Slab Jacking with Lighter Material Prevents Further Sinking

We are often asked about the biggest advantages of lifting settled concrete slabs with polyurethane foam vs. cement grout.  One of the biggest advantages is the weight.  Depending on the product, the density of structural polyurethane lifting foam is between 3 ½ and 5 pounds per cubic foot.  The same volume of cement grout weighs 140 pounds per cubic foot. This translates to 30 to 40 times more added weight using cement vs. polyurethane. By using lighter weight materials, you are giving yourself a much greater chance for long term success.  (Polyurethane is strong enough to support any structure, as explained in our earlier blog post How Strong is Strong Enough.)

Concrete Lifting with Polyurethane Creates Less Mess

Another advantage of using foam is the size of the drill holes.  Drilling holes for foam is quick and easy, requiring only a 3/8” hole to inject through.  For mud jacking you are drilling injection holes ranging from one to two and a half inches.  This takes longer, does more damage to the concrete, and the drills and drill bits are more expensive.  With mud jacking there are the additional problems of messier works sites and disposal of unused mixed cement.

Mudjacking with Cement Requires Longer Cure Times

The final advantage of foam over cement is time.  All of our AP Lift series products reach 90 percent of their final strength in 15 minutes and are fully cured in less than a day.  Literally, as soon as you are done packing up your equipment the foam under the slab is ready for traffic.  On the other hand, cement grout can take days to reach final cure.  Having immediate load bearing traffic is especially important for facilities such as warehouses that run 24/7 and need to use the lifted area as soon as the job is complete.  

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Aim for Opportunity

In this article, we'll identify opportunities and markets where slab jacking is needed. Three main markets we will take a look at are Residential, Commercial / Industrial, and Transportation.

Residential Slab Jacking

The residential market offers tremendous opportunities for the slab lifting contractor. Obviously, there are driveways and foundations. These can all sink for various reasons such as water runoff, excess weight, and poor compaction. But look a little further; this year alone we have had calls concerning the following areas: patios, outbuildings, pools, and porches. And don't think residential only includes houses. I'm not officilally saying that construction companies building condos and apartments would bury trash that would later cause settling issues; I'm just saying....

Commercial / Industrial Slab Jacking

Because the scenarios for slab lifting are endless for non-residential slab lifting, I am going to lump Commercial and Industrial together. Concrete parking lots are often lifted now instead of replaced. The same goes for busy warehouse floors; lifted and back in business in hours, not days. Another place to look is slabs beneath equipment; they are not always originally designed to support heavy loads but the equipment ends up there anyways. Anywhere there is a transition there could be a lifting opportunity. From inside to outside, from slab to slab, from parking lot to parking deck, and any areas where there is water runoff.

Slab Jacking for the Transportation Sector

Last but not least, take a look in the transportation sector. Our highway and road building contractors do a great job. But in the miles and miles of asphalt and concrete, there are going to be some settling issues. Look again at transitions, from highway to bridge (the bridge approach slab) is a good example. Think airport taxiway slabs don't ever sink? Wrong. Think slabs under railroad tracks don't ever need stabilizing and leveling? Wrong again. And the advantage for lifting with polyurethane really shines in this sector. Strong, fast, and back in business in hours, not days.

So get off your assets and go lift something.

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Raising Concrete with Confidence

When pumping a light-weight material beneath a slab, you need the confidence that it is strong enough for the application. How strong is strong enough? This is a commonly asked question by contractors that are new to slab jacking with polyurethane. Alchemy-Spetec structural foams only need to be as strong as dirt, but they're actually stronger than crystalline bedrock.

The Right Strengths for Concrete Lifting

Slab lifting foams are rated on density (weight per cubic feet) and compressive strength. This testing and rating is based on the foam in a free rise state; the parts A and B are mixed together and allowed to expand freely. Our AP Lift 430 and AP Lift 475 structural lifting foams, for example, will weigh 2.75 – 3.25 lbs (AP Lift 430) to 4.75 – 5 lbs (AP Lift 475) per cubic foot. But they have a compressive strengths of 50 psi and 100 psi in a free rise state. That's equal to 7,200 to14,000 lbs per square ft of support, just in a free rise state.

