Alchatek Blog

Mid South Concrete Lifting successfully executed an emergency repair operation at a Tennessee Valley Authority (TVA) lift station in New Johnsonville, Tennessee. What began as a new construction project quickly required an urgent repair when significant leakage was discovered at multiple joint locations immediately after installation. The contractor's rapid response and innovative solution prevented extensive water loss and potential environmental impacts.

Initial Assessment

The investigation began when facility managers discovered several critical issues:

• Structural weaknesses detected in multiple joint locations
• Massive water loss occurring within 24 hours of installation
• Thousands of gallons of water escaping through compromised joints
• Environmental concerns due to uncontrolled water discharge

The severity of the situation demanded emergency intervention to prevent continued water loss and potential damage to surrounding infrastructure.

Proposed Solution

After technical evaluation, Spetec PUR F400 was selected as the optimal solution due to its superior characteristics:

• Rapid-curing formulation for quick deployment
• Excellent adhesion properties for joint sealing
• Water-reactive chemistry suitable for wet conditions
• High structural strength for long-term durability
• Environmental compatibility for water infrastructure

Procedures

1. Complete dewatering of the lift station
2. Technical team rappelled into the structure
3. Systematic injection of Spetec F400 at all compromised joints
4. Progressive sealing to ensure complete joint stabilization

Results and Conclusion

The emergency repair proved successful on multiple fronts:

• Complete elimination of water loss through compromised joints
• Restoration of structural integrity to all sealed areas
• The system returned to full operational status within 24 hours
• Long-term solution achieved with minimal downtime
• Cost-effective resolution compared to alternative repair methods

The project demonstrated the effectiveness of chemical grout injection as a rapid response to critical infrastructure leaks. It successfully prevented ongoing water loss while providing a durable, long-term repair solution.

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

Initial Assessment

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

Proposed Solution

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

Procedures

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

Results

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

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Water leaks in concrete slabs can be a severe issue for property owners. These leaks occur when water from the ground seeps through cracks or gaps in the concrete foundation, leading to moisture problems inside the building. If not addressed promptly, these upward-moving leaks can lead to structural issues, damage flooring materials, and create an environment conducive to unhealthy mold growth. Curtain grouting with polyurethane is a proven technique for effectively fixing water leaks in concrete slabs. This method creates a barrier beneath the slab, preventing water from penetrating upwards and resolving the issue at its source.

The Curtain Grouting Solution

Curtain grouting is a well-established and highly effective method for addressing water leaks in concrete slabs. The process begins with drilling small holes through the concrete slab in a precise diamond grid pattern. Technicians then inject polyurethane grout into each hole, overlapping injections like shingles on a roof to ensure comprehensive coverage. Upon contact with water from the leak, the grout expands and forms a solid, watertight barrier beneath the slab. This durable seal effectively prevents further water intrusion, resolving the leak at its source.

Advantages of Curtain Grouting

This technique can address multiple leaks simultaneously, providing a comprehensive solution. Additionally, it delivers long-lasting results, ensuring the integrity of your slab for years to come. The process requires minimal equipment and causes less disruption compared to other methods. Moreover, the materials used in curtain grouting are environmentally safe and NSF-certified to meet strict environmental standards.

The Critical Role of Professional Expertise

Fixing a water leak in a concrete slab is not a task for DIY enthusiasts. Due to the complexity of the process, professional expertise is crucial. Experienced contractors possess specialized equipment and materials necessary for effective curtain grouting. Their expertise allows for accurate diagnosis of the leak's extent and location. Proper curtain grouting application requires precise techniques that professionals have honed through years of experience. Furthermore, experienced contractors provide comprehensive repairs that address not just the symptoms but the root cause of the leak.

Fixing Water Leaks in Concrete Slabs

Water leaks in concrete slabs seriously threaten your home's structural integrity. Understanding the problem and seeking professional help promptly are critical steps in addressing these issues effectively. When performed by experienced contractors, curtain grouting offers a reliable and time-tested solution to fix water leaks in concrete slabs. You can ensure your home's long-term stability and safety by taking swift action and relying on professional expertise.

