Concrete Foam Injections

Project Type: Soil Stabilization & Releveling 

Location: New Waverly, TX

Problem:

UFP Industries is a multibillion-dollar forestry products manufacturer and supplier, with 221 facilities worldwide. Their plant in New Waverly, TX had recently constructed an area experiencing major defects in the concrete slab’s infrastructure. This affected area consisted of over a hundred thousand square feet (ft2) of twelve inch thick reinforced concrete slabs designed to support high flow, heavy class-5 forklift traffic. Due to being built on top of an old lumber ash pit, the soil conditions were poor. Therefore, when the concrete pavement was installed, the subgrade was not stabilized adequately for the intended use. From our inspection, we discovered extensive water infiltration through the expansion joints of the concrete causing the supporting soils to become saturated. The continuous heavy forklift and 18-wheeler traffic caused the groundwater to rise to the surface, exit through the expansion joints, and wash out the subgrade. This left voids underneath the concrete which created slab deflection, differential settlement, and eventual failure. 

Summary:

The facility had replaced portions of completely failed concrete but were seeking an alternative solution for the areas that could be rehabilitated. The replacement process was extremely invasive to their operations. This downtime caused major delays and revenue losses for the company. C.A.T.FOAM personnel determined that polymer injection technology would provide an ideal solution for the ongoing soil issues, and that all the proposed work could be completed without interrupting the facility’s normal operations. C.A.T.FOAM consulted with civil engineers to develop the injection schematics, specifications, and timeline of the project. An economic proposal was submitted and approved by UFP Industries to begin production.

Solution:

C.A.T.FOAM designed a work schedule and injection schematic that best fit the facilities needs. By utilizing the Foamjection™ process, we were able to compact, consolidate, and reduce the permeability of the soil mass along the expansion joints. This process consisted of injecting hydro-insensitive polymers of high density into the soils supporting the problematic areas. Dynamic Cone Penetrometer (DCP) testing was performed and elevation monitoring devices were utilized by C.A.T.FOAM’s team, ensuring the injections were in accordance with the project design. 

Conclusion:

C.A.T.FOAM successfully completed the remediation work in a short, two week period. The problematic areas were treated, and the concrete slab deflection was reduced within the tolerable standards. As an added bonus, we were able to complete this job while avoiding heavy traffic times and the facility could maintain the steady flow of forklift and 18-wheeler traffic.

Is your pool deck cracked, sinking, or both? Have you heard of concrete foam leveling? Many pool owners don’t realize how important it is to fix sinking or cracked concrete before it’s too late. You don’t want to end up having to spend thousands on completely redoing your pool deck. The problem with unleveled concrete is that it will lead to water leaks and structural issues later on. That’s why you need to make sure your deck is properly leveled and sealed.

The good news is that many companies out there specialize in foam leveling – CatFoam being one of them! The team at CatFoam has years of experience in foam leveling services, so you know you’re getting quality work when you work with them.

What Is Polyurethane Foam Jacking?

Polyurethane foam is an efficient and effective way of leveling concrete. Foam leveling works by foam being injected underneath the concrete to fill the voids and raise it to its original height. The amount of polyurethane foam used depends on how many holes you need to fill and how high the concrete needs to be lifted. You can use this leveling process for a variety of projects and places, including residential properties, commercial buildings, and industrial sites. You can do foam injections quickly and without making a mess. 

Here are some reasons polyurethane foam leveling might be perfect for you. 

• If you want a clean and quick process. Foam injection doesn’t damage the surface of your concrete and minimizes dust exposure.
• Having hard-to-reach voids. Polyurethane foam injections are just what you need if your concrete is cracked deep under the surface because it can reach them!
• Filling in cracks. Foam injections can fill all the gaps in your concrete and be made to match the color or coating of your concrete. 

Does Concrete Foam Leveling Last?

Polyurethane foam concrete leveling lasts for about 20 years. The foam will eventually deteriorate over time because of exposure to the sun, moisture, storms, etc. For the best results, consider working with professionals. Using professional services will ensure long-lasting durability and a seamless job. 

How Much Does Concrete Foam Leveling Cost?

Most foundation repair companies will provide an estimate to determine how much your project will cost. Usually, polyurethane foam injection is very affordable because of how quick and mess-free it is. Instead of paying thousands to get cement repoured, invest in polyurethane foam injections to get your pool deck fixed today. 

CatFoam are experts when it comes to polyurethane concrete foam leveling. They have been servicing the Houston area by keeping concrete raised and foundations lifted. Give CatFoam a call today or check out their website if you’re interested in getting your pool deck fixed. 

Do you have sinking concrete?

The sinking process of concrete is a natural occurrence that happens over time. It’s due to the weight of the concrete and can put your building at risk for cracking or collapsing. Luckily there are some ways you can prevent this from happening by injecting foam into the foundation to lift the concrete. This will provide support and stop those pesky cracks altogether!

What are foam concrete injections?

Concrete injections consist of injecting a foam material into the ground to support sinking concrete. The injection process is performed by drilling holes in the foundation and pumping liquid polymer or polyurethane into the ground through a hose.

The foam that is injected into the ground will expand and cause the concrete to float back up to its original position. These injections are great for repairing sinking foundations because they can support large loads of weight! The injections can prevent the formation of cracks in buildings, garages, or homes.

Why do you need to inject foam?

The continuous weight of concrete will cause it to sink. This can be a huge problem, as the resulting damage could lead to cracks in your exterior walls and even collapse! If done correctly, these injections can provide support for your sinking foundation and prevent this from happening altogether!

Foam concrete injections have been found effective at preventing damage to:

• Backyard patios
• Sidewalks
• Front or back cement stairs
• The foundation of houses
• Driveways
• The foundation of businesses
• Porches
• Pool decks
• Anything that involves sinking concrete!

How often should you have foam injections done?

It depends on the size of your project or building. If it’s an entire house, we recommend doing it once every 2 to 5 years to ensure that none of the surrounding areas sink. With smaller projects like patios, sidewalks, or slabs, you can do it whenever you see that theirs a problem.

What happens if you have sinking concrete?

If you leave it by itself, the concrete will continue sinking until it collapses. There are often times when the surrounding areas won’t be affected too much. But if they are, that could lead to some serious problems, especially for your house!

If this problem occurs, there are some signs you may see around your property:

• Cracks in exterior walls and flooring (especially near the edges)
• Doors and windows that stick or don’t work properly
• Damage to interior wall surfaces such as drywall cracking and water seepage
• Sloping floors or sloping walls
• Cracking concrete

Why should you care?

These cracks are not only unsightly but can be potentially dangerous for anyone entering or exiting your building. They also increase the risk of mold growth inside your home due to excess moisture from increased water seepage in the cracks around your house. You don’t want that!

What are the benefits of foam injections?

Foam concrete injections have been found effective at preventing damage to foundations caused by sinking. This process has also been used to support structures in a large number of industries, and many homeowners use this method because it is fast and easy.

Are there risks associated with foam injections?

Not at all! The injection process consists of polyurethane or liquid polymer material that is non-hazardous, water-resistant, and chemical resistant. It has low toxicity levels, making it safe for the environment while preventing damage to the foundation. Polyurethane foam injections are also very cost-effective and have a quick return on investment.

If you’re concerned about your concrete foundation’s ability to withstand damage from sinking, contact CatFoam of Houston, Texas today! We can do an inspection and give you a quote with no obligations. Our inspectors will come out and determine exactly what the issue is and help put together a plan of action to get your foundation looking new again!