Colorado Bridge Approach Slab Settlement Lift

Bridge Approach Slab Settlement Repair – Crystal Valley Parkway, CO

Asphalt Pavement Lift of a Bridge Departure where the Subgrade had settled and the pavement needed to be lifted

In Castle Rock, CO, along the Crystal Valley Parkway, the Town of Castle Rock, CO was experiencing bridge approach slab settlement of 1,900 SF of bridge approach, departure, and sleeper slabs on two bridge ends and adjoining pavement. Settlement of adjacent sidewalk had also occurred causing an unsafe driving situation as well as dangerous conditions to pedestrians utilizing the crossover sidewalk area. The unstable subgrade reaching below the sleeper slab would need to be treated to stabilize the area before mill and fill of asphalt pavement could be performed.

Bridge Approach Slab Settlement Solution

CST partnered with the Town of Castle Rock, utilizing the URETEK Deep Injection (UDI) process to treat unstable soil, lift the slabs, and realign sidewalk and pavement areas. Dynamic Cone Penetrometer soil tests were performed to correctly identify the weak soil zones. Injection tubes were placed at depth and expanding structural polymer injected to densify and provide stabilization of subgrade soils. Once the soil is stabilized, injections are continued to provide lift and realignment of the slabs and overlying pavement. The URETEK UDI process provides proper support to the soil and heavy sleeper slabs to mitigate against future bridge approach slab settlement and movement, while also providing a solid subgrade for pavement.

Repairs were made in two shifts while allowing traffic to continue utilizing the area vs. time and money spent to reroute. Foundation soils were significantly strengthened to mitigate against future settlement. Bridge approach and departure slabs were lifted back to original elevation as well as stabilization and lift of sidewalk areas. Subgrade soils were quickly and effectively stabilized to provide a strong base for asphalt pavement mill and fill operations. The added benefit of water cutoff effectively arrests soil erosion within the area. Significant savings to municipalities and tax payers vs. alternative methods of rip out and replace. Extended use life of the bridge, sidewalk, and pavement.

Campbell County Detention Center – Gillette, WY

Concrete Stabilization Technologies, Inc., partnered with Campbell County Public Works Department and CEI Engineering, to repair the foundation of the Campbell County Detention Center in Gillette Wyoming during the summer of 2001.

Column Stabilization, Interior Wall Lifting, Floor & Thickened Slab Lifting, Void Fill, and Soil Densification were preformed in the facility to correct a number of settlement issues. Crews began on the outside columns of the building, lifting and stabilizing exterior columns. Using the Uretek patented DI process, the soil was stabilized around the columns, voids filled, and columns were placed back on original center. Post testing of the soils in the area proved significant increase in the soil densification, arresting any further settlement issues from occurring. Crews continued work inside the facility, with injections placed to lift and stabilize the floor slabs and lift walls back to grade.

Work performed at the Campbell County Detention Center was done during normal hours of operations, with very minimal disruption to staff or residents of the facility. Security of the residents was not compromised due to the non-intrusive methods and procedures employed by the Uretek patented technology. Work was performed in situ, and by utilizing the Uretek Technologies, Campbell County not only saved money by avoiding a rip out and replace scenario, but also avoided the hassle of having to relocate residents and staff. The project was completed on time and below the original estimate. Repairs made to the Campbell County Detention Center over a decade ago, are still holding strong!

Home Foundation Lift – Pine Haven, WY

Concrete Stabilization Technologies, Inc., partnered with Homeowner, Jim Noecker, and Engineer, Ed Scott, P.E. of CEI Engineering to provide a solution for Jim Noecker’s residence in Pine Haven Wyoming. Since construction of the Noecker residence, the home had experienced cracking & separation of the walls, doors sticking, and deformation of the roof. The problems were thought to be caused at least partially by heave or swelling shale in the subdivision where the residence was built.
Dennis Russell with STRATA Geotechnical Engineering performed soil tests. Dennis determined that swelling soils were not a problem, and a plan was developed for repairs using the URETEK Technologies.

