Alchatek Blog

The Significance of Forward-Thinking Maintenance

Grain silos are dynamic systems that benefit from regular, proactive upkeep. Immediate repairs like sealing leaks and leveling slabs are essential, but a long-term maintenance plan offers additional advantages. Proactive maintenance extends the silo's lifespan, reduces operational costs, and bolsters safety measures.

Energy Efficiency as a Strategic Focus

How Sealed Leaks and Stable Slabs Contribute to Energy Efficiency

Sealed leaks and level slabs enhance a grain silo's energy efficiency. Effective leak sealing, for example, prevents moisture ingress, reducing the need for dehumidifiers or other climate control measures. Likewise, a level slab ensures machinery operates efficiently, minimizing energy loss due to friction or misalignment.

The Economic Benefits of Energy Efficiency

Implementing energy-efficient practices can result in substantial cost savings. Lower energy consumption directly translates to reduced utility bills. In some areas, energy-efficient practices may also qualify businesses for tax incentives or grants, making it a vital aspect of long-term maintenance planning.

A Long-Term View on Cost-Effectiveness

Weighing Initial Costs Against Long-Term Benefits

While premium repair materials and energy-efficient solutions may come with higher initial costs, they often lead to long-term financial benefits. Durable repair solutions, for example, can reduce the frequency of reapplications, thereby lowering overall maintenance expenses. Similarly, energy-efficient practices offer ongoing utility bill savings.

The Value of Preventive Maintenance

Incorporating preventive maintenance, such as routine inspections and minor repairs, contributes to long-term cost-effectiveness. Early detection of issues helps avoid larger, more costly problems down the line. Planning scheduled maintenance activities during off-peak times further minimizes operational disruptions and costs.

Keeping Pace with Industry Changes and Staff Development

Staying Updated on Industry Trends

The landscape of grain silo maintenance is ever-changing. Keeping abreast of these changes is vital for ongoing operational success. Industry newsletters, webinars, and expert consultations are valuable resources for staying informed.

The Importance of Ongoing Staff Education

Continuous learning for staff members responsible for the daily operation and maintenance of grain silos is crucial. Training programs can update them on the latest best practices, contributing to both operational efficiency and safety. Investing in staff education is not only beneficial but often essential for maintaining high levels of operational excellence.

Key Takeaways for Comprehensive Maintenance Planning

Developing a long-term maintenance strategy is an ongoing commitment that involves regular inspections, proactive repairs, and a focus on energy efficiency. By understanding the long-lasting benefits of various repair materials, the economic advantages of energy-efficient practices, and the value of continuous learning, grain silo owners and operators can create a robust maintenance strategy. This strategy will ensure both the structural integrity and operational efficiency of the silo, leading to long-term cost savings.

For more information on sealing leaks with polyurethane grout...

In the world of grain storage, the focus often falls on the towering structures that dominate the landscape. However, what lies beneath these silos—the concrete slabs—plays an equally critical role in ensuring the safety and efficiency of grain storage operations. Sunken slabs can compromise the structural integrity of the entire silo, posing safety risks and operational challenges. Here, the importance of maintaining stable and level slabs, the role they play in structural integrity, and the use of polyurethane for slab leveling are explored.

The Role of Slabs in Structural Integrity

Structural Importance of Slabs

Concrete slabs serve as the foundation for grain silos. They bear the weight of the structure and its contents, distributing the load evenly to the ground below. When these slabs become unstable, they can cause uneven weight distribution, leading to undue stress on specific parts of the silo. Over time, this stress can manifest as cracks in the walls, deformations in the structure, or, in extreme cases, partial collapse.

Safety Concerns

An unstable slab isn't just an engineering problem; it's a safety hazard. The risk of structural failure poses a direct threat to anyone working in or around the silo. In addition, unstable slabs can make it difficult to operate machinery efficiently, leading to further safety risks. For example, forklifts or other heavy equipment may struggle to navigate an uneven surface, increasing the likelihood of accidents.

