Alchatek Blog

As we stated in a previous blog post, Lifting Slabs in Cold Weather, there are plenty of jobs that need to be done in the winter. This is just as true for sealing leaks as it is for slab lifting. So let's take a look at those cold weather leak seal markets. We'll also review some special considerations for conditioning leak seal material and equipment. Then we’ll leave you with a few cold temperature leak seal application tips.

Cold Weather Markets

You have a variety of options for seeking jobs that are inside, out of the elements, during the winter months.  Hopefully these ideas will spark more brainstorming on your part. First up we have tunnels, both pedestrian and vehicle. Tunnels often leak, sometimes significantly enough to result in quite a big job. Aquariums are another possibility. As you can imagine, there are infinite potential leak problems in a structure holding that much water. Other possible large jobs could include mines and water treatment plants (which have plenty of interior spaces with potential leak issues). On the smaller side, there are utility vaults, lift stations, manholes and elevator pits.

If you’re still up for working outside during the winter months, you’re in luck because concrete contracts during colder weather. The contraction makes cracks open wider. Wider cracks make leaks more apparent to the property owner and make them easier to repair.

Conditioning Materials and Equipment

One important point to understand is that cold weather requires you to make an extra effort to keep your materials and equipment warm. Cold material reacts slower and gets thicker. Be sure to store your materials and equipment in a heated room the night before the job. When on the jobsite, there are many ways to keep everything warm. Use an enclosed vehicle, like a box truck, enclosed trailer or pickup truck with a camper top or bed cover. Keep as much material and equipment inside the vehicle as possible when working. Use a portable heater to maintain a warm temperature. You can also use electric pail heaters to keep your resin ready for action.

Remember that it won’t do you any good to heat the resin if you’re pumping it through cold equipment. The cold steel inside the pump and the cold hose will literally suck the heat out of the resin before it gets where it needs to be. This will increase the viscosity, making it harder to mix with the water and it will slow down the reaction dramatically. So don’t neglect the equipment side of the equation!

Cold Temperature Application Tips

If you’re using a product with an accelerator, you may need to use a faster accelerator or increase your percentage. Also, bring lots of oakum. You may have to use more if the cold temperature slows down the material or the contracted concrete has made the cracks wider.

If your job requires you to inject into a structure underwater (and the water’s cold), you can use a technique called twin streaming. In this approach, you hook two valves together in parallel fashion – then inject warm water along with the resin to kick start it reacting before hitting the cold water.

Conclusion

I hope this overview has helped spark some ideas on your part for finding leak seal work during the winter months. Just remember to keep your materials and equipment conditioned and you should be fine. Have more questions about polyurethane leak seal in cold weather? Call us at 404-618-0438.

Editor's Note: This post was originally published in 2019 as Polyurethane Leak Seal in Cold Weather.

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Contrary to popular opinion, as a contractor, you don’t have to put up your equipment and rigs due to cold weather. There are many jobs to be done and many ways to keep your material conditioned. Use this season to your advantage and gain valuable business.

Cold Weather Markets

Seasonal attractions such as theme parks are a great place to start looking for winter work. Many of these parks (the ones that aren’t in Orlando) shut down for the winter and this is the time they do maintenance and repairs. Think of all the concrete lifting and leveling that can be done.

Factories can be less active in the winter months with production slowing down in many industries. This is a good time for them to do maintenance and floor repairs as well.

Warehouses typically operate year round, so there is always work available. Warehouse floors are used and abused on a daily basis and will sooner or later need some form of repairs done to keep business running at a steady pace. In addition, many warehouses have dangerous voids beneath their floors that require repair.  

Exterior concrete slabs are still worth considering, even in the cold weather. These slabs experience the most wear and tear from the environment itself (think erosion) and daily traffic. You’ll need to lift concrete slabs before the ground freezes and only after your materials have been thoroughly conditioned.

Conditioning Materials

Your slab lifting equipment probably has built in heaters and a heated hose. Each brand and model of pump has different sized pre-heaters and different ∆T (∆ = Delta and T = Temperature). This sounds complicated, but is actually quite simple.  ∆T is simply the change in temperature.  Let’s say your material has been sitting in a cold trailer all night and the temperature has dropped to 40 degrees F. If the required temperature of your B side material is 120 degrees F, then your pump better be rated with a ∆T of at least 80 degrees. However, if your material is preconditioned to 70 degrees F, then your machine only has to be rated for a ∆T of 50 degrees. As I said, every machine is rated differently based on the size of the heaters. What is important to know is that there are limitations to how much heating your machine can do.

