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.

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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.

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This guide outlines a step-by-step process for setting up your PolyBadger system for winter storage. Following these recommendations will not only preserve the integrity of your equipment but also make it easier to get it running when the warm weather returns.

Preparing a PolyBadger for Winter Storage

1. Establish power to the cabinet and heat the hose (A heater, B heater, and hose) to the target temperature of 130° F.
2. Introduce material to the cabinet.
3. Turn the air supply on and recirculate to heat up the ISO and resin.
4. Once the PolyBadger is up to temperature, turn off the air supply and remove the airlines from the stick pumps.
5. Remove the supply and the recirculation line from the A-side stick pump.
6. Drain all the remaining material from the pump and clean it with brake cleaner.
7. Place the stick A side stubby stick pump into a 5-gallon pail of AP Pump Flush.
8. Reconnect the supply line and leave the recirculation line to drain in a purge pail.
9. Repeat steps 5-8 on the B-side stick pump.
10. Reconnect the air supply to the stick pumps, hold the return lines in a purge pail, and slowly open the air valve on the stick pumps.
11. You will notice material slowly pushed out of the recirculation line into the purge pail. Continue to pump AP Pump Flush through the system until it comes out of the recirculation line clear, with no added color or debris.
12. Shut the air valve supplying the stick pumps. This will stop the flow of material.
13. Reconnect the recirculation lines to the appropriate stick pump and tighten.
14. Turn the recirculation pump valves to supply the hose.
15. You can remove the Handi Gun or leave it on for this stage, holding the hose in the purge pail. Turn on the supply valves on the end of the hose just before the Handi Gun. Slowly open the air valve on the stick pumps and pull the trigger on the gun.
16. You will notice material slowly pushed out of the hose line into the purge pail. Continue to pump AP Pump Flush through the system until it comes out of the hose line clear, with no added color or debris.
17. Shut the air valve supplying the stick pumps. This will stop the flow of material.
18. Remove the stick pumps from the AP Pump Flush. (Make sure to mark your pails A and B for future use).
19. Insert stick pumps into AP Pump Saver 195. (Make sure to mark your pails A and B for future use).
20. Push the AP Pump Saver 195 through the hose line. You will notice the AS Pump Flush slowly pushed out of the hose line into the purge pail. Continue to pump AP Pump Saver 195 through the system until it comes out of the hose line clear (you will notice a thick, clean fluid).
21. Turn off the supply valves on the hose just before the Handi Gun.
22. Disconnect the air supply to the stick pumps.
23. Move the hose supply valve into the recirculation position to depressurize the system.
24. Shut off supply valves to the cabinet.
25. Turn off heat zones.
26. Turn off the main disconnect.
27. Remove residual grease from interior cabinet pumps.
28. Replace with new grease.

If you follow these steps, your PolyBadger should be ready for secure storage during the winter months.

For in-depth information on geotech polyurethane applications...

As temperatures drop, contractors in certain areas need to winterize their slab lifting rigs for storage during the off-season. Below are the step-by-step guidelines to properly store your equipment.

Important Note

• Extra attention is devoted to the A-side of the system, which is standard practice.
• This guide assumes you're using a PMC pump for your slab lifting rig.

