Alchatek Blog

A Tennessee state correctional facility had a significant infrastructure failure when newly installed plumbing beneath a concrete slab malfunctioned. In an attempt to address the issue, the original contractor backfilled the entire plumbing system with concrete. When this approach proved unsuccessful, a second contractor was brought in to demolish the concrete and properly repair the plumbing systems. This process left a substantial void beneath the slab that required immediate filling to restore structural integrity and minimize facility downtime.

Initial Assessment

Following the plumbing repairs, engineers assessed a void measuring approximately 200 square feet in area and 4-5 feet in depth, totaling roughly 800-1,000 cubic feet of empty space beneath the concrete slab. The prison's security restrictions severely limited access to equipment, making traditional concrete replacement a challenging and time-consuming process. The facility required a solution that would minimize disruption to operations while providing structural support equivalent to the original concrete base.

Proposed Solution

Working with Alchatek, Mid-South Concrete Lifting recommended using  AP Fill 420, a two-component structural polyurethane foam, to fill the substantial void. This approach offered several critical advantages for the correctional facility environment. The material could be applied through a simple hose system, eliminating the need for heavy concrete trucks and mixing equipment that would be difficult to maneuver through security checkpoints. The foam's rapid curing time would significantly reduce the project timeline, and its structural properties would provide adequate load-bearing capacity for the slab above.

Procedures

1. Security clearance and equipment inspection were completed to bring polyurethane application equipment into the facility.
2. The void was accessed through existing openings created during the concrete removal process.
3. AP Fill 420 was applied using a free-shooting technique.
4. Material application was monitored to ensure complete filling and proper expansion throughout the space.

Results

The void filling was completed in 3 hours versus an estimated week for concrete replacement. AP Fill 420 polyurethane foam successfully filled the entire void space and provided adequate structural support. Prison officials expressed satisfaction with the efficiency and minimal operational disruption, leading the contractor to look at another similar project at a different state facility.

The polyurethane approach delivered 65-75% cost savings compared to traditional concrete replacement when accounting for materials, equipment, labor, and reduced facility disruption. The accelerated timeline also eliminated the extended security coordination costs typically associated with longer construction projects.

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A fire station access roadway developed cracking from subsurface voids caused by storm drain seam gaps that washed out soil during heavy rain, threatening daily emergency operations and pavement integrity. Geotech specialists from Helicon were brought in to assess the situation.

Initial Assessment

CCTV and probing identified voids up to several inches beneath the asphalt and open joints along the drain, allowing soil migration. Excavation replacement was rejected due to weeks-long closure risk, higher cost, and potential future seam misalignment, making trenchless permeation grouting the viable path.

Proposed Solution

AP Fill 700 was chosen for hydrophobic, single‑component injection with very low viscosity, and adjustable cure, enabling soil permeation, joint sealing, and formation of a water‑tight bearing layer for traffic.

Procedures

1. Map defects and mark the injection grid along the pipe and pavement.
2. Drill ports; set packers to target joints and halo around pipe.
3. Inject AP Fill 700 to refusal, prioritizing seam sealing.
4. Permeate surrounding soils to fill voids and densify subgrade.
5. Monitor pressures/returns; adjust set times for water presence.
6. Verify with sounding/CCTV and traffic proof-load.

Results

• Restored structural support and sealed joints with zero operational downtime.
• Completion in days vs weeks.
• Approximately 95% cost savings compared to full excavation and pipe replacement.

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A property in Atlanta featured a multi-level parking structure with a split-level design. The upper-level parking area began showing signs of significant distress, with visible cracking and pavement deterioration. Investigation revealed that soil was actively migrating through a lower retaining wall of the parking structure, creating voids behind the wall and compromising support for the pavement above. The color change in the asphalt surface clearly marked the affected area, and the problem was getting progressively worse, posing both functional and safety concerns for vehicles using the facility.

Initial Assessment

Engineers determined that soil was passing through the precast concrete retaining wall that separated the lower parking level from the surrounding earth. Testing revealed substantial voids had formed behind the wall, primarily involving clay soils that had become soft and unstable. While the wall itself remained structurally sound, the continued migration of soil threatened to create more significant issues if left untreated. Traditional repair methods would have required extensive excavation and potential wall replacement, a prohibitively disruptive and expensive approach for an active parking facility. The challenge was stabilizing the soil and filling the voids without impeding parking operations.

Proposed Solution

Alchatek recommended using two-component polyurethane foam (AP Lift 475) to stabilize the soil and fill the voids behind the wall. This material was selected specifically because of its high compressive strength and ability to effectively fill large voids in clay soil conditions. Since the wall was precast concrete and structurally sound, there was no concern about the polyurethane's strength pushing or damaging the wall. The expansive properties of the material would ensure complete penetration into irregular void spaces, while its closed-cell structure would prevent future water migration that could cause additional soil loss. This approach would stabilize the subsurface conditions without requiring excavation or disrupting the facility's operations.

