Leak Seal & Geotech Products & Procedures

March 14 & 15, 2019 at Alchemy-Spetec HQ in Tucker, GA

Get ready for a thorough education in Leak Seal, Slab Lifting, Soil Stabilization and the Alchemy-Spetec Deep Lift™ process. You’ll get hands-on training from a technical staff with decades of on-the-job experience.

Thursday - Leak Seal

• Leak Seal Product Line Overview
• Curtain Grouting
• Permeation Grouting
• Leak-Seal Product Mixing
• Pump & Packer Overviews
• Leak-Seal Accessories
• Municipal Applications
• Live Injection Demos
• Open Discussions

Friday - Geotech

• Geotech Product Line Overview
• Soil Stabilization
• Geotech Product Mixing
• Rig & Mobile System Overviews
• Geotechnical Accessories
• Slab Lifting Live Demo
• Deep Lift™ Overview
• Soil Testing with the
• GPR & Penetrometer
• Maintenance Discussions
• Pricing / Estimating / Cost Savings
• Open Discussions

Participants receive a Samsung tablet loaded with training material.

Your Instructors:

Stephen C. Barton (President/CEO), Jim Spiegel (VP Sales & Business Development), Andy Powell (Southeastern Regional Manager), Anthony Sandone (Eastern Regional Manager), and Charlie Lerman (Western Regional Manager). Each instructor is a seasoned professional with at least a decade of experience in the industry.  

Alchemy-Spetec products will now officially be promoted under the Leak Seal and Geotech lines.  As holds true with most mergers (Alchemy Polymers and Spetec formed Alchemy-Spetec in 2017), the integration of products and services can take time.  This rebrand will be reflected in two separate product catalogs.  One for Leak Seal products and one for Geotech products. We are confident that the two-catalog offering is the best solution for our partners and customers. 

Both product types are now easily discernible by the Spetec or AP nomenclature in which Spetec represents Leak Seal, and AP represents Geotech. 

The Geotech line encompasses all two-part rigid polyurethanes used for void filling, slab lifting, permeation grouting, and soil stabilization; as well as acrylic grout used for permeation grouting, and all associated pumping equipment and accessories. Due to the technical support requirements of geotechnical applications in terms of equipment use, accessory setup, and application technique, this line will remain a direct sale to contractors performing slab lifting and soil modification applications.  

Conversely, the Leak Seal line remains a distributor sale through our continued support of distribution partners.  The Leak Seal line encompasses all water-activated grouts, acrylic grouts, waterstop products, mechanical packers and ports, and all associated dispensing equipment.   Since structural repair products are also sold through distribution, they are included in the Leak Seal catalog.

If you have any questions about the Alchemy-Spetec Leak Seal or Geotech product lines, please contact Jim Spiegel at jspiegel@alchemy-spetec.com for further assistance. 

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After three decades in this industry, I still find myself in awe of what polyurethane foam can do.  From sealing massive dam leaks to stabilizing airport runway slabs to lifting entire buildings – the feats contractors achieve with this stuff is astonishing.  Yet some people who are new to this technology have a hard time understanding how a mere “foam” can be ideal for these most demanding of applications.  Or maybe they wonder how safe it is. 

The irony is, whether you think you are “new” to this technology or not – you’ve been surrounded by polyurethane all your life.  Sometimes an understanding of the past can provide more confidence for moving forward into the future.  So if you can’t quite grasp how “foam” has been developed to the point that it can lift a building – or you wonder how safe it is – pay close attention to this story.

Dr. Otto Bayer first made polyurethane foam in Leverkusen, Germany in 1937.  Polyurethane was initially used as a cheap replacement for rubber.  Widespread use began in World War II, when many other materials became scarce.  Polyurethane use quickly spread as a key component in many products, from specialized paper to protective military garments to gloss finishes and protective coatings.

In the 1950s, many companies such as DuPont, BASF, Dow, and Union Carbide started producing polyurethane for an even wider variety of applications including adhesives, insulation and foam upholstery cushions.  In the 1960s the Bayer company (no relation to Dr. Otto Bayer) exhibited an all-plastic car, parts of which were made with polyurethane. 

In the early 1970s, the introduction of polyurethane skateboard wheels as a replacement for the old metal ones completely revolutionized the sport, as the new wheels allowed for high impact activities such as jumping off of ramps.  In the 1980s, the first mass produced plastic-body automobile – the Pontiac Fiero – was made with the use of polyurethane technology.

Today polyurethanes can be found in an infinite amount of products including furniture, clothing, shoes, beds, moldings, etc.