Polyurethane for Slab Leveling

Structural Polyurethane Foam

When it comes to leveling slabs, polyurethane offers several advantages over traditional methods like mudjacking or concrete replacement. One of the most significant benefits is the speed of application. Polyurethane foam can be injected directly into the affected areas, expanding to fill gaps and level the slab. This process can often be completed in a matter of hours, minimizing operational downtime.
Another advantage is the material's lightweight nature. Unlike concrete, polyurethane doesn't add significant weight to the slab, reducing the risk of overloading the soil beneath. Its flexibility also allows for some movement, accommodating natural soil shifts without compromising the integrity of the repair.

Hire an Experienced Contractor

While polyurethane offers an effective leveling solution, proper installation is key to achieving optimal, long-lasting results. Look for a contractor who specializes in slab lifting and has expertise specifically with structural polyurethane foam. They will understand the intricacies of assessing the degree of settlement, calculating the void space, and injecting the precise amount of polyurethane foam needed. An experienced contractor will also follow best practices for drilling injection holes and sealing them after use.

Rushing through the job or cutting corners on materials and techniques can lead to subpar leveling results. While it may cost more upfront, hiring an experienced contractor is well worth the investment in the long run through superior results and minimized repeat repairs. Their expertise delivers slab leveling done right the first time.

Key Takeaways

The stability of the slabs beneath grain silos is a critical but often overlooked aspect of silo management. These slabs play a vital role in maintaining the structural integrity of the silo and ensuring the safety of workers. Unstable slabs can lead to a host of problems, from structural damage to operational inefficiencies.
Polyurethane offers a quick and effective solution for leveling slabs, with advantages such as rapid application and reduced weight. By taking a proactive approach to slab maintenance and repair, silo owners and operators can mitigate risks, improve operational efficiency, and safeguard both their investment and the people who depend on it.

Addressing unstable slabs is not merely a maintenance task but a strategic action that impacts the overall safety and efficiency of grain storage operations. By understanding the role of slabs in structural integrity, the advantages and disadvantages of using polyurethane, and the importance of regulatory compliance, actionable steps can be taken to ensure the long-term success and safety of grain silo operations.

For more information on leveling concrete slabs and stabilizing soil...

In the earlier posts of this series, the importance of slab leveling, and soil stabilization has been emphasized, along with the specific risks faced by various industries and the notable advantages of using polyurethane, as supported by real-world case studies. The focus now shifts to providing commercial property owners and managers with actionable steps for effectively addressing these critical issues.

Initial Inspection and Assessment

Why It's Important

Before you can fix a problem, you need to know what the problem is. An initial inspection will help you identify the areas that require attention.

How to Do It

• Visual Inspection: Walk around the property to look for visible signs of sinking slabs or unstable soil. This could include cracks in the concrete, uneven floors, or pooling water.
• Professional Consultation: For a more thorough assessment, consider hiring a professional who specializes in slab leveling and soil stabilization. They can use specialized equipment to measure the extent of the problem accurately.

Choose the Right Solution

Why It's Important

Different problems require different solutions. The right approach will depend on the extent of the issue, the type of soil, and the specific needs of your property.

How to Do It

• Consult Experts: Discuss the findings of the inspection with professionals to determine the most effective solution. This could range from polyurethane injections to more traditional methods like mud jacking or even slab replacement in extreme cases.
• Cost-Benefit Analysis: Evaluate the long-term benefits and costs of each solution. While polyurethane might have a higher upfront cost, its durability and speed could result in lower long-term expenses.

Select a Contractor or Service Provider

Why It's Important

The success of the project largely depends on the expertise of the contractor or service provider you choose.

How to Do It

• Check Credentials: Make sure the contractor is certified, insured, and has a good track record in slab leveling and soil stabilization.
• Get Multiple Quotes: Don't settle for the first quote you receive. Get estimates from multiple contractors to ensure you're getting the best value.
• Ask for References: A reputable contractor will be able to provide references or case studies that demonstrate their expertise.

