Middle School Chiller Lift – Denver, CO

A Denver, Colorado, middle school experienced the effects of expansive soil on a pair of large, 16 ton ice chiller thermal storage units used for numerous school refrigeration needs. Each storage unit was placed on independent, 32,000 lb. reinforced concrete pads to maintain a continuous, even elevation for support and proper unit function. Substantial damage and malfunction to each unit was highly probable if the supporting concrete pad was uneven.

Expansive soils shifted beneath the concrete support pads causing an unsatisfactory level for the chiller units to continue functioning. To avoid damage to the units, both were taken out of service until a repair plan was initiated. The concern for the school district was to have the chiller units functioning at capacity, supported on level concrete pads in time for the upcoming school year.

Due to the cost and downtime for the school and potential hazard of damaging each unit through relocation, a choice was made to use a high-density, polyurethane grouting technique perfected by URETEK. URETEK’s Deep Injection Process densifies weak soil zones at specified depths to resupport each pad. This process solved three main concerns:

  1. Eliminate relocation of the units
  2. Stabilized volatile soils
  3. Level the units to 3/4” tolerance to restore functionality and capability.

After elevation profiles were taken, injection locations were determined to stabilize weak soil strata and realign the chiller units. Operators injected at depths of 3 feet at an angle to allow greater material coverage for maximum unit stability.

After stabilizing the weakest soil zones, additional injections realigned the pads within the 3/4” tolerance for the ice chillers to function properly without damaging each unit.

Jefferson High Foundation Settlement – Edgewater, CO

Concrete Stabilization Technologies, Inc. worked with General Contractor Saunders Construction, on the Jefferson High School Remodel project, to stabilize soils and lift slabs in nine classrooms, a hallway, and a bathroom.  The work included cutting L-shapes  in carpet as required for injection holes, drilling of holes, testing, injection to stabilize soil & fill voids, grouting injection holes, and re-gluing carpet and replacement of any damaged tiles caused by drilling.

The work was scheduled to allow approximately 10 days to complete.

By lifting one of the classroom slabs back to original, it also realigned the cabinets along a wall   in one of the classrooms which is one  added benefit we commonly see when doing this type of  repair:  doors open and shut properly, cracks in walls close up, shelving becomes level again, etc.

The project was completed in four days vs. the ten day window for the work.  The stabilization work was completed with minimal disturbance to the facility, in half of the allotted time and under budget!  A major advantage of the URETEK Technologies is the non-invasive and fast, clean nature of the processes. Schools, Hospitals, Shopping Centers, and other Public Use buildings are typically repaired and put immediately back into use in a matter of days vs. weeks or months.  This makes an ideal solution for projects needing to be completed over Holiday and Summer breaks or during off hours with no loss of use.

Soil Stabilization and Slab Lift

Dental Clinic Foundation Stabilization – Gillette, WY

The Problem

Unstable fill soil had resulted in settlement and movement of the Dental Specialists building foundation that threatened the structural integrity of the building and had caused cracking and gaps in window and door casings. Surveys detected upwards of 5-inches of settlement in areas of the foundation and interior concrete slab. Exterior sidewalk and curb/gutter areas had also experienced settlement causing uneven walking surfaces and trip hazards.

Factors for Consideration

The foundation lift and stabilization needed to be completed during a short window of time and in coordination with other contractors who would be working in the building at the same time. Dental and Orthodontic equipment, including sensitive X-Ray machines were present in the building and could not withstand large amounts of dust and debris. Additionally, carpeting over the concrete floor slabs in certain areas would need to be left in place during repairs in certain portions of the building.

Method/Process Applied

The unique URETEK Technologies employ high-density expanding structural polymers to lift settled concrete foundations, slabs and other structures effectively, efficiently and economically. The soils are improved, voids are filled and poorly compacted soils are strengthened and permanently stabilizes using in-situ methodology.

Result

A thorough site survey was conducted measuring existing elevations and a surgically precise injection plan developed priot to injection of URETEK high-density expanding structural polymer. Complete lift of the interior floor slabs, foundation and curb/gutter areas was accomplished in only 3 shifts. Many of the existing gaps in window casings were closed during the process. The sensitive equipment in the dental offices was not disturbed and, due to the non-invasive processes, no carpet was removed and no landscaping disturbed. Due to the state of art injection equipment and no-dig technologies, CST crews were able to complete the foundation stabilization and concrete lift with no disruption to other contractors working on site.

Benefit

The settled foundation and floor slabs were efficiently and permanently lifted and stabilized, eliminating a very costly full scale repair. The existing structure and foundation were protected from any other damage. The dental office was able to re-open on schedule with zero disruption to their clients or business.

Foundation Settlement Repair

Pizza Hut Foundation Stabilization – Newcastle, WY

The Problem

Weak, poorly compacted soils beneath the building and parking lot areas with settlement occurring from undetected water leak. Original and addition foundation footers 5 ft. and 10 ft. depths. Extensive settlement of the foundation and floor slab ranging from 2 – 4.5 inches throughout the settlement area. Settlement of large exterior light poles adjacent to the parking area.

Factors for Consideration

Extensive damage from the floor and foundation settlement re-quired closure of the restaurant for repairs. The business owner needed a quick, clean, non-disruptive solution that would allow the restaurant to avoid a lengthy and more costly closure for repairs. Long term solution needed to lift building foundation to original level and mitigate against additional settlement and damage to the structure. Straighten light poles and arrest against future tilting could be completed as an add on which only takes a couple hours and little material.

Method/Process Applied

URETEK Deep Injection Method™ – The URETEK Technologies employ high density expanding structural polymers to lift settled concrete foundations, slabs, and other structures effectively, efficiently, and economically. The soils are improved, voids are filled, and poorly compacted soils are strength-ened and permanently stabilized using in-situ methodology.

The URETEK Deep Injection Method™ requires no excavation inside or out-side the building to lift the foundation. The interior finished concrete floor and the exterior sidewalk were lifted in place. The process allows for quick repair with the foundation back to original elevation with a permanent improvement of the soils.

Results

The foundation lift began Monday morning on the first day of the five day closure. By Tuesday evening, the entire settled foundation area was lifted up to 4-½ inch-es and the soils . The exterior sidewalks adjacent to the building were still intact and in place with no crack development. Final floor elevation adjustments were completed before noon Wednesday. The cosmetic interior and plumbing work began Monday morning with little to no interruption to other trades.

By early Wednesday afternoon, light pole bases were also aligned and stabilized. The entire foundation and light pole stabilization was completed in a total of 3 working shifts allowing the general contractor to finish work to be completed for opening on Saturday morning.

The URETEK Technologies allowed the franchise owner to save the existing building and avoid a rip out and re-place scenario. Total foundation Repair cost $87,562.12 with substantial savings and minimal disruption to the business.