In the 1960s, 3M Company in the U.S. and Takanaka in Japan both introduced polyurethane grouts.  3M’s product was called Elastromeric Sewer Grouting Compound.  As the name indicates, it was intended for use in underground utilities.  Takanaka’s product was called Takanaka Aqua-Reactive Chemical Soil Stabilizer (TACSS).  As the name indicates, it was intended for use in soil stabilization projects.  In the early 1980s, DeNeef obtained the rights to TACSS and began distributing polyurethane grout worldwide.  By the mid 1980s, there were almost a dozen manufacturers of polyurethane grouts.  I got my start pumping 3M 5600 to seal cracks in the Atlanta subway system back in 1985.  I was amazed at what it could do back then, and I am still amazed at what our products do today.  3M exited the business many years ago.

In the last few decades, polyurethane grouting has become a widely accepted method for sealing leaks, stabilizing soil and lifting slabs.  Many innovations have been made, including closed cell hydrophobic polyurethanes and the use of two-component foams in geotechnical engineering.  Polyurethane’s advantages over the old school approach of cement grout repair is covered thoroughly in our blog post Polyurethane vs. Cement for Slab Jacking.

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As I said previously in my blog post Stop Erosion Through Your Seawall with Polyurethane:

When it comes to seawalls, there is a lot more to learn than meets the eye. Seawalls are like living, breathing things: especially in the way that they are designed to function. But like all living breathing things, they have a finite lifespan. For many of them, it's a mere 20 – 30 years. Depending on where you live, replacing a seawall can cost anywhere from $150 to $500 per foot. That's enough for some homeowners to choose to move instead of rebuilding their seawalls. Today however, signs of seawall distress can be solved before they get too bad through the application of polyurethane grouts to seal leaks, fill voids, and stabilize the surrounding soils.

Here's a glimpse of polyurethane seawall repair in action. Hang 'Em High Charters in Key Colony Beach, Florida discovered massive voids inside their seawall. Watch closely as they are repaired with AP Lift 475 foam...

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As a technical consultant, I often assist customers when they're put to the test with difficult jobs. That's why we go out of our way to provide the powerful polymers and painless procedures they need to achieve the rapid results those projects require. For an in-depth dive into what we mean by powerful, painless and rapid - see this blog post I wrote awhile back. Then watch the video below to see powerful polymers, painless procedures, and rapid results in action... 

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Salt corrosion, tidal action, currents, boat wakes, storm surges and sometimes hurricanes all deliver a constant beating on the seawall. Contrary to popular opinion, many of the forces also come from the side of the wall facing the land. Did you realize that rainfall/storm events create more hydrostatic pressure than rising and falling tides? Every time it rains or the irrigation system runs, and every time the tide goes out; all of the groundwater above the waterline needs a place to vent or equalize. Massive pressure can build up if that water is trapped, making it impossible for it to drain into the sea or storm water system. That is a recipe for disaster which can easily be avoided with proper surveillance. Let's take a look at some of the external signs a seawall is in need of repair... 

Small Sinkholes Near the Wall

In landscaped areas, evidence of soil erosion is often quite obvious.  In this photo you can see that there is a small sinkhole developing at the inside corner of the seawall.  Some types of grass will actually keep larger sinkhole from being seen.  So check thoroughly.

Voids Near the Edge of the Wall

Obvious settling soil should have gotten the property owner’s attention in this case.  Too often, they ignore the warning signs until something more catastrophic occurs.

Cracking Concrete

Here, ground penetrating radar revealed loose soil zones beneath this concrete apron outside of a fish processing facility.  The steel sheet pile walls were losing soil and huge voids had developed.  Evidence of cracking concrete was not enough to get their attention as is often the case.  However, when a Lull forklift went through the slab, everything but foot traffic was prohibited from being on the apron.

Damage to Structures Up to 100 Feet Away

Capillary pathways of leakage can be found over 100 feet away from the visible leak, depending on the soil matrix.  The back of this pool deck had dropped about 6” already as the yard slumped towards the leaking seawall.

Causes of Seawall Damage – An Overview

Correct construction of a seawall will include a drainage system to handle the bulk of the water that comes from rain in addition to check valves, weep holes, or seams to handle the daily influx and outflow from tide and wave action. Although these systems are designed to retain the soil behind the seawall, over time the materials degrade or can be disturbed by settling.

This is a direct symptom of normal wear and tear from the natural environment and is unavoidable. The result is a loss of soil and the inevitable sinkholes and / or low spots that will occur along the wall. Other times, the weep holes and vents become clogged and the water has no way to escape except to force its way down and out from underneath the base of the wall. When this occurs there will again be sinkholes and sometimes wall failure.