Prepare for the Project

Why It's Important

Proper preparation ensures that the project goes smoothly, minimizing disruptions to your business operations.

How to Do It

• Schedule Wisely: Choose a time for the project that will have the least impact on your business. This could be during off-hours or a less busy season.
• Notify Stakeholders: Inform employees, tenants, or customers in advance so they can prepare for any temporary inconveniences.

Monitor the Project

Why It's Important

Active involvement in the project allows you to address any issues promptly, ensuring the project stays on track.

How to Do It

• Regular Updates: Ask for regular updates from the contractor, including any challenges they encounter and how they plan to address them.
• On-Site Visits: If possible, make occasional visits to the site to monitor progress and ensure that the work is being carried out to your satisfaction.

Post-Project Assessment and Maintenance

Why It's Important

Once the project is completed, a final assessment ensures that the issue has been effectively resolved and helps you plan for any future maintenance.

How to Do It

• Final Inspection: Conduct a final walk-through with the contractor to ensure that all objectives have been met.
• Maintenance Plan: Discuss any recommended maintenance or follow-up actions to ensure the longevity of the repair.

Taking proactive steps to address slab leveling and soil stabilization issues in your commercial property is not just a matter of maintenance; it's an investment in the safety, functionality, and longevity of your asset. Consult with professionals, choose the right solutions, and monitor the project closely to ensure its success.

For more information on concrete leveling and soil stabilization...

In the field of commercial property management, maintaining the integrity of concrete slabs and soil stability is crucial. Although the general advantages of using polyurethane have been discussed, real-world case studies provide the most compelling evidence of its effectiveness. This post will explore two such case studies to demonstrate the efficacy of polyurethane in addressing complex slab and soil challenges.

Case Study - Agricultural Plant Slab Lift

The Challenge

Located just outside Saskatoon, Saskatchewan, a 12,000-square-foot cement manufacturing plant built in the 1960s was being re-purposed as an agricultural seed sorting facility. The plant's 10-inch thick, double rebar, 8000 psi concrete floors had settled due to an undetected broken water main on an adjoining property. The floors had sunk as much as 7 inches, becoming independent of the footings. Initial plans to demolish and replace the slabs were halted when they proved too resilient for even a track-hoe-mounted jackhammer. With the harvest season fast approaching, the property owner was in a bind.

Powerful Polymers

AP Lift 440, a high-strength, hydro-insensitive structural polyurethane foam, was chosen for the job. Known for its exceptional lifting and supporting capabilities, especially for heavy concrete floors that have settled due to water infiltration, it provided an ideal solution.

Painless Procedure

An Alchatek-certified contractor was brought in to tackle the problem. Five slabs were lifted, and three others were fine-tuned, correcting the unsuccessful attempts made earlier with cement grout. In less than a week, nearly 900,000 pounds of the sunken slab were lifted using only twelve 100-gallon sets of AP Lift 440.

Rapid Result

The polyurethane foam delivered a level of precision far superior to traditional mud jacking methods. This allowed for the installation of high-tech seed-sorting equipment just in time for the fall harvest. The floors remain perfectly level to this day, showcasing the long-lasting effectiveness of polyurethane solutions.

Case Study - New Construction Foundation Stabilization

The Challenge

A general contractor working on a new commercial construction project in Atlanta faced a critical issue during the foundation phase. Sheet pile panels were used for erosion control while pouring the foundation walls. However, a layer of gravel and soil between the panels and the foundation needed to be stabilized before the sheet piles could be removed, to prevent the soil from becoming unstable and compromising the foundation.

Powerful Polymers

Alchatek’s AP Fill 720 structural polymer was selected for its ability to permeate soil and encapsulate gravel, creating a solid mass. This polymer is known for its high strength and versatility, making it an ideal choice for foundation stabilization.