The original estimate for this project was $59,850 plus $8,000 if resistance piers were needed to get the lift of the residence. A second URETEK truck was used for the final lift of the home. As a result, assistance of resistance piers was not necessary to return the home and floors to grade. The home was lifted approximately three inches on the side with most settlement. Final elevations of the foundation and floors were within 1/2 inch tolerance and soils were stabilized.

The foundation still has the original design and by using the URETEK Technologies, we do not have to worry about having half of the foundation on piers and half on spread footers. This is an important feature of using the URETEK patented technologies to prevent future problems in having mixed foundation combining deep foundations (piers) with shallow foundations (footings) on structures.

Final construction cost for repairing and stabilizing was below the original estimate and came in under budget at a total of $55,743.00.

The Homeowner, Jim Noecker, contacted CST in May of 2012 with an update of their residence, stating that they are very impressed! Jim stated that there was “not one new crack or sign of any further move-ment. You guys did a great job and the house seems very stable now. No doors out of square, roof looks normal, and the deck is now level. Glad to see it made it at least one year with the fix and hopefully many more to come. Thanks again for your expertise!” – Jim Noecker

Marriott’s Mountainside Resort – Park City, UT

The Mountainside Marriott is a luxury winter ski and summertime vacation resort, nestled in the Wasatch Mountains, in Park City Utah. Park City is a beautiful historic Utah town located about half an hour east of Salt Lake City. Early pioneers and settlers traveled through this region on the Mormon Trail, and in the early 1880’s large beds of precious metals were discovered in the area and the mining boom began. Much of the area’s soil has been affected by early silver mining activity and much of the Mountainside Marriott resort had been built on old mine tailings.

Concrete Stabilization Technologies, Inc. was contacted by the Park City Mountainside Marriott’s Chief Engineer, Dave Martin in November of 2013 concerning the resort’s pool and hot tub area that had suffered significant settlement, posing trip hazards and unsafe conditions for its many visitors. Mr. Martin and CST Field Consultant, Scott Paswaters, had known eachother through a prior work relationship at the Zermatt Resort in Midway, Utah. CST had completed a similar project there in 2012.

Two site visits were made to the resort in November and the affected areas surveyed. The 68 foot concrete deck slab around the pool showed settlement of one half to one inch differential. One end of the pool itself showed settlement of approximately three inches and a notable void. The upper hot tub on the south end of the pool had a slab settlement similar to the pool, in an approximate 18 foot section.

Dynamic Cone Penetrometer testing was proposed to accurately determine soil conditions in the settled areas. An estimate for repair was given based on the findings of the DCP tests.
With the 2013 Winter Ski season gearing up, the resort decided it would be best to wait and begin repairs in the spring of 2014.

Follow up on the project was made in February of 2014 and the work was coordinated with other contractors involved in additional remodeling in the pool area. Logistics of getting to the pool area with equipment was discussed and a plan devised to access the area from the south end of the pool, leading to the plaza with a run of approximately 300 feet of injection hose into the pool area.

Heat coils in the deck slabs were located and properly marked in a grid of safe zones using a Ground Penetrating Radar (GPR) system. This helped insure that no coils would be damaged during the injection process. Once the season officially closed in March, the pool was drained during the night and crews began working bright and early the next morning.

Results from the DCP tests showed unstable soil as far as 9 feet below the pool area. Injection of approximately 7,000 pounds of URETEK geopolymer was estimated to properly densify and stabilize the soil, as well as realign the overlying slabs and deck areas.

Crews began by mapping out the areas to be treated. URETEK geo-polymer was then injected through a pattern of 5/8 inch holes, filling voids beneath the pool & pool stairs, and re-aligning the pool deck and hot tub slab areas. CST crews completed the project in 2 days, which kept other contractors performing projects on their work schedule with no delays. The owners and Engineers of the Mountainside Marriott were very pleased with the results of CST’s precision repairs.

Benefits:

  • Realignment of the deck slabs eliminated trip hazards.
  • No excavation required for repair work to be completed.
  • Stabilization of the underlying soil arrested future settlement in the areas.
  • Increased the longevity of the pool and surrounding deck.

