Alchatek Blog

Suburban Basement was contracted to address a multifaceted water intrusion issue on a Rochester Hills, Michigan property. The basement had water ingress from both the furnace ductwork and the foundation. The ductwork, extending through the foundation wall into a garage-adjacent wall cavity, had sections below grade behind a garage curb. The root of the problem was water pooling under the back curb, caused by settled garage slabs from the main vehicle entrance.

Initial Assessment

The project was divided into two phases: first, addressing the leaking foundation and furnace ductwork, and second, void filling and concrete leveling of the garage floor and curb. The complexity arose from the undermined garage slabs and the need to prevent water intrusion while ensuring the safety of the furnace ductwork.

Proposed Solution

For the initial water intrusion, Suburban Basement proposed using Alchatek’s Spetec PUR Highfoamer for curtain grouting, given the limited accessibility and its fast reaction time. For the concrete leveling and void filling, AP Lift 430 was selected due to its expansion rate, soil stabilization capabilities, water displacement properties, and quick curing time for vehicle traffic.

Procedures

1. Applied curtain grout to the positive side of the wall to stop water intrusion and encapsulate the dual wall furnace ductwork
2. Commenced void filling and leveling at the garage curb, progressing toward the main vehicle entrance
3. Filled all voids beneath the garage curb and leveled the concrete across all areas of concern
4. Conducted water tests to ensure all leaks were addressed before proceeding to phase two
5. Performed void filling and concrete leveling, displacing significant amounts of water near the main vehicle entrance

Results

The project was completed successfully in two phases, with the curtain grouting finished within hours and the void filling and concrete leveling taking approximately half a day. All leaks were effectively stopped, and the concrete was successfully leveled. The homeowner expressed high satisfaction, notably as previous repair attempts had failed. Suburban Basement’s solution not only resolved the immediate water intrusion problems but also extended the lifespan of the garage concrete and driveway, providing a comprehensive fix to a complex issue.

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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.

Want more information on lifting slabs with polyurethane?

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.

A concrete staircase in a prominent mixed-use complex in Atlanta needed urgent repairs due to a set of 75-foot-long sunken steps. This issue posed a significant trip hazard, potentially compromising visitor safety. The problem stemmed from a combination of factors working together over time. Water infiltration through expansion cracks had created voids beneath the stairs, weakening their foundation. Compounding this issue was the natural tendency of separate concrete pieces to expand and contract, moving independently. This movement was particularly problematic as it caused the steps to separate from the adjacent sidewalk. Over time, the repeated cycles of expansion and contraction, coupled with the underlying voids, led to the steps sinking and rolling, creating a hazardous situation. 

Local experts from Engineered Restorations were called in to tackle this tricky situation. The team faced the challenge of addressing safety concerns while preserving the structural integrity of the staircase.

Powerful Polymers

AP Lift 430 was selected as the repair material for this restoration project. This polyurethane foam has expansive properties that are suitable for lifting sunken structures. Once cured, AP Lift 430 provides support for long-term stability, aligning with the project's requirements.

Painless Procedures

The repair process began with an assessment of the trip hazard. This allowed the team to determine the extent of the problem and plan their approach. Next, backer rods between the steps and sidewalk were removed to prepare the area for treatment. Alchatek Surface Guard 125 was applied around the injection area to prevent any excess polyurethane from bonding to the concrete. Protective sheets were placed to shield nearby glass surfaces.

The team drilled holes through the 8-inch concrete steps to reach the underlying soil. Soil probes revealed firm underlying conditions. The team then implemented their injection strategy. They created an initial foam layer slowly, injecting it just once every ten seconds. This gradual approach prevented existing hairline cracks from expanding during the lifting process. The team continued to inject AP Fill 430 until the steps were level. Finally, they redrilled and applied a second injection layer beneath the first to fill any voids created in the process. New backer rods were then installed.

To enhance the longevity of the repair, the team took an additional crucial step. They sealed the expansion joints with silicone, creating an optimal water barrier. This silicone sealant is flexible, accommodating future expansion and contraction. This extra measure was designed to protect the structure from water infiltration and movement, addressing the root causes of the original problem. 

Rapid Results

In just four hours, the steps were restored to a level position, aligning with the adjacent walkway. This efficient repair method addressed the immediate safety issue while extending the structure's lifespan. By lifting the existing steps rather than replacing them, the property owner avoided substantial expenses associated with demolition, new materials, and extended labor time for a complete replacement. This approach ultimately provided significant cost savings.

Want more information on concrete leveling with polyurethane?