Painless Procedure

The crew inserted injection rods about 12 feet deep at a spacing ratio of 3 feet apart along the entire length of the foundation wall. The structural polymer was then injected until it bubbled up through the surface of the ground, indicating that the soil and gravel had been fully encapsulated.

Rapid Result

The soil and gravel layer was effectively locked into place. When the sheet piles were removed, only a thin gap remained, which was then filled with cement. This left a solid, supportive wall of soil, gravel, and grout to support the foundation, showcasing the effectiveness of polyurethane in foundation stabilization.
These case studies demonstrate the unparalleled effectiveness of polyurethane in addressing complex slab and soil issues in commercial settings. Whether you're dealing with an old structure requiring slab lifting or a new construction needing soil stabilization, polyurethane offers a rapid, precise, and long-lasting solution.

For more information on concrete leveling and soil stabilization...

In the previous post, the basics of slab leveling, and soil stabilization were introduced, along with a discussion on the types of commercial properties commonly affected by these issues. Today's focus will be on delving deeper into the specific risks and dangers that different industries face when it comes to sinking slabs and unstable soil.

Warehouses and Manufacturing Plants

Risks

• Damage to Inventory: Sinking slabs can lead to uneven floors, causing racks to tilt and possibly collapse, damaging the stored goods.
• Machinery Misalignment: Production lines and heavy machinery require level surfaces for optimal operation. A sinking slab can lead to misalignment, affecting production quality and efficiency.
• Operational Delays: Uneven surfaces can slow down the movement of goods within the warehouse, leading to delays and increased operational costs.

Dangers

• Forklift Accidents: Uneven floors can cause forklifts to tip over, leading to potential injuries and damage to goods.
• Employee Safety: Trip hazards due to uneven floors can result in falls, leading to injuries and potential workers' compensation claims.

Retail Centers and Public Spaces

Risks

• Damage to Store Fixtures: Sinking slabs can lead to tilted shelves and display units, causing merchandise to fall and get damaged.
• Reputation: The appearance of cracked or uneven floors can deter customers, affecting foot traffic and sales.
• Legal Liability: If a customer trips and falls due to an uneven surface, the property owner could be held liable for injuries.

Dangers

• Customer Safety: Trip and fall hazards can result in injuries to customers, leading to potential lawsuits and a tarnished reputation.
• Employee Well-being: Staff members are also at risk of tripping over uneven surfaces, which can lead to injuries and absenteeism.

Healthcare and Educational Institutions

Risks

• Equipment Misalignment: In healthcare settings, specialized medical equipment like MRI machines and surgical tables require level surfaces for accurate operation. Sinking slabs can lead to misalignment, affecting patient care.
• Facility Damage: Lecture halls, classrooms, and laboratories in educational institutions can suffer from structural damage, affecting the quality of education.
• Operational Disruption: Both healthcare and educational facilities are places where timely service is crucial. Structural issues can lead to room closures and service interruptions.

Dangers

• Patient and Student Safety: Trip hazards can be especially problematic in healthcare settings, where patients may already be in a vulnerable state. In educational institutions, the safety of young students is a primary concern.
• Emergency Response: In healthcare settings, uneven floors can impede the quick movement of medical staff during emergencies, potentially affecting patient outcomes.

If you recognize your industry in this list and have not yet assessed the state of your property's slabs and soil, it's time to consult with professionals. Specialized contractors can provide industry-specific solutions to mitigate these risks and dangers effectively.

For more information on concrete leveling and soil stabilization...

If you own or manage a commercial property, you've likely heard the terms "slab leveling" and "soil stabilization." But what do these terms mean, and why should you care? This blog post aims to demystify these critical processes and shed light on their importance for maintaining the structural integrity and safety of your property.

Concrete Leveling and Soil Stabilization

Slab leveling refers to the process of correcting uneven or sinking concrete slabs. Over time, the soil beneath these slabs can shift or settle, causing the concrete to become uneven. Soil stabilization, on the other hand, involves treating the soil to improve its load-bearing capacity, thereby preventing future sinking or shifting of the slab.