Keeping your materials conditioned in the winter months is a lot easier than it sounds. The main point is to keep your AP Lift products above 60 degrees at all times. Keeping the polyurethane at or above that temperature can be accomplished in a number of ways.

If you have an insulated rig, it should stay around 40 degrees warmer than outside temperatures. Most foam rigs have built in electric heaters that require an extension cord to a power outlet at the job site or at your facility for overnight storage. Alternately, you could buy an electric radiator heater. Other available heating devices include drum band heaters and heated drum mats (be careful not to scorch the polymers by turning band heaters up too high). For a more DIY approach, you could build a hot box around the material storage area in your rig.

Heat Sink

Another consideration when lifting cold slabs is the heat sink factor. AP Lift products come out of the gun hot and get even hotter as they react. However, cold concrete acts as a heat sink and sucks the energy out of the foam as it starts to react. This can slow down the reaction speed of the foam. If you are pumping into a void, it will have little effect because most of the foam is not in contact with the concrete. If you are trying to lift a slab with little void, it will have more of an effect because more of the foam is in contact with the cold concrete and cold soil. More volume = more energy.

Conclusion

Don’t let common preconceptions deter you from slab lifting in cold weather. As noted above, there is no need to shut down completely for the upcoming winter months if you don’t want to. Opportunities still exist and one of them may just be the job you’ve been looking for all year. There are many ways to keep your equipment and materials conditioned to efficiently work in lower temperatures. Have more questions about slab lifting in cold weather? Call us at 404-618-0438.

Editor's Note: This post was originally published in 2018 as Slab Lifting in Cold Weather.

Want more in-depth info on slab lifting?

I don’t know what it is about this time of year but for some reason at the beginning of fall we receive the most tech support phone calls from slab lifting contractors. Some of it is related to the changing weather, but this past week several things happened that made me want to address a specific topic – the compressed air system of the polyurethane foam rig.

It’s easy when discussing a trailer or box truck rig setup to focus on what type of plural component machine you are running. We all want to know whether you have a PH-2 or an E30 for example, or maybe an air powered Boss proportioner. What is often overlooked and neglected is the compressed air system in the rig. For a slab lifting contractor, it’s likely your air system is working harder than any other component on your rig. If you have had the joy of standing next to the compressor while it is running, you can’t deny that.
I want to highlight the main components of the compressed air system; describing their purpose and offering a few tips for keeping them running like they’re supposed to.

These components include:

• Air Compressor
• Coalescing Filter and Moisture Separator
• Refrigerated Air Dryer

Air Compressor

The majority of slab lifting rigs we see have reciprocating air compressors, also known as piston air compressors. These are identified by having a tank, and they are in a horizontal or upright configuration. They can be either gasoline or electric powered. There are also rotary screw compressors out there which don’t have a tank but still need to be maintained. If you have a compressor with a tank, that tank needs to be drained of the moisture it collects. Some have automatic drains that pop open after the unit shuts down; others must be drained manually.

Last week we worked with a contractor who had an air powered proportioner. His machine could build up pressure, but once he started injecting poly the flow would slow down to just a trickle. He would then shut off the gun and the proportioner would pressure up again. Turns out the air compressor tank was almost completely full of water so he would exhaust the remaining air supply right away when shooting the foam. A good policy is to drain the tank every day at the end of the shift. If it doesn’t drain automatically then there are typically valves that are easy to access. I actually like to start my compressor up the next shift with the tank valve open because it will always blow some more water out when it fires up. Then I shut the valves and things pressure up per usual.

In addition to draining the tank, you need to check and change the compressor oil per the manufacturer’s guidelines. This is for all compressors. If you don’t have a manual on board the rig to tell you when to change the oil or what oil to put in, this info can easily be found on the internet or hopefully from your rig provider.

Filters and Moisture Separators

You can usually find the moisture filter and separator mounted on the wall, often combined with the regulator and air pressure gauge. These filters have a housing below them that collects moisture that is coming from the air compressor. This is the first line of defense (after the air compressor) from keeping moisture out of your transfer pumps, so make sure to open the little valves at the bottom and drain these filter/separators daily. I do it at the end of the day and once again at the beginning of the shift when I am checking my air pressure upon startup.

Refrigerated Air Dryers

The refrigerated air dryer is the last line of defense before the compressed air is sent over to the transfer pumps. I have seen these mounted in various places in a rig from on the floor to up on the wall. First, do not pile tools and other rig items on top of and around the air dryer. These units work nonstop, and they need airflow to do their job without overheating. Take care not to block them in. Second, I believe most of these air dryers also have filters and coils that need to be cleaned occasionally. Check the manufacturers guidelines for your model and keep those items clean so that your unit can run more efficiently and for a longer life.