Conclusion

When signs of sinking ground are observed, you can almost be sure there are voids below that are that are not seen from the above the surface easily and are indeed dangerous. Sometimes these voids can extend below an adjacent patio, dock, or pool deck, causing those to sink and crack as well. The key to keeping those problems at bay is to actively anticipate them.

If you live along the water, it is always going to be man against nature. That seawall is keeping your property from damage and from disappearing altogether. The key to extending the life of your seawall is the advanced polyurethane technology from Alchemy-Spetec. For more on the repair process itself, read An In-Depth Look at Polyurethane Seawall Repair. It's fast; clean, easy to install, and most of all, effective.

Want more in-depth info on polyurethane seawall repair?

In the previous post, An In-Depth Look at Polyurethane Seawall Repair – Part 1, we looked at causes of seawall deterioration, typical evidence of deterioration to look out for near seawalls, and the three most common seawall repair options: excavation, cement grout repair and polyurethane repair.

Now we’re going to take a deep dive into the qualities, applications and advantages AP Fill 700 – the Alchemy-Spetec product most typically used for seawall repair. We’ll also share a case study on a seawall crisis at an upscale marina that was resolved by contractors using AP Fill 700.

AP Fill 700 Advantages

AP Fill 700 is a single component, water activated, hydrophobic, low viscosity, closed cell polyurethane injection resin. In addition to seawalls, it’s a proven polyurethane concrete crack sealant for all types of structures. From our experience advising contractors, we’ve found it to be the most cost effective method for repairing seawalls.

Here are some of the advantages it has over other polyurethanes:

Lowest viscosity on market

AP Fill 700 has a viscosity of 110 to 130 cps. This allows for getting into thin cracks.

Closed cell, 0% permeability

The closed cell structure of this foam allows for ZERO percent permeability. No compromising of the repair material to worry about.

Adjustable set time

Adding various amounts of catalyst to adjust the set time allows for custom application of the material to address the specific nature of the seawall problem. A longer set time allows for the material to permeate and soak in around the structure before setting up. A shorter set time makes the material set up more immediately, which may be appropriate when there are large voids to fill or gushing leaks to stop.

Single component

This particular product does not require a “B” side to react with before setting up. This allows for simple, efficient installation.

Phthalate free

Some companies use phthalates in their polyurethanes. Because of their environmentally unfriendly nature, it’s not even legal to manufacture phthalates in the United States. Companies using them have to import them from overseas. Needless to say, AP Fill 700 does NOT contain phthalates – a known marine pollutant.

Approved for contact w/ drinking water

As mentioned in the previous post in this series, AP Fill 700 has been NSF certified for contact with drinking water. So, obviously installation in recreational or commercial bodies of water is no problem from an environmental perspective. Read more about NSF certification in the blog post Alchemy-Spetec's NSF Certification Spells Environmental Protection.

High bonding characteristics

Once AP 700 is installed, it’s NOT coming off. The adhesive qualities are unparalleled. This contributes to the vast advantage polyurethane has over cement grout when it comes to durability.

More about AP Fill 700

This material is designed to be efficiently delivered into all sized gaps and eroded depressions. It reacts with water or moisture in the soil and expands to fill the voids. It’s compatible with any seawall material: concrete, steel, vinyl, etc. And it permeates the most sandy of soils to form a solid, strong, watertight mass. It sets in less than 10 minutes. By being impermeable to water once in place, the likelihood of future erosion is vastly diminished. 

AP Fill 700 Applications

In addition to seawall repair, there are many other general applications for AP Fill 700. Here a few to keep in mind…

• Cutting off low and high flow leaks
• Concrete void / crack filling for all structures
• Cutting off underground water flows
• Soil stabilization
• Filling voids under concrete slabs
• Encapsulating contaminated soils

Durability

Leading experts in the polyurethane industry predict that this material lasts for hundreds of years once installed. Polyurethane is made from similar materials as plastic. There’s a reason why people campaign against the dumping of plastic waste in the middle of the ocean: it will be there forever. The edge of the ocean, properly installed as part of a seawall repair, is a much better place for it. And, yes, it tends to last forever.

Powerful

If needed, AP Fill 700 can quickly shut down leaks of thousands of gallons per minute. Rapid expansion makes it great for filling voids, wide cracks, pipe joints, pipe penetrations. Originally developed over 30 years ago, and continuously improved since, this technology has one of the longest histories of success in the field among uses of polyurethane foams

Efficient Installation

Results are immediately clear due to the visible exiting of sea water when the foam is injected. The low viscosity allows it to be injected into hairline, expansion joints and smaller cracks as well. AP Fill 700 is field proven in “curtain grouting” (earthen dam seepage protection), and consolidating loose soils.