Types of Commercial Properties Affected

Almost every type of commercial property has areas with large concrete slabs. Whether you own a warehouse, a retail center, or an office building, chances are you have concrete slabs that could be affected by sinking or shifting soil. Here's a quick list of property types commonly affected:

• Warehouses and Distribution Centers
• Manufacturing Plants
• Retail Centers and Malls
• Office Buildings
• Data Centers
• Airport Terminals and Hangars
• Parking Garages
• Hotels and Resorts
• Hospitals and Medical Centers
• Educational Institutions
• Sports Arenas and Stadiums
• Convention Centers
• Grocery Stores and Supermarkets
• Auto Dealerships and Service Centers
• Public Transit Stations
• Theaters and Cinemas
• Fitness Centers and Gyms
• Restaurants and Cafes
• Self-Storage Facilities
• Agricultural Facilities

Why It Matters

Ignoring the signs of sinking slabs and unstable soil can lead to a host of problems, ranging from minor inconveniences to major structural issues. Here are some reasons why you should take these issues seriously:

Safety Risks

Uneven slabs create trip hazards, putting employees, customers, and visitors at risk of injury. In a worst-case scenario, this could lead to lawsuits or regulatory action against your business.

Structural Integrity

Sinking slabs and unstable soil can compromise the structural integrity of your building. Over time, this can lead to more severe problems like cracks in the walls, misaligned doors and windows, and even structural failure in extreme cases.

Operational Efficiency

In industrial settings like warehouses and manufacturing plants, uneven slabs can disrupt the smooth operation of machinery, leading to inefficiencies and increased operational costs.

Aesthetic Appeal

For retail centers and hotels, aesthetic appeal is crucial for attracting customers. Sinking slabs and cracked floors can significantly diminish the appearance of your property, affecting your business's reputation.

Financial Implications

Ignoring the problem today can lead to more expensive repairs down the line. Early intervention is often more cost-effective, saving you money in the long run.

For more information on concrete leveling and soil stabilization...

Polyurethane grouting is an essential process in construction and infrastructure projects with the need to lift structures, fill voids, and stabilize soil. While polyurethane grouting has been utilized for decades, advancements in technology and technique have enabled a new level of precision and control in modern grouting applications. Innovations in polyurethane injection methods and equipment allow design and construction teams to achieve highly accurate, consistent injections for maximum strength and longevity. 

Precision is critical in polyurethane grouting applications. Inadequate filling of voids or inconsistent distribution of grout can lead to structural instability, settlement, and even collapse. Precise injections ensure that soil is saturated, voids are filled, and slabs are leveled accurately. This provides uniform load distribution and protection against shifting, vibration, and erosion. Precision also prevents wasted materials and rework due to incorrect amounts or placement of grout. 

Modern polyurethane grouting equipment and techniques enable accurate monitoring and adjustment of grout injection rates, depths, pressures, and consistency. Some examples of modern technology include: 

• Hydraulic and Electric Pumps: Modern polyurethane injection equipment includes hydraulic or electric pumps. These pumps provide precise control over pressure and flow, ensuring a more uniform injection of grout material.
• High-Pressure Injection: Modern equipment can handle high-pressure injection, making it suitable for stabilizing deep structures and addressing challenging soil conditions. High-pressure injection ensures better penetration of the polyurethane grout.
• Remote Monitoring and Data Logging: Advanced systems come with remote monitoring and data logging capabilities when necessary. Operators can monitor the injection process remotely and collect data on pressure, flow, and other parameters for quality control and documentation.
• Compact and Portable Systems: Some advanced injection grouting systems are designed to be compact and portable, making them easier to transport to job sites and set up quickly.
• Safety Features: Modern equipment includes safety features such as shut-off valves and pressure relief mechanisms to protect both operators and the equipment itself.

