Alchatek Blog

The Army Corp of Engineers (ACOE) builds and manages numerous projects along the rivers and waterways of the United States. On our mightiest river, the Mississippi, the ACOE was tasked with upgrading the large siphon systems that are used to draw down the river level during flood events. To prevent catastrophic flood damage, these siphons kick on if the river is going to crest over the top of the levees.

The first thing you see when you visit the site is a massive concrete bulkhead about 30 feet tall, 8 feet thick, and over 100 feet wide. Penetrating through the bulkhead are eight 84” ductile iron pipes through which the river water is ejected if the siphon kicks on. It is at these penetrations that the ACOE was looking for some ideas.

When the bulkhead was constructed, eight large square holes were formed across the face before pouring the concrete. It is through these large square holes that the 84” diameter pipes are placed. The ACOE was looking for solutions to fill the annular space between the round pipe and the square hole.

Powerful Polymers

After consulting with New Orleans-based contractor KMH Coatings and the ACOE, it was decided that a high-density polyurethane foam would be perfect for the application. NSF-approved AP Lift 430 was selected as the go-to product. Its combination of excellent strength, yield, and bond is ideal for these kinds of structural void fill applications, but most importantly it is watertight.

Painless Procedures

KMH mobilized their polyurethane spray rig and the AP Lift 430 was sprayed into the annular space around each of the 8 pipes. AP Lift 430 is most commonly known as a first-class concrete lifting polymer but a large percentage of applications are void fills. Once the void was filled, they attempted to cut off the overspray but it proved to be too dense to cut. Instead, a disc grinder was used to sand down the polymer foam flush with the face of the concrete bulkhead.

Rapid Result

The ACOE was extremely impressed by the toughness of the product and with the minimal time that it took to install it; two days from start to finish. 

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In Cape Canaveral, Florida, a heavily loaded slap stand structure was planned for construction along a transfer aisle in the Vehicle Assembly Building (VAB). This slap stand would be critical in servicing the proposed Space Launch System vehicle (SLS). However, the project faced a significant challenge when it was discovered that the near-surface subsoils consisted of loose fill materials susceptible to further densification and volume loss due to vibrations and water infiltration. With the slap stand tentatively designed to bear directly upon the ground-level floor slab of the VAB, the degree of subsoil support beneath the floor slab section became a critical concern.

Powerful Polymers

To address this issue, the geotechnical engineer of record recommended a ground improvement solution using permeation grout. Helicon, a leading soil stabilization contractor, worked alongside the geotechnical design team to develop a permeation grout program that would meet the building code load criteria. AP Soil 600, a high-strength, hydro-insensitive structural polyurethane foam, was selected as the ideal product for this project due to its exceptional ability to support heavy structures.

Painless Procedure

Helicon’s technicians installed permeation grout injection pipes on a center-to-center spacing of approximately 2 feet across each of the slap stand areas. The injection points were driven to a depth of at least 5 feet below the floor slab grade. Grout was injected at a relatively low pressure (less than 50 psi), and grout needles were slowly withdrawn during pumping to ensure a uniform distribution of grout to about 3 feet below the bottom of the slab level. The amount of grout used was carefully controlled, with less than 15 gallons per foot per injection point.

Rapid Result

The permeation grout project was a resounding success, effectively improving the load-bearing capacity of the existing soils at the site. The precise application of AP Soil 600 ensured that the slap stand structure would have a stable and reliable foundation, allowing for the safe and efficient servicing of the Space Launch System vehicle. Thanks to Helicon’s expertise and the power AP Soil 600, this piece of critical infrastructure in Cape Canaveral was reinforced and readied for countless future space exploration missions.

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Essential Details

Dates/Pricing

Slab Lifting Masterclass: April 15th & 16th, 2024 – $685.00
Public Works Infrastructure Repair: April 18th & 19th, 2024 – $685.00

Location

Spray Foam Systems
1502 Airport Rd.
Greensboro, GA 30642
Click Here for Directions

Discount

Register for both classes and get a 25% discount

Slab Lifting Masterclass: April 15th & 16th, 2024 – $685.00

The concrete lifting master is an intensive opportunity to learn what it takes to start a concrete lifting business and then take it to the next level. The training you will receive will include Safety, Site Evaluation, Estimating, Product Selection, Sales, Equipment, Concrete Lifting Techniques, and Deep Lift / Deep Lock. You will also learn about taking your concrete lifting business to the next level. You will learn about other tools we have to help you land bigger jobs and how to engage the engineering community to gain access to unique markets. Join the industry’s top team of concrete lifting professionals for training, learning, and fun.

