x 4’ long steel grout pipes were then hammered into the pressed holes to serve as grout pipes.  Each grout pipe was hammered 2-3 feet into the bored hole and then terminated at the top with a high-pressure valve and a quick connect.

The typical application rate for soil stabilization is around 1 gallon per vertical foot.  When the polyurethane resin is pumped into a pressed hole, the entire hole is pressurized, and the resin will find the weakest soil zones to penetrate and expand. AP Fill 700 was injected through the entire grid pattern of directly pushed holes using air-powered and gas-powered hydraulic-powered pumps. After 28 gallons were installed per point, the injections were stopped.  There was some contractor discretion on site if it was determined one point had looser soil and another area was tight.  A few holes could not be pumped because of the grout's migration, and the soil's compaction would cause an adjacent hole to be closed.  If a new pipe could be inserted there, the technicians would try and pump it, but typically, once a hole gets filled/squeezed shut, it becomes like rock in there, and the hole cannot be re-bored.

AP Fill 700 was also injected through ½” steel injection probes in a circumferential pattern around the 12’ diameter brick manhole.  These were extra injections in addition to the grid pattern to ensure the brick structure was sealed up and the soil around it compacted.  Looking down through the opening of the 12’ brick manhole, one can see the reacted grout permeating the loose brick walls.

Slab Lift and Void Fill

Slab lifting and void filling was done using AP Lift 475.  DOTs and geotechnical contractors use this type of structural polyurethane nationwide to lift concrete, support slabs, fill voids, and stabilize infrastructure.  The high-density poly is a two-component system with an A-side and a B-side chemical.  The reaction occurs when the two components meet, resulting in a high-density, watertight polyurethane foam.  This product expands 15x by volume, depending on conditions. The equipment used was a PMC PHX-40 plural component proportioner capable of 4 gallons per minute of output.

A grid pattern of approximately 4’ on center was drilled through the 75’ x 25’ slab. Injection holes were 3/8” in diameter. Each injection hole was checked with a probe before injecting poly, and in some areas, the technicians found voids up to 60”.  AP Lift 475 was injected beneath the concrete until the voids were filled and the lift was detected.  In areas requiring more lift, slab recovery was attempted with more injections.  Extra care was taken not to create too much lateral force when injecting around the brick manhole. 
A walk-behind concrete saw was brought in to cut the joints and free up binding slabs in the area where more lift was needed.  After the joints were freed, the technicians got more lift.  The 2” core and 3/8” injection holes were patched with concrete.

CIPP (Cured-In-Place Pipe) Point Repair

Pipe relining specialists from Pelican Underground were called in to perform point repairs on the two failed joints. They ultimately performed four-point repairs. One of the failed joints required two overlapped CIPP repairs. Additionally, they discovered and addressed an additional breach further up the pipeline.  
A CIPP point repair is a fiberglass and felt composite liner impregnated with epoxy resin and then pressed into the walls of the host pipe with pneumatic pressure.  A CIPP repair is a structural repair, not a patch.  That pipe is now as strong as new in those areas.

Before installing the point repair, a bypass pumping system was set up upstream from the repair work. Water was constantly flowing in this CMP, so it was dammed off and pumped (bypass) around the repair work area.  After the water was diverted, interior surface prep was performed.  This involved cleaning and removing AP Fill 700, which had permeated the pipe and coated the walls and floor, then pressing some of the jagged metal with hydraulics to bend it back into place as much as possible.  Sharp edges were also trimmed.

Once this was complete, the point repair liners were assembled.  They rolled out the fiberglass liner, coated it with epoxy, combined it with the felt liner, and then wrapped it around an inflatable packer.  That entire assembly was lowered through the manhole opening and pulled into place by the crew.  Compressed air was applied, and the packer expanded and pressed the CIPP liner into place.  The packer was then deflated and removed after the initial cure.  This was repeated for each point repair.

