Alchatek Blog

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.

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.

Want more information on the Deep Lock® process?

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.

Want more information about the Deep Lock® process?

If you're a contractor grappling with deep soil stabilization challenges or looking to expand service offerings, Alchatek offers comprehensive support and training to elevate skills and expand business opportunities. Here's how the Alchatek team can assist you in enhancing your Deep Lock® soil stabilization capabilities:

Skill Upgrades for Contractors

• If you're currently facing difficulties with deep soil stabilization projects, Alchatek provides the expertise to upgrade your skills and tackle these challenges effectively.
• For slab lifting contractors, incorporating the Deep Lock® process into your service offerings can be a significant step towards diversifying your business and increasing revenue.

Technical Guidance and Support

• Alchatek's technical support team is highly skilled in on-the-job applications of deep soil stabilization techniques.
• The team brings a wealth of experience, having successfully consulted on a wide range of projects.
• On-the-job training is available, offering practical, hands-on learning to ensure you are fully equipped to handle various stabilization scenarios.

Comprehensive Training Programs

• Alchatek offers training programs, which are designed to provide in-depth knowledge and hands-on experience in the latest soil stabilization techniques.
• Training programs are an excellent opportunity for contractors to learn directly from experts and gain valuable insights into the industry’s best practices.

Collaboration with Engineers

• Alchatek assists contractors in working with engineers. This includes providing education and specification assistance to ensure that engineers are well-informed about the Deep Lock® process and its benefits.
• The support team can help bridge the gap between contractors and engineers, facilitating smoother project execution.

Project Design Support

• This service ensures that your deep soil stabilization projects are well-planned, efficient, and effective.
• Alchatek experts can help you design your projects from the ground up, ensuring the best possible outcomes for your clients.

Contact Alchatek Today

If you’re looking to enhance your deep soil stabilization services or need expert assistance, reach out to Alchatek today. With comprehensive support, training, and vast experience, you can confidently tackle any soil stabilization challenge and grow your business.

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

Want more information on the Deep Lock® process?

This post features three case studies that highlight the versatility and effectiveness of the Deep Lock® process across a variety of applications.

Deep Soil Stabilization at a Shopping Center

• Location: City Creek Center, Salt Lake City.
• Problem: A trench filled with pea gravel began settling, affecting underground power lines.
• Solution: The trench was stabilized using structural polymers.
• Process: An Alchatek consultant developed an injection plan, and the geotech crew installed 10 injection tubes 30 feet deep, pumping approximately 1 gallon per vertical foot.
• Outcome: The site work was completed in just two days, allowing for the rapid continuation of the construction work.

Deep Soil Stabilization for New Construction

• Location: A commercial construction site.
• Problem: The need to stabilize gravel and soil held in place by sheet pile panels between the panels and the foundation.
• Solution: Structural polymers were used due to their ability to permeate soil and encapsulate gravel into a solid mass.
• Process: The crew injected the polymer to a depth of about 12 feet, grouting to refusal, ensuring the entire layer of soil and gravel was locked in place.
• Outcome: The stabilized soil and gravel provided a solid supportive wall for the foundation when the sheet piles were removed, and the gap filled with cement.

Deep Soil Stabilization at a Two-Story House

• Location: A two-story house in North Carolina, built on poorly compacted fill dirt.
• Problem: The house showed signs of settling, with interior cracks and uneven floors.
• Solution: A structural foam was used for its high-strength, hydro-insensitive properties, ideal for densifying soil and stabilizing foundations.
• Process: 18 injection tubes were installed to depths of 7 feet and 3.5 feet, injecting foam beneath exterior footings and load-bearing interior walls.
• Outcome: The stabilization process not only densified the soil and stopped the settlement but also achieved a half-inch lift both from exterior and interior injections, impressing both the customer and the engineer.

These case studies demonstrate the adaptability and effectiveness of the Deep Lock® process in addressing diverse soil stabilization challenges. From commercial construction sites to residential properties, Deep Lock® provides a reliable and efficient solution for soil stabilization needs.

Want more information on the Deep Lock® process?

In the world of soil stabilization and concrete leveling, the choice of materials is as important as the technique used. Alchatek's Deep Lock® process utilizes a range of specialized structural polymers, each designed to cater to specific stabilization needs.