Conclusion

Your compressed air system is vital to your plural component machine running on ratio and making good polyurethane foam. Components that remove moisture from the air are critical for keeping your transfer pumps running like they are supposed to without breaking down or losing pressure.

Always keep these critical points in mind:

• Drain the tank
• Change the oil
• Drain the filter/separator units
• Don’t block in your refrigerated air dryer, and keep the unit clean

These essential maintenance tasks don’t take but a few minutes, and they can save you hours of frustration and head scratching.

Want more information on Geotech material and equipment?

As a consultant on many deep soil geotech jobs over the years, I have found myself recommending one critical piece of equipment repeatedly: The Dynamic Cone Penetrometer (aka the DCP). I highly recommend this tool as an essential part of your Deep Lift® rig set up. As Jim Spiegel explained in his blog post on this subject, this device is used to measure the strength of subgrade soils, and can be utilized to identify weak layers of soil within a soil mass. As you can see in the video below, a hydraulic pump drops a 30kg (60lb) hammer, driving the measuring rod into the ground.

To measure soil strength, the operator counts the number of blows it takes to drive the steel rod in 10-centimeter increments. Good soil requires 10+ blows to drive the rod 10 centimeters. Anything less is typically indicative of weak soil conditions.

DCP testing is a widely accepted means of in situ testing. Due to the common acceptance of DCP testing, many municipalities and agencies are willing to pay for this service.

Here is a hypothetical scenario for DCP use:

Soil strength data is needed under a concrete parking lot before a Deep Lift® job. Multiple tests would be performed, spread out evenly over the area. For thorough testing, each DCP test would be executed to a minimum depth of 15 – 20 feet or refusal (when the hammer blows no longer cause movement.) The test results can then be compared and analyzed to find where potential weak soil conditions may be present. This allows for accurate and effective application of the polymer to address the weak layers.

DCP testing can also be utilized prior to bidding any Deep Lift® job to develop effective injection plans, as well as accurately estimate material usage on projects. With that said, it’s not always possible or practical to perform pre-bid testing. When pre-bid testing is not performed, it would still prove highly beneficial to perform DCP testing prior to injection. I have personally encountered many situations where injection plans have been drastically altered after test results were analyzed (injection depth was added or subtracted, the weakest layers were identified, etc.) The Dynamic Cone Penetrometer is a portable tool which can easily be used in many locations where other testing methods are not feasible and it provides valuable insight into the soil conditions that need to be improved.

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A lot of customers have recently been asking about the hand sanitizer that we sell vs. others they are finding on the market. It turns out that there can be a significant difference. For example, my parents bought a 16 oz bottle of ethyl-based hand sanitizer from the grocery store, and after reading through the label, we realized there was a critical differentiator between that version and the one we sell.

According to the Centers for Disease Control, hand sanitizers deemed most effective against COVID-19 pathogens contain 80% ethanol or 75% isopropyl by volume. The brand that my parents bought, as well as a few other popular offerings I researched, contained between 60-70% ethyl by volume. This formula, according to the CDC, is not as effective against the current outbreak.

On the other hand, our FDA-approved hand sanitizer contains 75% isopropyl by volume.  This hand sanitizer was formulated specifically according to the World Health Organization guidelines for killing COVID-19.

Embedded below is a crack and curtain grouting video demo I recently recorded.  For those not familiar with me, my name is Charlie Lerman. I'm the Director of Technical Services for the Leak Seal Division at Alchemy-Spetec (and I'm also known as the Grout Geek). I have been involved in a wide variety of grouting jobs from dams to tunneling, municipal to sewer system work, residential, commercial, and industrial.

Prior to joining the Alchemy-Spetec team, I was with the Navy in the submarine and recruiting services. I have 20 years of construction experience – I was with a restoration contractor for five of those twenty years and earned a bachelor degree in Business Management during that time. I have been providing technical support and training for polyurethane grouts for over fifteen years and have been involved with the International Concrete Repair Institute (ICRI) for a decade.

Social distancing does not have to mean downtime. This is an excellent time to learn about polyurethane chemical grouting. From my home "studio" I bring to your home office demonstrations on crack injection, curtain grouting, and pump operation/maintenance.

Want more info on Leak Seal products?