Modern polyurethane grouting equipment has revolutionized construction and infrastructure project challenges, offering engineers and design teams an array of precision-driven advantages. The evolution of polyurethane injection equipment, including hydraulic pumps, pneumatic pumps, and computerized control systems has empowered design teams and application technicians to achieve precise outcomes.

For more information...

The approach and departure slabs adjacent to a bridge in McKenzie County, North Dakota had settled, leading to an uneven and hazardous road surface. A geotechnical contractor was brought in to level the road surface and mitigate any further settlement. 

Powerful Polymer

The contractor selected AP Lift 475, a two-component, hydrophobic, structural lifting polymer designed for airport, highway, and railroad applications. It can be used to stabilize structures, fill voids, and lift slabs supporting tremendous loads. In addition to tremendous in situ load-bearing capacity, AP Lift 475 is also traffic-ready in less than one hour.

Painless Procedure

AP Lift 475 was injected through the approach and departure slabs to fill subterranean voids, compact the existing subgrade, and lift the settled structures. As the material was injected, the material rapidly expanded, compacting the subgrade soils. Once the subgrade was compacted and the load-bearing capacity of the soil improved, the material raised the settled slabs.

Rapid Result

The approach and departure slabs were lifted to their proper elevation and the underlying soil was improved to mitigate future settlement. This work was performed in two days. 

Want more information on geotech products and equipment?

The terms hydrophobic and hydrophilic may not mean anything to the average person. But, to a contractor, these terms can mean a world of difference. Hydro means water while phobic means “to fear” and philic means “to love”. Alchatek offers both hydrophobic and hydrophilic polyurethanes, so it is important to be aware of the differences between the two types.  

Hydrophobic Polyurethanes

Hydrophobic polyurethanes naturally repel water (similar to the way oil would repel water and stay separate if you were trying to mix them in a glass). These products push water out of the area in question as they expand. Hydrophobics are used with catalysts which allow you to adjust the set time. They also have zero shrinkage after curing.

Check out these hydrophobic polyurethanes:

• Spetec PUR HighFoamer 
• Spetec PUR F400
• Spetec PUR H100 
• Spetec PUR H200 
• AP Fill 420
• AP Deep Lift® 420
• AP Lift 430
• AP Lift 435
• AP Lift 440
• AP Lift 475
• AP Soil 600 
• AP Fill 700
  
• AP Fill 720

Hydrophilic Polyurethanes

Hydrophilic polyurethanes naturally mix with water before curing (similar to the way gin and tonic mix thoroughly in a glass). This characteristic allows for a very strong chemical and mechanical bond, as water helps pull the material into the pores of the concrete. These products do not require a catalyst. You can pump them straight out of the pail.

Check out these hydrophilic polyurethanes:

• Spetec PUR GT350
• Spetec PUR GT380
• Spetec PUR GT500

Don't Oversimplify These Concepts

Don't get caught in the trap of oversimplifying hydrophilic vs. hydrophobic.  There are varying degrees of each (see chart below for more information on how this is measured).  

Some hydrophilic materials will keep absorbing water (10-15 times their original volume).  Others (such as Spetec PUR GT500) only absorb as much water as is necessary for their reaction and then they reject the rest.  Yes, hydrophilic gels will shrink like crazy in the absence of water, but Spetec PUR GT500 won't.  It is completely safe to use in a dry environment.

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Raising Concrete with Confidence

When pumping a lightweight 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 are 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, weigh 2.75 – 3.25 lbs (AP Lift 430) to 4.75 – 5 lbs (AP Lift 475) per cubic foot. But they have compressive strengths of 50 psi and 100 psi in a free-rise state. That's the equivalent of 7,200 to 14,000 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 list stiff clay at 4,000 psf and crystalline bedrock as having 12,000 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.

Concrete Leveling for Any Job with the Right Foam

Today polyurethane concrete 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.

Want in-depth info on slab lifting procedures and products?