Alchatek Blog

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?

Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $745.00

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: November 12th-14th, 2024 – $695.00
(Special pricing for all who register before October 7th at 5pm Eastern. $745 after.)

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.

Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $695.00
(Special pricing for all who register before the end of September. $745 October 1st and later.)

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.

A sunken concrete staircase posed a unique challenge in a grand mansion undergoing renovation for sale. The vintage stairs had settled unevenly, with the right side sinking three inches and the left two inches. This issue arose after the driveway slab had been replaced and the supporting slab around the staircase had been partially cut out. Rather than opting for costly replacement, the property owner sought a permanent solution to restore the staircase's level and preserve its aesthetic harmony with the surrounding patio. Enter Lift It Rite, a geotech company called upon by the general contractor to tackle this delicate task.

Powerful Polymers

AP Lift 430 was selected as the repair material for this project. This product features expansive properties, ideal for filling voids beneath the sunken stairs. Moreover, once cured, AP Lift 430 is very strong, ensuring robust support for the concrete staircase. The material's capabilities aligned perfectly with the project's requirements, offering stability and longevity. Importantly, using this material allowed for a cost-effective solution compared to full replacement. Additionally, this approach preserved the vintage look of the concrete staircase, maintaining its match with the existing patio.

Painless Procedures

The repair process began with strategic drilling. Two holes were carefully bored into the slab in front of the steps at a steep angle. This approach ensured the material would travel underneath and towards the back of the stairs against the porch wall. Next, injection commenced from the front in three to five-second bursts. The crew used a dial indicator to monitor movement with remarkable precision throughout the process, detecting changes as small as 1/100th of an inch. As the material spread, lifting became visible. The team paused when material emerged from the sides, allowing for initial curing. Subsequently, re-drilling and more injection from the front raised the stairs further, maintaining the original slant with the right side down. A hole was drilled in the slab next to the back right area to correct the slant. Short bursts of injection here helped level the slab. Finally, injection resumed from the front to complete the lift, achieving the final quarter-inch of elevation. 

Rapid Results

The meticulous approach yielded impressive outcomes. Most notably, the final lift level perfectly matched the newly formed driveway, addressing the customer's primary concern. This precision restored functionality and enhanced the property's aesthetic appeal. The property owner expressed great satisfaction with the results. Furthermore, the successful repair of the antique staircase improved the home's resale value. By preserving the vintage concrete stairs, the project maintained the cohesive look of the exterior, seamlessly blending with the existing patio. The permanent solution eliminated potential concerns for future buyers, positively impacting the property's marketability. Ultimately, this project demonstrated how innovative repair techniques could address structural issues while preserving architectural integrity.

Want more information on lifting slabs with polyurethane?

Essential Details

Dates/Pricing

Geotechnical Masterclass: November 12th-14th, 2024 – $695.00
(Special pricing for all who register before the end of September. $745 October 1st and later.)

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.

When addressing sunken concrete slabs, homeowners often choose between two primary methods: mudjacking vs. foam lifting. Both techniques aim to elevate and level concrete without complete replacement. However, these methods differ significantly in their approach and effectiveness. This article examines the details of mudjacking vs. foam to assist in making an informed decision for concrete repair needs.

Traditional Approach: Mudjacking

Mudjacking has been a standard practice for over six decades. This method involves pumping a cement-based slurry under the sunken concrete. The process requires drilling holes in the slab and forcing the thick mixture underneath. As a result, the concrete rises back to its original position.

However, mudjacking has several limitations. The material is quite heavy, weighing up to 100 pounds per cubic foot. This additional weight may contribute to further settling over time. Furthermore, the large holes drilled for mudjacking can be visually unappealing. Even after patching, these holes often remain noticeable.

Modern Alternative: Concrete Leveling with Polyurethane Foam

In contrast, foam lifting utilizes polyurethane to raise concrete slabs. This innovative technique offers several advantages over traditional mudjacking. Notably, the foam is extremely lightweight, typically weighing only 2-4 pounds per cubic foot. Consequently, it doesn't add unnecessary burden to the underlying soil.

Mudjacking vs. Foam: Key Differences

Foam lifting demonstrates superiority in multiple areas where mudjacking falls short:

• Smaller injection points: Foam injection requires tiny 3/8-inch holes, which are much less noticeable after patching.
• Rapid curing: The polyurethane foam cures quickly, reaching 90% of its total strength in just 15 minutes. This allows for almost immediate use of the repaired concrete.
• Minimal disruption: Foam lifting requires less heavy equipment, reducing mess and inconvenience for property owners.
• Strong adhesion: The foam creates a permanent bond with the concrete's underside, ensuring long-lasting support and stability.
• Water resistance: Unlike mud, foam resists water, helping to prevent future erosion and settling caused by moisture issues.

Evaluating Polyurethane Foam vs. Mudjacking

When comparing mudjacking vs. foam, the latter is the preferred choice for most scenarios. Its lightweight nature, quick curing time, and superior bonding capabilities make it an excellent option for concrete leveling. Moreover, the foam's ability to resist water and prevent future settling gives it a significant advantage over mudjacking.

Precision and Longevity in Concrete Lifting

Concrete leveling with foam offers a more effective and durable solution for sunken concrete. While mudjacking has been a long-standing method, foam technology has significantly advanced the concrete repair industry. By opting for foam lifting, property owners can benefit from a faster, cleaner, and longer-lasting fix for their uneven concrete surfaces.