Case Study

Let’s close out this two part series with a look at polyurethane seawall repair in action…

Situation

Owners of an upscale marina in Riviera Beach Florida noticed cracking in the slabs outside of their main boathouse. They also noticed that the slab had settled in several areas. The slabs in question were subject to heavy dynamic loads as a large forklift traversed the area, bringing 40' motor yachts in and out of the boathouse. Contractors came in and did a site evaluation, drilling holes to probe beneath the slab and also a sub surface investigation of the seawall to see if soils were being lost.

Solution

Most of the joints in the seawall were leaking sandy soil out - resulting in a void beneath the concrete slabs, which then cracked and settled. AP Fill 700 was specified to seal the concrete panel joints. It was injected behind the panels in the area of the joints, both vertically through the concrete, and horizontally from the water side of the panels. Proper venting was then installed to relieve hydrostatic pressure.

Results

The sandy soils have been stopped from escaping from behind the seawall. The concrete slabs were then lifted back into place with a combination of helical piles and AP Lift 475. There are no longer any voids beneath the slab so it is not flexing and cracking any longer. This marina was saved from a much larger, more catastrophic failure.

Want more info on polyurethane seawall repair?

Spanning the Pithlachascotee River in New Port Richey, Florida is the Madison Street Bridge. Built in 1985, this structure was buttressed with four semi-circular seawalls at the base of each footing in the year 2000.

Over the years, tide fluctuation caused soils to wash out from underneath the seawalls. This caused the heavily used sidewalks on top of the walls to crack and settle, allowing even rainwater in. Without an alternate way for pedestrians to traverse the bridge, this structural problem quickly became a critical public safety issue.

Powerful Polymer

To rapidly address the problem a certified contractor relied on AP Fill 700 and its NSF 61-5 certification (approved for contact with drinking water). The rapid expansive properties of this semi-rigid hydrophobic resin made it the optimal solution for painlessly filling the voids that had developed in the seawall and stopping the erosion beneath the sidewalks.

Painless Procedure

To rapidly address the problem a certified contractor relied on AP Fill 700 and its NSF 61-5 certification (approved for contact with drinking water). The rapid expansive properties of this semi-rigid hydrophobic resin made it the optimal solution for painlessly filling the voids that had developed in the seawall and stopping the erosion beneath the sidewalks.

Rapid Result

Stopping the leaks in all four seawalls only took a few days. More than a year later the seawalls are still as good as new.

Want in-depth info on polyurethane seawall repair?

The Problem

As tidal flows rise and fall, water pushes its way in through cracks, joints, and defects in seawalls.  The water pushes in on incoming tides and flows out on outgoing tides.  As the water flows out, it carries sand and soil with it which causes undermining of the structure, voids to form, and deteriorates the structural integrity of the seawall.  This cycle is exacerbated during periods of heavy rain which continue the outflow of soil.

The Solution

AP Fill 700 is a semi-rigid hydrophobic polyurethane foam that reacts with water or moisture in the soil and expands to fill voids while it permeates sandy soil to form a solid, strong, watertight mass.  It has been used extensively in seawall applications to seal cracks, voids and defects as well as for filling voids and stabilizing the soil.

The Process

AP Fill 700 can be injected through pipes directly into voids and loose sandy soil using a single component pump (airless sprayer or double diaphragm pump).

Step 1:  Insert pipes down to the lowest level to be injected.  This can be done through driving the pipes mechanically, water jetting, or air jetting them down.

Step 2:  Ensure the soil has enough moisture content to cause a reaction of the AP Fill 700 (slightly damp to saturated).

Step 3:  Blend catalyst with AP Fill 700 to desired level.  Typically, between 2% and 5% AP 106 Catalyst will be sufficient.

Step 4:  Connect the hose from the pump to the injection pipe.  The hose should have a ball valve to control the flow of the material.

Step 5:  Inject AP Fill 700 either at a pre-determined rate (rule of thumb is 1 gallon per vertical foot) or until sufficient back pressure is established.

Step 6:  After each “point” is injected, raise the pipe 12” and repeat the process.  Once the pipe is within 24” of the surface you will probably get material flowing back to the surface (known as “refusal”).  Stop at this point and move to the next pipe.

Step 7:  Repeat this process until the entire area has been injected.

Note:  A containment barrier should be used on the water side of the seawall to capture any foam that leaks out of the seawall during the process.

Note:  Check valve type drains may need to be installed in the seawall after injection to allow water from heavy rains to vent out and reduce pressure on the seawall.  These drains will allow water to flow out, but not soil.

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