The brick manhole with the failing concrete base was then injected through the floor with polyurethane to fill any voids below it and provide support for rebuilding the base. Pelican Underground used a polymer-modified concrete patching material from AW Cook to fill any holes in the base and provide a new wearable surface for the concrete.

Rapid Results

Lift It Rite performed manual compaction testing by going through the 75’ x 25’ grid pattern with a ½” probe to see any loose soil zones.  With the manual probe, it was difficult to penetrate the ground, which indicated good compaction and void fill throughout the zone.

Ground Consolidation Services then brought back a dynamic cone penetrometer to do post-project DCP testing in the areas where testing had been done before. DCP results indicated a great increase in bearing capacity. A few shallow core samples were also taken and showed complete fill and compaction.

Ground-penetrating radar was then run along the same scan lines to compare before and after scans; those also showed improvement.

The Upper core sample showed high-density polyurethane that filled the void between the slab and subgrade.  The lower core is AP Fill 700 polyurethane binding gravel together.  There were areas of gravel encountered on site, and the permeation material glued it together into a solid mass.

Want more information on stabilizing soil with polyurethane?

Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $695.00
(Special pricing for all who register before October 7th at 5pm Eastern. $745 after.)

Location

To Be Determined
(in Georgia)

Discount

$50 discount for each additional participant.

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.

Aging culverts pose a significant challenge for many communities. As these vital drainage structures deteriorate, they can lead to road collapses, flooding, and environmental issues. Fortunately, culvert repair with curtain grouting offers a powerful and efficient solution to this problem. Moreover, this innovative technique can extend the life of culverts without the need for costly and disruptive excavation.

What is Curtain Grouting?

Curtain grouting is a specialized leak-sealing method. Specifically, it involves injecting water-activated resin through a leaking wall in a grid pattern. Once injected, the resin interacts with water on the other side. Consequently, it cures into a solid mass, effectively sealing the leak. This approach is particularly useful when there are many cracks or when cracks are not easily identifiable. Additionally, it proves effective in situations where traditional repair methods have failed.

The Curtain Grouting Process

The process of culvert repair with curtain grouting is straightforward yet effective. Here's a simplified overview:

1. First, technicians drill holes in a diamond pattern along the culvert wall.
2. Next, they inject grout from the bottom row upwards.
3. Subsequently, the grout flows down on the other side of the wall, creating overlapping circles of sealant and curing to stop the leaks.

This systematic approach ensures comprehensive coverage and, as a result, provides a robust seal against water infiltration.

Materials Used in Culvert Repair

Several types of resins are suitable for culvert repair with curtain grouting. These include:

• Spetec PUR H100: Offers lower expansion but more flexibility
• Spetec PUR H200: Provides high expansion with some flexibility
• Spetec PUR HighFoamer: Combines high expansion with enhanced flexibility
• Spetec AG200: Features low expansion but high flexibility and low viscosity, ideal for tight spaces

In essence, the choice of resin depends on the specific conditions of each culvert repair project. Furthermore, the versatility of these materials allows for tailored solutions to various leak scenarios.

Benefits Beyond Culverts

While this article focuses on culvert repair with curtain grouting, it's worth noting that this technique has broader applications. It's equally effective for sealing leaks in manholes, water treatment plants, catch basins, tunnels, and even basements. Therefore, this versatility makes curtain grouting an invaluable procedure in infrastructure maintenance.

A Lasting Solution for Leaking Infrastructure

Culvert repair with curtain grouting represents a significant advancement in infrastructure maintenance. A durable, flexible seal addresses the root causes of leaks and structural decay. Furthermore, it does so with minimal disruption to daily life and the surrounding environment. In conclusion, as communities grapple with aging infrastructure, this technique offers a beacon of hope for efficient, effective repairs. Ultimately, curtain grouting provides a long-term solution to the ongoing challenge of maintaining critical drainage systems.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on curtain grouting?