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

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Aging culverts pose a significant challenge for many communities. As these vital drainage structures deteriorate, they can lead to road collapses, flooding, and environmental issues. Fortunately, culvert repair with curtain grouting offers a powerful and efficient solution to this problem. Moreover, this innovative technique can extend the life of culverts without the need for costly and disruptive excavation.

What is Curtain Grouting?

Curtain grouting is a specialized leak-sealing method. Specifically, it involves injecting water-activated resin through a leaking wall in a grid pattern. Once injected, the resin interacts with water on the other side. Consequently, it cures into a solid mass, effectively sealing the leak. This approach is particularly useful when there are many cracks or when cracks are not easily identifiable. Additionally, it proves effective in situations where traditional repair methods have failed.

The Curtain Grouting Process

The process of culvert repair with curtain grouting is straightforward yet effective. Here's a simplified overview:

1. First, technicians drill holes in a diamond pattern along the culvert wall.
2. Next, they inject grout from the bottom row upwards.
3. Subsequently, the grout flows down on the other side of the wall, creating overlapping circles of sealant and curing to stop the leaks.

This systematic approach ensures comprehensive coverage and, as a result, provides a robust seal against water infiltration.

Materials Used in Culvert Repair

Several types of resins are suitable for culvert repair with curtain grouting. These include:

• Spetec PUR H100: Offers lower expansion but more flexibility
• Spetec PUR H200: Provides high expansion with some flexibility
• Spetec PUR HighFoamer: Combines high expansion with enhanced flexibility
• Spetec AG200: Features low expansion but high flexibility and low viscosity, ideal for tight spaces

In essence, the choice of resin depends on the specific conditions of each culvert repair project. Furthermore, the versatility of these materials allows for tailored solutions to various leak scenarios.

Benefits Beyond Culverts

While this article focuses on culvert repair with curtain grouting, it's worth noting that this technique has broader applications. It's equally effective for sealing leaks in manholes, water treatment plants, catch basins, tunnels, and even basements. Therefore, this versatility makes curtain grouting an invaluable procedure in infrastructure maintenance.

A Lasting Solution for Leaking Infrastructure

Culvert repair with curtain grouting represents a significant advancement in infrastructure maintenance. A durable, flexible seal addresses the root causes of leaks and structural decay. Furthermore, it does so with minimal disruption to daily life and the surrounding environment. In conclusion, as communities grapple with aging infrastructure, this technique offers a beacon of hope for efficient, effective repairs. Ultimately, curtain grouting provides a long-term solution to the ongoing challenge of maintaining critical drainage systems.

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

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Are you a contractor looking to expand your service offerings? Consider becoming a leak seal contractor. This specialized field offers lucrative residential, commercial, and municipal opportunities. Adding leak sealing to your repertoire allows you to tap into a growing market and significantly boost your business. Let's explore how you can leverage your existing skills and experience to excel in this high-demand niche.

Become a Leak Seal Contractor and Tap Into an Expanding Market

The demand for leak seal contractors is on the rise. The need for waterproofing solutions grows as homeowners increasingly convert basements into living spaces. Moreover, aging infrastructure in commercial and municipal settings presents ongoing challenges that require expert intervention. The opportunities are vast and diverse, from parking garages to water treatment systems.

Residential Leak Sealing

Homeowners are becoming more aware of the health risks associated with damp basements. As a result, they're seeking professional solutions to address foundation cracks and floor-wall joint issues. By focusing on this sector, you can build a steady stream of residential clients. You'll also provide a valuable service that improves living conditions and property values.

Commercial and Industrial Applications

The commercial sector offers even more extensive opportunities. Large office buildings, retail spaces, and parking structures all require regular maintenance and waterproofing. Elevator pits and electrical utility vaults are particularly vulnerable to water ingress, creating a constant demand for skilled professionals. By mastering these applications, you can position yourself as an indispensable service provider in the commercial realm.