Structural Polymers for Deep Stabilization

Here's an overview of the key polymers used in the Deep Lock® process:

• AP Lift 430:
  This polyurethane foam is adequate for the vast majority of deep soil stabilization jobs. AP Lift 430 is known for its versatility and reliability, making it a go-to choice for standard deep stabilization tasks. It provides a strong, stable, and durable solution for most soil types and conditions.
  
  
• AP Lift 440:
  AP Lift 440 is formulated for jobs where the soil supports structures larger than a single-story house.  This foam supports a bit more weight compared to AP Lift 430, making it suitable for heavier and more demanding applications. It's ideal for projects that require additional strength and stability, particularly in supporting larger buildings or heavier structures.
  
  
• AP Deep Lift 420:
  This is a specialized polyurethane foam used in scenarios where a slight lift is required along with deep soil stabilization. AP Deep Lift 420 is designed to offer slight lifting, soil stabilization, and void-filling capabilities, making it an excellent choice for projects where minor elevation adjustments are necessary along with stabilization. Its unique formulation allows it to address both settlement issues and provide additional support to the foundation or structure.

Technical Support for Product Selection:

Choosing the right polyurethane foam for a specific project can be a complex decision. Alchatek’s technical team is available to assist contractors in selecting the most suitable product for their specific needs. With in-depth knowledge of each product’s properties and the varying demands of different stabilization scenarios, the tech team can provide valuable guidance. This ensures that the chosen foam perfectly aligns with the project requirements, soil conditions, and the desired outcome.

Want more information on the Deep Lock® process?

The Deep Lock® process, a robust and effective method for soil stabilization, requires specialized equipment to ensure precision and efficiency. Here's a breakdown of essential equipment for Deep Lock® soil stabilization in cold weather:

• PMC PH2 Hydraulic Proportioner (or Equivalent):
  Used to inject two-component structural polyurethane foams for Deep Lock® soil stabilization, as well as void filling and slab lifting. The PMC PH2 Hydraulic Proportioner is known for its durability and reliability, using relays and circuit breakers instead of circuit boards to enhance reliability and reduce maintenance issues.
  
  
• MixMaster Pro Injection Gun:
  Specifically manufactured for injecting two-component structural polymers, the MixMaster Pro is designed to handle back pressure effectively.
  
  
• Drum Heaters:
  Drum heaters are employed to maintain the temperature of the materials in 50-gallon drums, ensuring proper viscosity and preventing freezing.
  
  
• Space Heater:
  Utilized to maintain an optimal working temperature in the rig, especially crucial in colder environments.
  
  
• Hilti TE 60 Drill (or Equivalent):
  A powerful drill is essential for creating the necessary openings in the soil for the ground rods.
  
  
• 36-64” Drill Bit:
  Strong enough to penetrate through frozen surfaces, this drill bit is essential.
  
  
• 16-18 Gauge Half Inch Ground Rod Tubing – 10 Foot Sticks:
  These ground rod tubing sticks are integral for the precise delivery of materials during the stabilization process.
  
  
• Ground Rod Driver:
  This tool is used for driving ground rods into the earth. It facilitates the installation of ground rods, making the process safer and faster.
  
  
• Rotary Level and Receivers:
  These tools are vital for measuring surface levels. The rotary level emits a rotating laser beam to create a horizontal plane, while the receiver detects the laser beam over long distances, ensuring accuracy and precision in the stabilization and – if necessary – lifting process.

Each piece of equipment plays a critical role in the Deep Lock® process, ensuring that the soil stabilization and concrete leveling tasks are performed efficiently, accurately, and safely, even in challenging weather conditions. Employing the right tools not only enhances the effectiveness of the process but also contributes to the longevity and stability of the treated structures.

Want more information on the Deep Lock® process?

Deep Lock® is a specialized deep soil stabilization process developed by Alchatek. It involves injecting a structural polymer deep into the soil, where it expands and solidifies. This process enhances the stability and strength of the soil, making it an effective solution for various geotechnical challenges. One key feature of Deep Lock® is its ability to stabilize soil below the freeze/thaw line, making it particularly useful in cold weather conditions.