Essential Details

Dates/Pricing

Geotechnical Masterclass: March 25th - 27th, 2025

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

Location

To Be Determined
(in Georgia)

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.

Are you a geotechnical contractor facing challenges with unreliable lifting foam that leads to costly callbacks? You can significantly reduce these issues by choosing quality lifting foam from a manufacturer focused on slab lifting applications. The right solution makes all the difference in achieving consistent, successful results.

The Painful Costs of Job Callbacks

The financial impact can be severe when callbacks occur due to subpar lifting foam. You can lose revenue when you have to redo jobs without additional payment. Meanwhile, new project starts may be delayed, creating a ripple effect throughout the schedule. As a result, resource allocation becomes inefficient, further straining the business.

Impact on Business Reputation

Low-quality foam products can severely damage customer relationships. Negative online reviews may start appearing, which can hurt your lead-generation efforts. Property managers and other repeat customers may look elsewhere for future projects. Moreover, the likelihood of receiving valuable referrals decreases substantially. In this competitive industry, maintaining a solid reputation is essential for long-term success.

Benefits of a Specialized Manufacturer

Choosing a manufacturer focusing exclusively on polyurethane for slab lifting makes a notable difference. Specialized manufacturers maintain rigorous quality control standards throughout the production process. Furthermore, this dedicated approach ensures that you receive consistent results with every application. This approach provides better outcomes than relying on a general foam manufacturer who could be producing everything from spray foam insulation to material for couch cushions.

Quality Lifting Foam: The Foundation of Success

Reliable quality lifting foam leads to satisfied customers and more substantial business growth. With proper materials and consistent results, contractors can build lasting relationships with repeat customers while maintaining a solid reputation in the industry. 

Want more information on quality lifting foam?

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.

Want more information on geotech products and equipment?

A critical infrastructure issue emerged on a four-lane road near downtown San Francisco. Soil erosion caused a bridge approach slab to settle 2.5 to 3 inches over time. The affected area had an asphalt surface with a thin sleeper slab underneath. California Department of Transportation (Caltrans) engineers initially advocated for complete replacement. The situation changed when Bay Area Underpinning entered the scene. Together with Alchatek, they presented an alternative solution: Deep Lock® soil stabilization and concrete leveling. After careful consideration, the DOT engineers agreed to try this innovative approach. This method promised to minimize traffic disruption and significantly reduce costs compared to full replacement, which would have required closing the entire roadway and replacing a 40x12 foot area of asphalt and sleeper slab.

Powerful Polymers

The project team chose AP Lift 475 as the repair material. This substance offers impressive compressive strength while maintaining good expansion properties. Once injected, the material spreads out effectively, filling voids in the annular space within the soil. This combination of strength and expansion makes AP Lift 475 ideal for stabilizing and leveling the settled bridge approach slab. The material's ability to penetrate and fill voids addresses the underlying cause of the settlement, providing a more comprehensive solution than - for example - simply adding a new surface layer.

Painless Procedures

Before starting the repair, DOT engineers conducted thorough soil testing. They performed soil borings to determine soil types and characteristics at various depths. This crucial step provided insights into the subsurface conditions contributing to the settlement. Additionally, they used a DCP (Dynamic Cone Penetrometer) test to identify areas of weak soil density. Armed with this information, the contractor developed an optimal application plan.

The team installed injection tubes on four-foot centers at six- and 10-foot depths. They injected about 40 pounds of material per tube, using 10-15-second shots. This measured approach allowed for controlled material distribution. Throughout the process, the team carefully monitored the slab lift using a rotary laser and zip-level altimeter. These precise instruments ensured even raising of the slab to the desired level, preventing any potential issues from uneven lifting.

Rapid Results

The modular approach to repair minimized traffic disruption, a critical factor for this busy thoroughfare. At any given time, only two out of four lanes remained closed. Consequently, traffic continued to flow throughout the project, preventing gridlock in the area. The team completed the entire leveling process in just four eight-hour shifts, a remarkably short timeframe for such a significant repair. Compared to full replacement, the method significantly cut labor requirements, traffic disruption, and financial costs. Moreover, the repair addressed the root cause of the problem by stabilizing the eroded soil beneath the roadway.

Unlike simply adding an asphalt layer for leveling, which would have provided only a temporary fix, this solution offers long-lasting results. By directly treating the underlying issue, the team greatly reduced the likelihood of recurrence. The success of this project offers a blueprint for similar infrastructure challenges. It showcases how modern materials and techniques can provide cost-effective, efficient, and durable solutions to complex engineering problems. 

Want more information on Deep Lock® soil stabilization and slab lifting?

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.

Want more information on slab lifting products and equipment?