Municipal Projects

Perhaps the most significant opportunity lies in municipal projects. Aging sewer and stormwater systems across the country are plagued by infiltration and inflow issues. These problems lead to leaking sewer systems, settling roadways, and increased water treatment costs. The demand for leak seal contractors in this sector far outweighs the current supply. You can secure a steady flow of high-value projects by entering this market.

Seize the Opportunity to Become a Leak Seal Contractor

You'll need the right tools, knowledge, and support to become a successful leak seal contractor. Alchatek offers a comprehensive package to help you succeed. High-quality polymers and reliable equipment ensure efficient and effective repairs. Moreover, Alchatek provides expert technical and marketing support to help you overcome common challenges. With Alchatek's assistance, you can deliver consistent results and grow your leak seal business.

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At Krog Street Market in Atlanta, a shop about five feet below grade had water infiltration issues during heavy rains. The foundation wall was leaking, causing problems for the shop owner. To address this issue, leak seal experts Lift It Rite were called in to implement a solution. Their approach involved creating a curtain wall to waterproof the affected areas. This waterproofing method is particularly effective for structures below ground level, where traditional methods may not suffice.

Powerful Polymers

The technicians chose Spetec PUR HighFoamer for this project due to its extraordinary expansion rate. Moreover, Spetec PUR HighFoamer can quickly stop leaks across large areas. After injection, it follows the infiltration path and effectively seals leaks off. As a result, this material was ideal for addressing the shop's water infiltration problem. This versatility makes it an excellent choice for various waterproofing applications, especially in challenging underground environments.

Painless Procedures

The repair process began with driving injection rods down the outside of the wall. These rods were inserted to a depth of five feet, reaching the footing. The rods were spaced two feet apart along about 30 feet of wall to ensure thorough coverage. Next, the material was injected through each rod at one gallon per vertical foot. This method created a curtain wall, completely waterproofing the leaking areas. The precise spacing of the injection rods and the carefully calculated injection rate were crucial factors in achieving a uniform and effective waterproof barrier. 

Rapid Results

The entire repair process took only one day to complete. As a result of the curtain wall installation, the leaking was stopped immediately. Furthermore, this solution will prevent future leaking, ensuring the shop's safety from further water infiltration. In the end, mall management was satisfied with the quick and effective resolution of the problem. The shop can now operate without concerns about water damage during heavy rains. This successful intervention solved the immediate issue and provided long-term protection for the shop. 

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A cooling tower lift station under construction in Iuka, Mississippi, had a significant water leak problem. The facility was losing approximately 1,000 gallons of water daily. The source and destination of the leak were unknown. A solution was implemented using concrete sealing techniques. Leak seal experts at Mid-South Concrete Lifting were called in to perform the repairs.

Powerful Polymers

The technicians chose Spetec PUR F400 for the repair. This polyurethane-based material has a closed-cell structure that seals cracks and joints. It remains flexible after curing, which allows for structural shifts. The material is NSF-certified, meeting environmental standards for water-related applications.

Painless Procedures

Due to the leak's unknown location, a comprehensive approach was necessary. The team injected the solution into all of the control joints and treated any visible hairline cracks within the concrete. The entire process was completed in two days, minimizing operational disruption.

Rapid Results

The treatment showed noticeable effects in the control joints. After the procedure, the company refilled the pit. The results met their expectations. Construction at the facility resumed without further delays. The solution effectively addressed the water loss issue while maintaining the structural integrity of the cooling tower lift station.

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Manhole infiltration can pose serious risks to nearby structures. In a recent case, water infiltration pulled soil into a manhole, eroded the ground beneath a walkway in front of a residence, and threatened to compromise the home's foundation. Specialists from SiteMix Pressure Grouting, LLC were called in to perform repairs to address this urgent situation.

Powerful Polymers

Two key products were selected for the job. First, AP Fill 700 was chosen to stabilize the soil around the manhole and seal the leaks. This product features low viscosity, making it ideal for permeating soil and sealing thin cracks. Additionally, it activates with moisture, which is perfect for damp environments like this one. Secondly, AP Lift 430 was selected to stabilize the house's footing. This high-density product cures quickly. Furthermore, it excels at filling voids and stabilizing soil near structures due to its high load-bearing capacity.