Applications of Deep Lock® in Cold Weather

• Foundations: Deep Lock® is extensively used to stabilize and strengthen foundations, especially in areas where the soil is compromised due to moisture or other factors.
  
  
• Under Sunken Slabs: For sunken slabs, where soil erosion or voids have occurred deeper down, Deep Lock® provides an effective solution to fill and stabilize these gaps.
  
  
• Settling Structures: Entire structures that are settling, not just the slab, can benefit from the deep soil stabilization offered by Deep Lock®.
  
  
• Interior Footings: In scenarios where exterior piers are used for stabilization, Deep Lock® can be employed for interior footings, avoiding damage to floors and providing a balanced stabilization approach.
  
  
• Brick and Stone Foundations: These types of foundations, which are challenging to stabilize with piers, can be effectively supported using the Deep Lock® process.
  
  
• Pre-construction Soil Stabilization: Before construction begins, stabilizing the soil ensures that the foundation rests on solid ground, a crucial step for long-term structural integrity.
  
  
• Culverts: Deep Lock® can be used for stabilizing and sealing culverts both from the outside (probe-grouting style) and from the inside by injecting the polymer just below the steel.

Why Deep Lock® is Used in Cold Weather

Cold Weather Performance: Deep Lock® can be performed even when the top layer of soil is frozen, making it ideal for cold weather applications.

• Addressing the Root Cause: By stabilizing soil deep below the surface, Deep Lock® addresses the underlying causes of structural problems rather than just the symptoms.
  
  
• Preventing Resettlement: It ensures that once slabs or structures are stabilized, they remain in place without resettling.
  
  
• Warranty Benefits: When employing the Deep Lock® process, contractors can offer better warranties due to effective and long-lasting stabilization.
  
  
• Ease of Process: The process is relatively easy to learn and implement, making it a practical option for a wide variety of contractors.

Deep Lock® offers a versatile and effective solution for a range of soil stabilization needs, particularly beneficial in cold weather conditions. Its ability to work below the freeze/thaw line and address deep-rooted soil issues makes it an invaluable tool in the geotechnical contractor’s arsenal.

Want more information on the Deep Lock® process?

Unstable soils present significant challenges in civil engineering projects. Whether caused by erosion, improper compaction, freeze-thaw action, or decay of buried organic matter, loose and shifting soils undermine structural integrity. Together, these mechanisms prevent soil from remaining firmly in place. This necessitates methods to stabilize and strengthen the matrix. Geotechnical engineers must find solutions to reinforce the substrate and restore load-bearing capacity.

Polymer injection grouting offers an innovative approach, transforming loose soil into a strong, consolidated mass. These polymeric resins permeate porous soils and compact denser soils, then expand and cure in place. The resulting soil-polymer matrix has high compressive strength, stopping subsidence, erosion, and migration of fines. Alchatek's standard soil stabilization products and deep soil stabilization products provide specification-grade stabilization.

Polymer Foam Stabilization Mechanisms

• Permeation of loose sediments, gluing them into a firm matrix
• Displacement of water from eroded zones, reversing further erosion
• Filling of void spaces from decayed organics or poor compaction
• Adhesion to soil particles creates a strong substrate

Additionally, these foams are NSF/ANSI/CAN 61 certified for contact with potable water supplies. This enables environmentally safe use.

Performance Characteristics

Polymeric foams provide exceptional soil stabilization and foundational reinforcement. Key advantages include:

• Ability to permeate and treat loose or unstable soils in situ without excavation
• Ability to compact dense soils such as clay
• High compressive and shear strength, restoring structural load capacity
• Permanent stabilization without ongoing maintenance requirements
• Mitigation of subsidence or erosion with bonded soil matrix

When applied correctly, polymeric foams offer lasting soil stabilization and ground improvement. Alchatek case studies document successful performance for applications including commercial, industrial, new construction, and other geotechnical engineering projects.

Additional Guidance for Geotechnical Engineers

Specify these advanced soil grouting products to permanently resolve instability issues. They deliver rapid installation, minimal invasive work, and results that last. Let us provide guidance on product selection, specs, and installation techniques for your next soil stabilization project. Polymer grouting is an innovative, low-impact way to reinforce unstable ground.

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