Preparing a Slab Lifting Rig for Winter Storage

1. Remove and clean the A and B stick pumps. Clean the exterior of the pumps with brake cleaner to remove as much residual resin and polyol as possible.
2. Place the A-Side transfer pump into a 5-gallon pail of the AP Pump Flush.
3. Remove the recirculation hose from the A-Side drum and place it in a purge pail.
4. Open A-Side inlet valve and recirculation valve on your PMC machine.
5. Slowly open the air valve on the A-Side transfer pump to start introducing the AS Pump Flush through the A-Side of the machine.
6. You will notice iso material being pushed out of the recirculation line into the purge pail. Continue to pump AS Pump Flush through the system until it comes out of the recirculation line clear, with no added coloring or debris.
7. Shut the air supply feeding the transfer pump. This will stop all flow of material.
8. Un-cap the A-Side of the PMC whip hose. Once un-capped, place the hose into the purge pail.
9. Close the recirculation valve on the A-Side of the PMC machine.
10. Slowly open the air valve on the A-Side transfer pump to start the flow of AS Pump Flush through the heated hose.
11. You will notice iso material being pushed out of the whip hose into the purge pail. Continue to pump AS Pump Flush through the system until it comes out of the recirculation line clear, with no added coloring or debris.
12. Now that this process is complete, the A-Side has been completely cleaned of any iso material.
13. Remove the A-Side transfer pump from the pail of AS Pump Flush and place it into a 5-gallon pail of AP Pump Saver 195.
14. Slowly open the air valve on the A-Side transfer pump to start introducing the AP Pump Saver 195 through the A-Side of the machine. Continue to pump the AP Pump Saver 195 until you have pure and clean AP Pump Saver 195 coming out of the end of the whip hose.
15. Place the B-Side stick pump into a separate 5-gallon pail of AP Pump Saver 195.
16. Slowly open the air valve on the B-Side transfer pump to start introducing the AP Pump Saver 195 through the B-Side of the machine and heated hose. Continue to pump AP Pump Saver 195 through the system until it comes out of the end of the whip hose, with no added coloring or debris.
17. Once the entire system is full of clean AP Lube 190, slowly start to recirculate the AP Pump Saver 195 through the entire system. When doing this, it is best to let the PMC machine cycle while recirculating the AP Pump Saver 195.
18. Once all these steps are complete, close the air on each transfer pump and re-cap the heated PMC whip hoses.

If you follow these steps, your slab lifting rig should be well-prepared for the winter storage period.

For in-depth information on geotech polyurethane applications...

Alchatek's AP Surface Guard 125 is a water-based barrier product specifically used for protecting concrete from polyurethane resin stains. AP Surface Guard 125 may also be used to purge mixed resin from the MixMaster gun block only. Do not use to purge hoses as it is a water-based product and will react with isocyanate (part A).

Applications

• Preventing foam from staining/bonding to concrete and other surfaces.
• Flushing polymers from the MixMaster impingement gun.

Advantages

• Environmentally safe.
• Biodegradable.
• Zero toxicity.

Packaging: 5 Gallon Pails
Item #: 125M005

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Polyurethane grouting is an essential process in construction and infrastructure projects with the need to lift structures, fill voids, and stabilize soil. While polyurethane grouting has been utilized for decades, advancements in technology and technique have enabled a new level of precision and control in modern grouting applications. Innovations in polyurethane injection methods and equipment allow design and construction teams to achieve highly accurate, consistent injections for maximum strength and longevity. 

Precision is critical in polyurethane grouting applications. Inadequate filling of voids or inconsistent distribution of grout can lead to structural instability, settlement, and even collapse. Precise injections ensure that soil is saturated, voids are filled, and slabs are leveled accurately. This provides uniform load distribution and protection against shifting, vibration, and erosion. Precision also prevents wasted materials and rework due to incorrect amounts or placement of grout. 

Modern polyurethane grouting equipment and techniques enable accurate monitoring and adjustment of grout injection rates, depths, pressures, and consistency. Some examples of modern technology include: 

• Hydraulic and Electric Pumps: Modern polyurethane injection equipment includes hydraulic or electric pumps. These pumps provide precise control over pressure and flow, ensuring a more uniform injection of grout material.
• High-Pressure Injection: Modern equipment can handle high-pressure injection, making it suitable for stabilizing deep structures and addressing challenging soil conditions. High-pressure injection ensures better penetration of the polyurethane grout.
• Remote Monitoring and Data Logging: Advanced systems come with remote monitoring and data logging capabilities when necessary. Operators can monitor the injection process remotely and collect data on pressure, flow, and other parameters for quality control and documentation.
• Compact and Portable Systems: Some advanced injection grouting systems are designed to be compact and portable, making them easier to transport to job sites and set up quickly.
• Safety Features: Modern equipment includes safety features such as shut-off valves and pressure relief mechanisms to protect both operators and the equipment itself.