It's important to note that consulting with experienced professionals is crucial when considering concrete leveling options. These experts can assess specific situations and recommend the most appropriate action. With the right approach, restoring concrete to its original level and ensuring a safe, stable surface for years to come is achievable.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on lifting slabs with polyurethane foam?

Many property owners face the frustrating issue of sinking concrete slabs. This problem not only affects the appearance of the property but also poses safety risks. Fortunately, modern solutions can effectively address sinking concrete without the need for complete replacement. Let's explore the causes of this common problem and discuss innovative repair methods.

Why Does Concrete Sink?

Several factors contribute to concrete settlement. First, erosion can wash away soil beneath the slab. Second, poor soil compaction during initial construction may lead to instability. Finally, biological decay of buried organic matter can create voids. As a result, the ground beneath the concrete becomes unstable, causing the slab to sink.

The Dangers of Ignoring Sinking Concrete

Failing to address sinking concrete can lead to serious consequences. For instance, uneven surfaces may cause trip hazards, potentially resulting in injuries and liability issues. Moreover, sunken slabs can damage vehicles and expensive structures. In extreme cases, a neglected settlement might even lead to sinkhole formation.

Traditional vs. Modern Repair Methods

Replacing the Slab

Historically, replacing the entire slab was a common solution. However, this approach is messy, time-consuming, and expensive. Additionally, it often involves significant disruption to the surrounding area.

Mudjacking

Another traditional method is mudjacking, which involves pumping a cement-based slurry under the slab. While effective in the short term, the injected material may crack or erode over time, leading to future issues. Furthermore, this technique requires large drill holes and disruptive heavy equipment.

Polyurethane Foam for Lifting Sinking Concrete

In recent years, polyurethane foam lifting has emerged as the preferred method for repairing sinking concrete. This innovative technique offers numerous advantages over traditional approaches.

Strength and Durability

Polyurethane foam features impressive strength, often surpassing that of bedrock. Once injected, the foam continues to gain strength, providing long-lasting support for the repaired slab. As a result, this solution offers exceptional durability compared to other methods.

Minimally Invasive Process

Unlike mudjacking or replacement, foam lifting requires only small drill holes. Consequently, this method causes minimal damage to the existing slab and surrounding area. The lightweight equipment used also reduces the risk of disruption and further soil compaction.

Rapid Results

One of the most significant advantages of polyurethane foam lifting is its speed. The foam cures to 90% strength in just 15 minutes. Therefore, repaired areas can often be used the same day, minimizing disruption to daily activities.

Environmentally Friendly

Alchatek offers polyurethane lifting foams that are NSF-certified to meet strict environmental standards. These products won't leach harmful chemicals into the soil or groundwater. As a result, property owners can feel confident in choosing contractors who offer this eco-friendly solution.

The Foam Lifting Process

The concrete lifting process using polyurethane foam is straightforward and efficient. First, technicians drill small holes in the slab. Next, they inject the foam through these holes. As the foam expands, it fills voids and gently lifts the slab. Finally, the holes are patched, and any cracks are sealed.

Choosing a Professional for Sinking Concrete Repair

When dealing with sinking concrete, it's crucial to hire experienced professionals. Skilled technicians can assess the situation accurately and determine the best course of action. Moreover, they have access to high-quality materials and specialized equipment necessary for effective repairs.

Restoring Your Property's Safety and Value

Addressing sinking concrete promptly can prevent further damage and costly repairs. Property owners can quickly and efficiently restore their concrete surfaces by choosing modern foam lifting techniques. This not only enhances safety but also improves the overall value and appearance of the property.

Fill out this form or call 404-618-0438 for a contractor referral today!

Want more information on lifting sinking concrete with polyurethane?

The management team at a community pool in Midvale, Utah, faced a significant challenge. A water leak had saturated the silty soil beneath the structure, causing uneven settlement and safety hazards. To address this issue, they brought in geotechnical specialists from Rhino Foundation Systems, who proposed an innovative solution as an alternative to tearing out and replacing the pool. This approach not only promised to stabilize the pool but also lift it back to its proper position.

Powerful Polymers

The key to this solution was Alchatek's AP Lift 440 polyurethane foam. This powerful polymer was chosen for its soil stabilization, load-bearing, and lifting capabilities. Deep soil injections were planned to address the underlying issues. The foam's expanding properties would displace water and stabilize the soil base. This method offered a non-invasive alternative to traditional approaches like helical piles.

Painless Procedures

The process began with a thorough site assessment. The technicians analyzed soil saturation and settlement patterns. Based on this data, a 3-foot by 5-foot injection grid was designed. Next, holes were drilled through the bottom of the pool, and injection rods were installed. AP Lift 440 was injected beneath the structure. As a result, the expanding foam displaced water and stabilized the soil base. Following this, the pool was lifted by 3.5 inches. Finally, the pool deck was adjusted to match the new level.

Rapid Results

The pool was successfully stabilized and leveled with minimal disruption. Moreover, there was no need for extensive excavation. This method proved to be both effective and efficient. The foam injections effectively displaced water and stabilized the soil. Additionally, the lifting process was precise, raising the pool by exactly 3.5 inches. Perhaps most importantly, this solution was cost-effective. It proved quicker and more economical than complete pool replacement.

Want more information about lifting and stabilization with polyurethane?