Public Works: April 18th & 19th, 2024 – $685.00

The public works course is two days dedicated to training and teaching Public Works professionals and specialty grouting contractors. You will learn how to utilize polyurethane technology to solve problems that municipalities and public works departments commonly face and how to do it at a fraction of the cost of traditional methods. There will be a heavy emphasis on sealing underground infrastructure and stabilizing and lifting roads. We will cover the full spectrum of our product line including Leak Seal, Permeation, Soil Stabilization, and Slab Lifting. Join the industry’s top team of infrastructure specialists for training, learning, and fun.

Make Higher Margins with Slab Lifting

Booth: 324

Dates: March 5th & 6th , 2024

Hours: March 5th 2pm – 6 pm, March 6th 2pm – 5pm

Location: Westgate Resort in Las Vegas, Nevada

Website: Sprayfoam.org/Sprayfoam24

Come by our booth at the show to speak with our slab lift experts and learn just how easy and affordable it is to maximize your profits. We'll explain how you can equip your current spray foam rigs to lift slabs. With just a minor investment in some additional slab lifting equipment and materials, you can equip your current spray foam rigs for these lucrative new jobs. Slab lifting takes less time, uses less material, and brings in more revenue per job than standard spray foam work.

Speaking Engagement

Speaker: Erik Prinzing

Subject: Spray Foam Rig to Lifting Rig Conversion

Date & Time: March 5th, 11:00am

Location: Pavilion 3

In this seminar, you will learn how to make higher margins by equipping your existing spray foam rigs for more lucrative slab lifting jobs that take less time, require less material, and net more money per job than standard spray foam applications.

Erik Prinzing is a driven professional with over 20 years of experience in the construction sector. Over the years Erik has become well-rounded in construction practices, with experiences ranging from working in the field as a contractor to assisting customers as a regional manager in the concrete leveling industry.

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Before embarking on any bird bath repair project using the Deep Lock® process, it's crucial to consult with industry specialists. The Alchatek support team, with extensive experience in advanced pavement repair techniques, offers invaluable insights for assessing site conditions, choosing appropriate materials, and implementing effective repair strategies.

In addition, Alchatek has established connections with skilled contractors proficient in the Deep Lock® process. Ask for referrals to trusted professionals who ensure the safe and efficient execution of your pavement repair projects.

Partner for Success

Don't leave the durability and safety of your roads to chance. Partner with Alchatek to harness the full potential of the Deep Lock® process for your bird bath repair needs. Our expertise in advanced road repair techniques makes us the ideal ally in ensuring long-lasting and effective solutions.

Reach Out Today

To learn more about how Alchatek can assist in your road repair projects or to get connected with experienced contractors, contact Alchatek.

Call 404-618-0438 or fill out this form to contact Alchatek today!

In the previous post, the causes and consequences of bird baths in road pavement were explored. Now, attention will turn to an innovative solution for repairing these issues: the Deep Lock® process.

The Deep Lock® Process Explained

The Deep Lock® process is a unique method for stabilizing and repairing bird baths in roadways. Here's how it works:

1. Site Evaluation: It starts with a comprehensive site evaluation, including soil borings, Dynamic Cone Penetration (DCP) testing, and Ground Penetrating Radar (GPR) as necessary.
2. Preparing the Area: Potential binding issues are addressed with saw cutting, clearing joints, and removing old grout.
3. Grid Spacing and Injection Depths: Based on the soil data, specialists calculate grid spacing and injection depths.
4. Injection Process: Specialized grout rods are driven to the correct depths and locations.
5. Polymer Injection: Structural polymers are injected in a predetermined sequence. During this, lift is monitored to determine when sufficient compaction has been achieved.
6. Adjusting Injection Depths: The grout plan is followed, adjusting injection depths and locations as the soil stabilizes beneath the structure.

Equipment and Materials

The process utilizes high-quality structural polymers, including AP Deep Lift 420, AP Lift 430, AP Lift 440, and AP Lift 475. These materials are chosen for their strength, environmental safety, and their NSF/ANSI/CAN 61 certification for contact with drinking water. This means they can be used without negatively impacting water quality.