Procedures

1. Established a precise injection grid with tighter three-foot spacing in the first row close to the wall and slightly wider spacing in the second row.
2. Drove injection pipes through the soil to reach the void areas behind the wall.
3. Injected approximately 15 pounds of two-component polyurethane every 1.5 feet vertically, ensuring complete filling from bottom to top.
4. A hydraulic pipe puller was used to extract injection pipes during material placement for controlled distribution.
5. Monitored for any structural movement throughout the process using zip levels and dial indicators to prevent over-pressurization.
6. Injected material systematically across the affected area, adjusting quantities based on observed soil conditions.

Results

The project successfully halted soil migration through the retaining wall and stabilized the pavement above. The two-component polyurethane effectively filled all voids while creating a waterproof barrier to prevent future erosion. Most importantly, the solution eliminated the need for disruptive and costly excavation, allowing the parking structure to remain operational throughout the repair process. Post-treatment monitoring showed complete stabilization with no further signs of settlement or cracking in the pavement. The property owner avoided significant reconstruction costs that would have been incurred with traditional methods, while also preventing potential revenue loss from parking facility closure. This case demonstrates how polymer injection technology can provide effective structural solutions with minimal operational impact, a key consideration for commercial property remediation.

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The US Army Corps of Engineers (USACE) required a solution to fill the annular spaces between eight 84-inch ductile iron pipes and the concrete bulkhead at a new pump station along the Mississippi River in Port Sulphur, Louisiana. Traditional methods, such as pouring non-expanding resin, were cost-prohibitive (approximately $50,000 per void) and lacked the necessary performance characteristics. The voids posed a risk of instability and water infiltration, demanding a material that combined strength, adhesion, and environmental safety.

Initial Assessment

Inspections revealed significant annular gaps around the pipes, necessitating a material that can bond to both ductile iron and concrete while forming a waterproof seal. The USACE prioritized a solution that avoided excavation, minimized downtime, and provided long-term durability. Based on the scale of the pipes and typical annular space requirements, the voids were estimated to range from 6 to 12 inches in width around each pipe, although exact dimensions would depend on site-specific conditions.

Proposed Solution

Alchatek’s AP Lift 430, a high-density, two-component polyurethane foam, was selected for its compressive strength of 7,200 psf, ensuring structural support while adhering tightly to both ductile iron and concrete. Its hydrophobic nature prevents water infiltration,  and its expansion capability allows for complete void filling without precise volume calculations. AP Lift 430 provided a balanced solution for strength, durability, and cost efficiency.

Procedures

1. Material Application: AP Lift 430 was free-sprayed into the annular spaces using a Graco Fusion spray foam gun, ensuring deep penetration and adhesion to both the ductile iron pipes and the concrete bulkhead.
2. Curing and Expansion: The foam expanded to fill the voids, creating a seamless and waterproof barrier.
3. Surface Finishing: Excess foam was ground flush with the concrete surface to allow secure installation of flanges and gaskets.

Results

The project was completed in two days, with no disruptions to ongoing site operations. AP Lift 430 formed a durable, watertight seal, meeting all USACE requirements for strength and longevity. Total material costs were approximately $30,000, representing a 90% cost savings compared to other resin-based alternatives. The USACE supervisor conducted daily inspections and praised the efficiency and quality of the repair.

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A Utah-based geotech specialist partnered with a general contractor to address a critical DOT infrastructure challenge involving the replacement of an existing culvert on a major roadway in Utah. The project involved the installation of precast concrete slabs on both sides of the box culvert, designed to create a seamless transition from the culvert to the compacted road base.

Site Investigation and Challenge

During the design phase, engineers identified that constructing a compacted road base beneath the slab would inevitably leave voids underneath. These voids posed a risk of uneven support and potential rocking of the slab when subjected to heavy traffic load.

Proposed Solution

To address this, ¾” holes were drilled four feet apart to allow for injection rods to be inserted through the slab. The foam selected for this slab was AP Lift 440 structural foam due to its rapid expansion and high strength needed for DOT projects. This foam expands 17-19 times its original volume within 8-10 seconds of injection, ensuring comprehensive void filling. Dial indicators were used to ensure that there was no vertical movement of the slab during the injection process.  

Results and Conclusion

The entire operation was executed in approximately three hours, utilizing about 400 lbs of structural foam. This successful application filled all of the voids, providing uniform support for the precast slabs and enhancing overall road stability. The rapid curing properties of the foam allowed for swift project completion with minimal disruption to traffic.

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Suburban Basement was hired to address significant voids beneath a slab foundation residence in Roseville, Michigan. The voids were suspected to have been caused by a compromised sewer line under the bathroom shower, resulting in extended leakage affecting a substantial portion of the home’s foundation. After plumbers discovered the issue, a local property restoration company managing the overall project engaged Suburban Basement.

Initial Assessment

The extent of the voids was assessed using 4-foot-tall plow markers as probes. The voids almost entirely engulfed these probes, indicating severe foundation undermining. The situation required a solution that could effectively fill large voids, bond with both soil and concrete, and perform well in wet environments.

Proposed Solution

Suburban Basement proposed using Alchatek's AP Lift 430 for the void filling. This material was chosen for its high expansion rate, making it cost-effective for large voids. Its ability to bond with soil and concrete, perform in wet conditions, and displace residual moisture from the plumbing leak made it ideal for this application.

