Project Type: Void Fill, Slab Stabilization, & Concrete Repair
Location: Victoria, TX
Problem:
A commercial manufacturing company in Victoria, TX contacted C.A.T.FOAM regarding a deteriorating section of their warehouse foundation, needing immediate attention. This particular area of compromised concrete was absolutely vital to the smooth operation of their facility, as it provided essential load-bearing strength for the support columns of their 10-ton overhead crane. Situated alongside the east side wall of the warehouse, the crane structure recently failed its annual OSHA compliance inspection due to misalignment and severe damage to multiple concrete footers. With the crane now out of commission, the client urgently sought the expertise of C.A.T.FOAM for professional assistance.
Analysis:
After consulting with the owner & shop manager and inspecting the affected area, C.A.T.FOAM discovered the settlement issues were due to soil loss and erosion of the slab’s supporting soils. The area also had consistent cracking defects from heavy storage of steel-coil rolls. Damage from Hurricane Harvey allowed rainfall to infiltrate the foundation’s supporting soils on the east side, causing washout through the warehouse’s precast walls. To address these issues, C.A.T.FOAM collaborated with MacGyvered Engineering & Contractors to develop a three-stage repair strategy using foam injection technology among other methods. This strategy also involves realigning the overhead crane and replacing three irreparably damaged concrete footers. The goal is to effectively resolve the problems with minimal disruption to facility operations.
Solution:
C.A.T.FOAM and MacGyvered Engineering have successfully addressed void issues under the 5-inch concrete slab and restored strong support to the foundation. By injecting high density polymers and following a systematic injection plan, we effectively filled the affected area. We then leveled the defective overhead crane structure to meet CMMA tolerance requirements by raising each crane column and installing steel shims. New anchor bolts were securely installed at each column base, and mortar was applied around the base plate. Finally, we fully replaced three inadequate concrete footers using standard construction methods, reinforcing the crane columns with custom brackets and cribbing blocks before demolition.
Conclusion:
In just two weeks, C.A.T.FOAM and MacGyvered’s team successfully completed the factory’s rehabilitation project, all within the regular business hours. The client was extremely satisfied as the 10-ton overhead crane structure swiftly passed the rigorous OSHA inspection and was promptly restored to full operational service. Our team addressed the problem areas, employing a clever solution that saved valuable time and money by eliminating the need to disassemble the entire overhead crane system.