Securing Repair Contracts

For contractors looking to secure bird bath repair jobs:

• Reach out to Departments of Transportation (DOTs), cities, and municipalities.
• Network with neighborhood and Homeowners' Association (HOA) associations.
• Emphasize your ability to provide a quick, environmentally safe solution with minimal disruption.

Deep Lock® Repair for Bird Baths

The Deep Lock® process offers a revolutionary approach to repairing bird baths in road pavement. With its quick application, minimal environmental impact, and long-lasting results, it stands as a preferred choice for modern road maintenance. If you're facing bird bath issues on your roadways, consider consulting a professional who specializes in the Deep Lock® process for effective, durable repairs.

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Have you ever noticed shallow, pond-like formations on the surface of roads, particularly in private neighborhoods, subdivisions, or parking lots? These are known as "bird baths" in the road surface, and they're more than just a quirk of the road. They signify deeper issues in road maintenance and safety that are crucial to address.

What are Bird Baths in Road Pavement?

Bird baths are small depressions in the road surface where water accumulates. Unlike potholes, bird baths are shallower and often wider, resembling a natural birdbath. They typically form in areas where the pavement has sunk or where water is unable to drain properly. These features are commonly seen in areas with lower traffic, like private neighborhoods and parking lots, where regular maintenance may not be as common.

Causes and Consequences

The primary causes of bird baths in pavement include tire ruts from repetitive vehicle traffic and insufficient soil compaction during road construction. Over time, the weight of vehicles passing over the same spot causes the pavement to deform, creating these depressions. Additionally, if the underlying soil was not compacted properly, it can settle unevenly, leading to surface irregularities.

The presence of bird baths is not merely a cosmetic issue. They can pose significant trip hazards for pedestrians, especially when hidden by water or ice. For vehicles, these depressions can lead to uncomfortable rides and, in some cases, damage to the vehicle itself. In winter, bird baths can be particularly dangerous as they form ice patches, posing a risk for both vehicles and pedestrians. Furthermore, they can also cause problems for snowplows, leading to inefficient snow removal and additional road wear.

Road Pavement Birth Baths

Understanding the causes and effects of bird baths in road pavement is crucial for effective road maintenance and safety. Addressing these issues not only improves the longevity of the pavement but also ensures a safer environment for all road users. The next part of the series will delve into bird bath repair methods, focusing on innovative techniques offering long-lasting solutions, such as the Deep Lock ® process.

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Addressing the complexities of coating failure requires more than just a superficial understanding of the issue. It necessitates a deep dive into the technical aspects and an experienced partner to guide the process. 

For Contractors: Guidance and Product Access

Guidance from experienced specialists provides major advantages when dealing with coating failures. The right partner will have deep knowledge of leading repair products and solutions to accurately diagnose issues and devise effective repair strategies. Contractors can benefit from Alchatek's expertise and facilitate access to high-quality products like Spetec PUR HighFoamer through their distribution network. This thoughtful approach saves contractors time in devising solutions while ensuring access to optimal materials.

For Property Owners & Managers: Guidance and Contractor Referrals

Property owners seeking solutions for coating failure damage need a partner who can provide expert technical guidance and connect them with qualified repair contractors. Partnering with Alchatek for coating failure projects provides comprehensive support beyond just an immediate fix. 

Contact Alchatek for Assistance

Whether you’re a contractor seeking to accurately diagnose and repair issues or a property manager aiming to preserve real estate assets, guidance from industry experts proves invaluable. Technical mastery combined with access to optimal materials paves the path to effective long-term solutions.

Call 404-618-0438 or fill out this form to contact Alchatek today!

Want more information on sealing leaks with polyurethane grout?

In the field of coating failure solutions, curtain grouting with polyurethane is very effective, especially in scenarios where water intrusion is a primary concern. Curtain grouting is an effective method that not only addresses existing coating failures but also acts as a preventive measure.

Curtain Grouting for General Coating Failure

• Historical Context: Originating in the 1960s, curtain grouting has evolved into a reliable method for strengthening and waterproofing structures. Its application has been crucial in extending the lifespan of countless structures.
• Process Overview: The procedure involves strategically drilling holes and injecting a specialized grout, forming a barrier that prevents water from penetrating the structure. This barrier is instrumental in preserving the integrity of coatings, protecting them from the harmful effects of moisture.

Step-by-Step Guide to Implementing Curtain Grouting

1. Drilling Pattern: Holes are drilled in a grid pattern.
2. Grout Injection: Starting from the lowest point, grout is injected and gradually worked upwards, ensuring complete coverage.
3. Overlap Technique: Each subsequent layer of grout overlaps the previous one, creating a comprehensive barrier against moisture.