Pocket-Sized Squeeze Bottles

A 2.1 Oz (63 ml) Bottle Size Will Soon Be Available:

• FDA Approved
• WHO Formula
• Ideal for Field Work

Join the notification list for this new hand sanitizer option and you'll be the first to recieve pricing and availability details.

We often get calls from spray foam insulation installers who are interested in adding slab lifting capability to their rig set up. If you're reading this article, you yourself may be looking for info on the matter. If so, we have good news for you. With just four additional pieces of equipment and one set of material, you can quickly and easily add slab lifting to your service offerings. Let’s take a look at exactly what additional equipment and material you'll need to get started...

Slab Lifting Equipment

MixMaster Pro Slab Lifting Gun
The MixMaster Pro is a two-component resin injection gun manufactured specifically for lifting concrete slabs, designed to handle back-pressure. 

Titan Impact 440 (Modified) Pump with Flush Hose
The Titan Impact 440 (Modified) pump is used for flushing the MixMaster Pro gun in between foam injections. (It's also used for pumping one-component material in soil stabilization and seawall repair applications.)

3/8” MixMaster Ports
These heavy duty ports create an airtight seal for injecting foam into drill holes. 

Dial Indicator Crane
This precision tool is used to measure the lift of the slab within 1/10” of an inch.

Polyurethane Slab Lifting Material

AP Lift 430, AP Lift 440, or AP Lift 475 (100 Gallon Unit)
Sunken concrete slabs can be lifted back into place with these two-component polymer foams designed to work in wet or dry conditions. The expansion force of these concrete leveling foams coupled with the pressure of a specialized pump generate enough controlled force to lift virtually any structure back into position with 1/8” precision.

AP Flush 125 (5 Gallon Unit)
Water based gun flush specifically used for flushing out the MixMaster Pro impingement gun. Also used to protect concrete from resin stains.

AP Lube 190 (5 Gallon Unit)
This product is a multi-purpose lubricant for use with both airless electric injection pumps and proportioner/reactor pumps.

Want more info on adding slab lifting to your rig setup?

Polyurethane – Quality and Selection

Alchemy-Spetec offers one of the most technologically advanced grout product lines currently on the market, including our unique, highly-effective Spetec PUR HighFoamer. Known in the industry for its expansive properties, this product is the only one in its class that can shut down gushing leaks and fill voids as quickly and effectively as it does. We offer a wide variety of materials, including slab lifting foams, deep-soil lifting foams, soil stabilization foams, injection resins for crack leak seal, foams for curtain grouting leak seal, acrylic injection resins that penetrate thin cracks and saturate soil, epoxy resins for structural repair and preventative waterstop products. The superior quality of these materials guarantees fewer callbacks from your customers. Many of these products are also certified for contact with potable water, making them safer for the environment.

Equipment and Accessories Selection

We’re a one-stop shop for all things polyurethane concrete repair, with one of the most versatile equipment and accessory product lines in the industry. Once you’ve picked out the product that best fits your needs, we can provide it all: pumps, hoses, packers/ports, and specialty accessories.

Tech Support – Experience and Dedication

Do you need technical support? You’re in luck—we’re home to the industry’s premier technical support squad. Averaging decades of experience, we also pride ourselves in being incredibly responsive. For example, our team was recently called on to assist with a large metro project in the Western United States. The customer informed us at 4pm on Monday evening that assistance was needed at 9am the very next day! Our Technical Services Director Charlie Lerman, Vice President Jim Spiegel, and Western Regional Sales Manager (that's me!) traveled to the site Monday evening to help diagnose the location of the leaks and develop an action plan. Our Technical Services Manager Charlie remained on site for two more days to ensure that the project was successful. Depending on the size and scope of the project, response time and participating team members may vary, but this story serves to illustrate the lengths we will go to assist customers.

Training and Education

We offer the industry's most thorough training and education for both Leak Seal and Geotech polyurethane infrastructure repair. We conduct training workshops at distributor locations, consult with contractors on job sites, and hold intensive programs twice a year at our headquarters in Tucker, GA. We also offer in-depth online training videos to current customers.

Marketing Support

Our Marketing Department provides qualified customers with product application illustrations and photos for use on websites, customized brochure PDFs for printing, and truck signage graphics. We also offer the use of our educational videos and animations. Lastly, we’re available for guidance on everything from online lead capture strategies to internet advertising, and more.

We’re Committed to Your Success

The overriding theme here is our commitment to your success. Obviously, this is not totally altruistic in nature.  The more successful you are, the more materials and equipment you buy.  But it is 100% genuine.  Our entire team understands the relationship between YOUR success and OUR success.  This point of view is thoroughly ingrained in our company culture.

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