Polyurethane Slab Jacking Compared to Clay and Bedrock

To put that into perspective, the National Home Builders Association and the International Building Code lists stiff clay at 4000 psf and crystalline bedrock as having 12000 psf of load bearing capacity. Consider the job site conditions where the foam will be injected into a confined area. Testing data in the lab shows that our lifting foams will increase in compressive strength: In a space confined 25% by volume there will be an increase of 31% in psi and in a space confined by 75% there will be a 79% increase in the psi.

Slab Jack for Any Job with the Right Foam

Today polyurethane lifting foams are used to level airport slabs supporting jumbo jets, equipment and building slabs supporting tremendous loads, and even railway sleepers that support the heaviest freight trains. So don't let the word “foam” fool you. These resins cure to strengths beyond what is needed to support any structure.

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Today is our last day exhibiting at the No-Dig Show!  Visit us at booth #146!

 

Watch this video to preview a couple Alchemy-Spetec product demos!

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We are proud to announce that we are currently exhibiting at the No-Dig Show in Palm Springs, CA. Visit us in Booth #146!

"NASTT’s No-Dig Show is the largest trenchless technology conference in North America, where professionals attend to learn new techniques that will save money and improve infrastructure. This show offers six tracks and 160 peer-reviewed, non-commercial presentations, including case studies detailing environmentally friendly trenchless solutions and cost-saving opportunities for municipalities and utilities. With over 190 exhibiting companies and multiple networking events, spend quality time with current colleagues/customers and grow your connections. Whether you’re a newcomer or a show veteran, NASTT’s No-Dig Show is the must-attend conference for underground infrastructure professionals."

Click here to read more about the No-Dig Show.

Reps Attending: Jim Spiegel, Thad Brown
Polyurethane Solutions Demonstrated: Seal Leaks, Stabilize Soil, Lift Slabs
Booth Number: 146
Address: Palm Springs Convention Center 277 N. Avenida Caballeros, Palm Springs, CA 92262 

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The Deep Lift™ process is different from common slab lifting in that it requires polyurethane foam to be injected deep into the soil beneath the structure. Deep Lift™ is often appropriate for certain larger structures and more flexible pavements that may not be ideal candidates for conventional slab lifting. It can also be used in conjunction with conventional slab lifting. In this post, I'll provide a quick overview of the Deep Lift™ process and its many applications.

The Process:

1. Complete a thorough site evaluation including – soil borings, DCP testing, and GPR as necessary
2. Address any potential binding with saw cutting, clearing of joints, and removal of old grout
3. Based upon soils data, calculate grid spacing and injection depths
4. Drive injection tubes to the correct depths and locations
5. Inject the appropriate AP Lift series polymer(s) in the predetermined sequence while monitoring for lift
6. Follow the grout plan, adjusting the injection depths and locations as the structure raises into place

The Applications:

• Bridge abutments
• Highway approach slabs
• Rigid and flexible pavements
• Ports and airports
• Settled buildings
• Soil densification and encapsulation
• Lift stations
• Pipe and tunnel segments
• Equipment pads

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Poor compaction, water erosion, broken pipes, and organic material in the soil can all lead to settling of a foundation or a roadway. Traditional slab lifting can bring concrete and structures back into place but it doesn’t necessarily address the underlying issue or guarantee a long term fix. Other methods of addressing deep soil issues require heavy equipment, extended down time, and collateral property damage. These situations create problems for property owners as well as opportunities for the elite contractors that know how to fix them.

Introducing the Deep Lift™ process! Alchemy-Spetec offers a unique combination of high quality structural lifting foams along with the equipment and training needed to address deep soil issues. Now you can achieve soil densification and lifting on large projects with the smallest footprint and least amount of heavy equipment required. The Deep Lift™ process is powerful, painless, and rapid. Deep Lift™ gets to the root of the problems in the soil, it brings the structure back to level, and accomplishes this with minimal imposition or downtime to the property owner.