Painless Procedures

The repair process began with stabilizing the soil around the manhole. To achieve this, injection rods were driven into the ground around the structure. Then, AP Fill 700 was injected to seal the leaks and stabilize the surrounding soil. Next, the team focused on the large void areas around the house's footing. Once again, injection rods were utilized. This time, AP Lift 430 was injected to fill the voids and secure the foundation.

Rapid Results

The repair project yielded impressive outcomes. First and foremost, the manhole was successfully sealed. In addition, the surrounding soil was stabilized, preventing further erosion. The walkway, previously at risk, was now secure. Importantly, the voids adjacent to the house were filled, protecting the foundation. Remarkably, all these tasks were completed in less than a day. Finally, the repaired area was prepared for the county to add backfill around the newly stabilized manhole. This swift and effective solution ensured the safety of both the property and its residents.

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A broadband provider in Alpharetta, Georgia, contacted a local leak seal contractor after discovering water infiltration through a crawl space wall during heavy rainstorms. Over time, cracks had developed, allowing not only water but also sediment to enter, creating substantial voids outside the fissures upon inspection. Given the sensitivity and high value of the equipment housed within the facility, eliminating all potential leaks in the crawl space became a top priority.

Powerful Polymers

The technicians chose Alchatek’s Spetec PUR HighFoamer to address this leak. This highly expansive polyurethane grout creates a robust, waterproof barrier, effectively sealing a wide variety of leaks without extensive excavation. Spetec PUR HighFoamer’s remarkable expansion capacity (40x-50x) ensures comprehensive coverage and a tight seal, making it ideal for projects requiring minimal downtime. Its NSF 61 certification guarantees safety for potable water applications, positioning this product as a versatile and cost-effective choice for leak sealing projects across various industries.

Painless Procedures

The repair process consisted of three efficient steps. First, the crew drilled through the concrete wall, installing zerk fittings into each hole for subsequent injections. Next, they used an electric airless sprayer to inject water into each fitting, ensuring proper activation of the foam. Finally, they injected Spetec PUR HighFoamer through these fittings. This created a curtain wall of polyurethane foam that effectively sealed the cracks, prevented further water ingress, and filled voids in the soil substrate.

Rapid Results

Within 24 hours, the technicians successfully sealed all leaks in the underlying crawl space. This injection process was completed in a fraction of the time required for a full membrane replacement. Months after the repair, following several heavy rainstorms, the facility manager confirmed that the crawl space has remained completely dry, with no recurrence of leaks.

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Clearwater, Florida public works administrators faced a critical stormwater infrastructure issue. A junction box was leaking through multiple pipe penetrations, compromising system integrity. City officials invited infrastructure repair specialists Helicon to address the situation. This project showcases an innovative solution to a common urban infrastructure challenge, enhancing stormwater management capabilities for municipalities.

Powerful Polymers

Helicon chose AP Fill 700 as the primary repair material. This polymer offers several advantages for stormwater system repairs. Firstly, it's ideal for point grouting, allowing for precise application. Additionally, the polymer features a quick reaction time, enabling rapid repairs. Perhaps most importantly, AP Fill 700 excels at filling voids. These voids, created around the junction box due to ongoing leaks, needed to be addressed to ensure a comprehensive repair.

Painless Procedures

Injection rods were utilized to deliver the polymer solution. These rods were pushed down from the surface to the depth of the leak, ensuring targeted application. As the injections progressed, they served multiple purposes. The polymer filled existing voids, stabilized the surrounding roadbed, and effectively cut off the leaks. To ensure complete coverage, the injection rods were raised in stages. At each stage, additional injections were performed. This methodical approach guaranteed thorough treatment of the affected area.

Rapid Results

The repair operation proved remarkably efficient. In just two hours, the entire job was completed. More impressively, the leaks were sealed immediately upon application of the polymer. This rapid resolution minimized disruption to the city's infrastructure and daily operations. As a result of this swift and effective repair, city administrators expressed high satisfaction with the outcome. 

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