Procedures

1. Drilled a systematic grid pattern of holes throughout the residence
2. Employed controlled injection shots to avoid excessive product usage and prevent lifting
3. Carefully filled all voids without causing any lifting of the foundation

Results

The project restored the foundation's integrity, filling all voids within a day. This efficient execution led to significant time and cost savings for all parties. The insurance company reduced relocation expenses, the restoration company delivered ahead of schedule, and the homeowners returned to their structurally sound homes earlier than expected. The outcome satisfied all stakeholders, demonstrating the effectiveness of the chosen solution in addressing complex foundation issues promptly and efficiently.

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An old farmhouse with a wrap-around porch in Lake Orion, Michigan, presented a unique challenge. Beneath the porch lay an old cellar, initially used for coal storage but now serving only as a conduit for a well line into the residence. The primary concern was the inward buckling of the cellar walls, which posed a significant safety hazard. Many contractors suggested demolishing the porch and excavating the cellar, a solution that would have incurred substantial costs for both demolition and reconstruction.

Initial Assessment

Suburban Basement was engaged to address this issue. Upon evaluation, the team identified a more cost-effective and less invasive solution. The cellar, measuring 12 feet in length, 5 feet in height, and 5 feet in width, could be filled with foam to mitigate the risk of further wall collapse. This approach would spare the property owner the expensive and disruptive process of demolition and reconstruction.

Proposed Solution

The team proposed filling the cellar with Alchatek’s AP Lift 430 foam. This material was chosen for its extensive expansion rate, superior compressive strength, and lower application temperatures. These properties allowed for quicker application intervals while maintaining optimal temperatures between applications and minimizing ignition risks.

Procedures

1. Encapsulated the well line with sonotubes elevated above the cellar floor, ensuring future accessibility.
2. Installed OSB sheathing to define foam boundaries and prevent overflow.
3. Applied AP Lift 430 in layers, allowing cooling intervals between applications to optimize expansion and stability.
4. Coordinated with masons to prepare for CMU block installation at the containment boundary, ensuring seamless alignment with the existing foundation.

Results

The foam-filling solution successfully stabilized the cellar walls, eliminating the collapse risk while preserving functionality. Compared to traditional approaches, this method saved the client approximately $25,000 and maintained the home’s historic features. Completed in just five days, the project significantly outpaced conventional methods. Homeowners were highly satisfied with the noninvasive approach, cost savings, and seamless integration with their property’s historic character, demonstrating the effectiveness of innovative techniques in addressing complex structural challenges in historic properties.

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The owner of a gas manufacturing facility contacted a Georgia-based contractor regarding significant floor settlement issues, with a warehouse slab dropping approximately 3-4 inches. The settlement made issues for the forklift traversing in and out of the warehouse and posed a risk to the workers.

Initial Assessment

Upon arrival at the site, the team conducted a thorough investigation. Using a probe, voids were identified beneath the slab, with the probe sinking up to 2 feet in some areas. A Dynamic Cone Penetrometer test revealed large voids 2-4 feet below the slab.  Poor drainage was evident, with improper crowning causing water to flow towards the building instead of away from it. Interestingly, a layer of unusually hard clay was noticed outside the building, suggesting possible prior remediation attempts.

Proposed Solution

AP Lift 430 was chosen for this project, providing an excellent injectable polyurethane grout solution. With its impressive 22x expansion capability and 7,200 psf compressive strength, it’s ideal for warehouse slabs that support heavy equipment. The grout’s hydrophobic properties ensure long-term stability by blocking water infiltration that could otherwise lead to void formation.

Procedures

1. Deep Injection (Void Fill)

• 32 injection points were established in a grid pattern (16 on each side) at 4 ft apart.
• At each point, the team injected 15-20 pounds of material at about 5 feet depth.
• A slight lift (approximately 1/16 inch) during this phase indicated successful void filling.

2. Slab Lifting

• Additional holes were drilled next to the wall, 3 feet from the wall, and 9 feet from the wall (6 feet from the first row).
• Injection began from the holes nearest to the wall and moved outward.
• Multiple passes were made, with some areas requiring 3-4 injections.
• Gradual lifting was employed to prevent slab cracking.
• Dial indicators were used to ensure even lifting across the warehouse floor.

Results

The project successfully stabilized the warehouse floor and restored it to its proper level. Effective void-filling addressed the underlying instability, providing a solid foundation for the slab. Success was evident in the restored functionality of the warehouse space and the elimination of safety hazards posed by the uneven floor. The property manager was pleased with the work and requested additional slab lifting services for their other facilities.

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Essential Details

Dates/Pricing (Discount Deadline Extended!)

Geotechnical Masterclass: March 25th - 27th, 2025

$695.00
This is special pricing for all who register before the end of the day, March 2nd. $745 March 3rd and later. ($50 discount for each additional participant.)

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.

Essential Details

Dates/Pricing

Geotechnical Masterclass: March 25th - 27th, 2025

$695.00
This is special pricing for all who register before the end of the day, February 25th. $745 February 26th and later. ($50 discount for each additional participant.)

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.