Curtain Grouting for Precast Concrete Manholes

• Historical Overview: Introduced in the mid-1950s, precast concrete manholes became the standard by 1970. Now, many of these structures are hitting or have surpassed their 50-year design life.
• Urgency of Maintenance: Given the age of these manholes, many may be nearing the end of their structural life, particularly considering the damage factors like hydrogen sulfide corrosion can inflict over time.

The Hidden Threat of Hydrogen Sulfide Corrosion

• EPA Report Findings: An Environmental Protection Agency technical report highlighted the alarming rate of concrete degradation due to hydrogen sulfide, potentially eroding an inch of concrete every decade.
• Implications for Maintenance: This rate of erosion is a clarion call for municipalities and communities to proactively inspect and maintain their manhole structures, especially as they approach or exceed 50 years.

Epoxy Coating and Curtain Grouting

• Popularity and Effectiveness: Epoxy coatings are widely used to protect manhole interiors from corrosion and water intrusion.
• Importance of Proper Application: Before applying an epoxy coating, it is critical to address any water leaks to ensure the longevity and effectiveness of the coating.
• The Role of Curtain Grouting: To ensure the success of epoxy coatings, it's essential to first halt any water intrusion. Curtain grouting stands out as a highly effective method for this.

Curtain Grouting with Spetec PUR HighFoamer

• Product Application: Alchatek's Spetec PUR HighFoamer is particularly effective in curtain grouting applications. Its properties make it suitable for creating durable, water-resistant barriers that are essential for preventing and repairing coating failures.
• Versatility: This product is compatible with a variety of structural materials, reinforcing its usefulness in diverse scenarios where coating integrity is compromised due to water intrusion.

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Coatings are more than just a cosmetic layer on a structure; they play a vital role in protecting buildings from various environmental factors. Essentially, a coating is a layer of material applied to the surface of an object, intended to protect, decorate, or add functionality. In terms of structural integrity, coatings serve as a barrier against moisture, chemicals, UV radiation, and mechanical wear. They prevent corrosion, enhance durability, and ensure that the underlying material, such as concrete, metal, or wood, remains unharmed by external elements.

Water Intrusion: A Major Cause of Coating Failures

Water intrusion is a common cause of coating failures. When water seeps into a structure, it can compromise the coating's adhesion to the substrate, leading to various forms of deterioration. The presence of water can cause blistering, and peeling, or even promote microbial growth, which accelerates the degradation process. Understanding the dynamics of water intrusion and its impact on different types of coatings is critical in diagnosing and addressing these failures effectively.

The Importance of Early Detection and Repair

The early detection and repair of coating failures are paramount in maintaining the structural health of a building. Regular inspections and maintenance can identify potential issues before they escalate into major problems. Understanding the signs of coating failure and the conditions that promote it is crucial for any maintenance or engineering team.

Causes of Coating Failure

Understanding why coatings fail enables architects, contractors, and facilities managers to mitigate risks during design, construction, and maintenance.

• Osmotic Blistering: Osmotic blistering occurs when water permeates through a coating, creating a difference in osmotic pressure which leads to blister formation. These blisters can lead to coating detachment and expose the underlying substrate to further damage.
• Microbially Induced Corrosion (MIC): MIC happens when microorganisms, such as bacteria and fungi, interact with coatings and the substrate, leading to accelerated corrosion. This can weaken structural integrity and lead to costly repairs or replacements.
• Poor Surface Preparation: Inadequate surface preparation can result in poor adhesion, leading to peeling, blistering, and delamination.
• Poor Coating Application: Common mistakes include uneven application, incorrect thickness, and improper curing.
• Adhesion Failure: Adhesion failure can occur due to incompatibility between the coating and substrate, and the presence of contaminants, or moisture.
• Cracking and Peeling: Cracking and peeling often occur due to environmental factors, movement in the substrate, or aging of the coating.

The Curtain Grouting Solution

Curtain grouting is a specialized construction technique used to prevent water intrusion in structures by creating a waterproof barrier. The process involves drilling a pattern of holes into a wall and then injecting a grout material, which usually forms a resin-soil mixture, to seal off water pathways. The next post will explore the curtain grouting process more deeply. Stay tuned for insights into leveraging curtain grouting to maintain structural integrity and longevity in the face of coating failures.

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