Modern polyurethane grouting equipment has revolutionized construction and infrastructure project challenges, offering engineers and design teams an array of precision-driven advantages. The evolution of polyurethane injection equipment, including hydraulic pumps, pneumatic pumps, and computerized control systems has empowered design teams and application technicians to achieve precise outcomes.

For more information...

Alchatek offers world-class custom-built pump systems for both slab lifting and soil stabilization applications. If you're looking for a full-sized trailer rig system, click here to read more on that subject. In this blog post, we'll take a look at two propriety systems designed by the professionals at Alchatek. 

The PolyBadger: Compact Lifting System on Wheels

The wheel-mounted PolyBadger two-component pump system is an extremely valuable addition to any slab lifter's arsenal. It is perfect for new contractors looking to make an initial investment and for experienced contractors looking to add a portable option for those hard-to-reach locations. Small enough to fit in the back of a pickup truck, this simple system requires minimal equipment.

• Lower Initial Investment
• Less Equipment Needed
• Easily Fitted to a Truck, Trailer, or Cart

The PolyShark: Skid-Mounted Soil Stabilization System

The skid-mounted PolyShark single-component pump system is essential for large-scale soil stabilization and void-fill projects. The PolyShark system includes a gas-powered high-pressure injection pump, two hose reels, and flow meters. The entire skid-mounted system can easily be fitted to a flatbed truck for efficient transport.

• Ideal for Large-Scale Jobs
• Complete System (Pump, Hose Reels, Flow Meters)
• Easily Fitted to Flatbed Truck

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Alchemy-Spetec HQ in Tucker, GA

Registration Deadline - April 15th

May 2nd - May 4th
$745 Registration Fee
$665 for each additional participant from
the same company.

Get ready for a thorough education in Slab Lifting, Soil Stabilization, the Deep Lock® process, Crack Injection, and Curtain Grouting. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Agenda Items

• Geotech Product Line Overview
• Geotech Applications & Case Studies
• MixMaster Pro Slab Lifting Gun
• Slab Lift Rig Demonstration
• Pump Demos & Training
• PolyShark® / Soil Stabilization
• Deep Lock® 
• Ground Penetrating Radar
• PolyBadger® Mobile Slab Lifting System
• Crack Injection
• Curtain Grouting
• Estimating Material for Jobs

Alchemy-Spetec HQ in Tucker, GA

May 2nd - May 4th
$745 Registration Fee
$665 for each additional participant from
the same company.

Get ready for a thorough education in Slab Lifting, Soil Stabilization, the Deep Lock® process, Crack Injection, and Curtain Grouting. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Agenda Items

• Geotech Product Line Overview
• Geotech Applications & Case Studies
• MixMaster Pro Slab Lifting Gun
• Slab Lift Rig Demonstration
• Pump Demos & Training
• PolyShark® / Soil Stabilization
• Deep Lock® 
• Ground Penetrating Radar
• PolyBadger® Mobile Slab Lifting System
• Crack Injection
• Curtain Grouting
• Estimating Material for Jobs

Alchemy-Spetec HQ in Tucker, GA

May 2nd - May 4th
$745 Registration Fee
$665 for each additional participant from
the same company.

Get ready for a thorough education in Slab Lifting, Soil Stabilization, the Deep Lock® process, Crack Injection, and Curtain Grouting. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Agenda Items

• Geotech Product Line Overview
• Geotech Applications & Case Studies
• MixMaster Pro Slab Lifting Gun
• Slab Lift Rig Demonstration
• Pump Demos & Training
• PolyShark® / Soil Stabilization
• Deep Lock® 
• Ground Penetrating Radar
• PolyBadger® Mobile Slab Lifting System
• Crack Injection
• Curtain Grouting
• Estimating Material for Jobs