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The Alchemy-Spetec PolyBadger lifting system is tough and compact. This system is an affordable entry-level slab lifting option for new contractors, as well as an extremely portable addition to the experienced contractor’s arsenal. The PolyBadger is a lot less expensive than your standard 20 foot trailer rig. The set up is simple and requires minimal equipment. The entire system can easily fit in the back of a pickup truck!

The genius of the PolyBadger is the auto calibrator. It keeps the flow of A-side and B-side slab lifting material on ratio, eliminating the possibility of crossover clogging in the gun or the whip hose. The two low-pressure transfer pumps and auto calibrator are literally the only moving parts in the whole system. That means less downtime, less maintenance, and more productivity on the job. This system is easier to use and a more affordable than many options on the market.

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“If you don’t love something, you’re not going to go the extra mile, work the extra weekend, challenge the status quo as much.” – Steve Jobs

Who is Colt Hullander? Even if you're an experienced concrete repair industry professional, you still may not know this man by name. He started his grouting career on the contractor side directly out of high school. For the next several years, he developed key skills in the chemical grouting space with countless hours in the field lifting slabs and stabilizing soils. During these years, Colt gained priceless experience in an extremely technical process: mixing and pumping single and dual component polymer grouts through expensive multi-component proportioning equipment at high volumes to stabilize and lift very large structures in both the public and private sector. Some would say these are some of the most important skills one could have in our industry. But his commitment to his team is far more impressive.

Fast forward to Christmas weekend, 2017. Over the next four weeks, including all weekends, a typical week for Colt involved servicing field technical support, welding several custom made structures up to 10’ tall (some in aluminum!), building custom-made wood demo models with masonry block faces, designing and fabricating a custom cart for a several hundred-pound piece of equipment, and much more. Most of us would see this is a lot of work. However, the job had yet to begin.

Two weeks ago, on a Wednesday afternoon, Colt loaded up an F-350 with a 20’ trailer full of all of the above-mentioned items, and more, and left Atlanta, GA. He drove for 4 days until he reached Las Vegas on Saturday. Once there, Colt worked the entire weekend assembling an entire show display prepared for the 70,000 people that were about to come through the doors. As the Sales and Management team poured into company meetings on Monday, Colt excused himself only to return to the lot for last-minute setup well into the night-time hours. On Tuesday morning, Colt assumed his position in the booth as a live demo operator conducting live applications every 2 hours, all week long. On Friday of last week, Colt packed up all of the remaining gear and set out from Las Vegas, making the drive back to Atlanta. Three days later, Colt would be back in Atlanta, coming to work the very next day. I spoke to Colt today, and to little surprise, he was on a job-site. Colt Hullander is an Alchemy-Spetec Technical Field Services Representative, and we are very proud to have him on our team.

It’s appropriate to thank our entire team for all of their work last week at World of Concrete. Colt is certainly not the only one on our team who deserves a blog notice. And undoubtedly, many of you reading this have those teammates who went the extra mile as well. But true to the format of this People section, it was an easy choice to share the story of Colt Hullander. Well done Colt! And well done to all of those who make World of Concrete such a productive week for all attendees.

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We have launched our new application!

Finally, a polyurethane estimating calculator for slab lifting and void fill jobs.

This app is a simple, fast, and reliable way to take the guesswork out of estimating Alchemy-Spetec polyurethane slab lifting and void filling materials while prepping for a job.

Follow these steps to download and operate this app:

1. Download App
Search Alchemy-Spetec in your Apple App Store or Google Play Store to install the Poly Estimating App.

 

2. Create an Account for the App
After installing the app, create an account by clicking "Sign Up" at the bottom and following the prompts.

3. Click the Slab Lifting Material Estimator or Void Filling Material Estimator button at the bottom.

4. Select Your Product: 430, 440 or 475
Watch for the expansion rate to appear at the bottom once you've selected the product.

       

5. Input Data
Enter the square footage of the slab and number of inches the slab has settled, then press enter.

6. End Result
The final screen displays the amount of resin needed for your specific job. You will see options for slabs in which 1 side is settled, 2 sides are settled, and all sides are settled. 

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