The Mangy Moose Restaurant – Jackson Hole, WY

Since opening in 1967 at the base of Jackson Hole’s new ski resort, the Mangy Moose has been a prominent local landmark along Village Drive in Teton Village, Jackson Hole Wyoming. The 30,000 square foot building houses a restaurant, saloon, grocery market, and retail space. It has long been a favorite of locals and the many visitors touring throughout this area.

The owner of the Mangy Moose, Jim Terry, had contacted Nelson Engineering in Jackson, Wyoming about settlement that had occurred in the building. It was discovered, by cutting a hole through the concrete slab on the ground floor of the building, that a sewer line leak from a dish washer had softened the supporting soils of the foundation and columns. Warped wooden beams in areas of the building indicated that the leak had likely gone undetected for a number of years, causing settlement and compromising the structural integrity of the building’s foundation.
Concrete Stabilization Technologies’ Regional Engineer, Roy Mathis, was contacted by Robert Norton, P.E., of Nelson Engineering concerning the settlement issues the building was experiencing and to help design a repair option that would effectively stabilize and preserve the building’s foundation.

After review of plans and photographs, a site visit and survey were performed by Roy Mathis and Kelly Schild. Initial soil density tests were performed and analyzed. Additional concerns were raised during excavation for the sewer line repair. Cracks in the mortar and a change in slope at one of the columns indicated the pivot point of the settlement.

Two repair options and pricing were presented for mitigation to stabilize the soils and get a slight lift. One option to stabilize the soil only, and a second option to obtain a partial lift of the foundation, columns, and floor. It was desirable to obtain a maximum lift without causing additional distress to the building; a full lift was not recommended however, due to the time warped timbers, and not wanting to cause additional distress to the building. The work proposal to stabilize and perform the partial lift was accepted and work scheduled for the following week. With ski season quickly approaching and final preparations being made, it was very important to the owner that repairs be completed in a timely manner.

CST Project Superintendent Tomas Ramos, and manager David Yoder met on site on November 13th to discuss de-tails of the planned repair. Work began the same day as the crew set probes and prepared the injection layout. Extent and depth of the weakened soils were determined during drilling and probe placement. Injection depths and areas were determined to assure a permanent and long lasting solution.

Inclement weather, two feet of new snow, and minus twenty degrees halted work the following day as equip-ment would not start in the freezing temps. The crew got an early start on day three, however, and after finishing probe placement, shot an initial survey, and began injections using the URETEK technologies. Injections were made directly below the columns and spread footers with emphasis on the weak soil zones. Existing voids were filled, and soil stabilized as crews completed repairs. All injections were completed from the interior of the building with very little disruption to owners and management. The project was completed on time and on budget, allowing owners to complete last minute details before welcoming skiers and tourists for the 2014 winter ski season. By using the URETEK technologies, the long lasting repairs provided a tremendous cost savings to the owners and very little disruption to their pre-ski season preparations. Stabilization of the building’s foundation will provide for many more years of use and enjoyment of this famous local landmark.

Fox Hall Apartments – Las Vegas, NV

Concrete Stabilization Technologies, Inc. was contacted by Mr. Bill Sublette P.E., Owner of Foundation Stabilization, Inc., Las Vegas, NV concerning the multi-unit Fox Hall Apartment Complex at 1600 E. University Avenue in Las Vegas. Mr. Ed Russ had contacted Mr. Sublette concerning the remediation of this property. Mr. Sublette in turn contacted Roy Mathis of CST for help in determining the best solution for repairs of the property, utilizing the advanced URETEK Technologies.

The complex had experienced significant distress and settlement due to the solubility of subsurface soils which had produced a significant settlement of 6.25 inches on the one corner of the building and a differential settlement of over 5 inches of the concrete floor slabs. Initially one unit of the complex was identified for repair. Two additional units were also included in the project.

Factors for Consideration

Significant distress of the property had occurred due to the solubility of the subsurface soils. Settlement differential of over 5 inches on the concrete floor slab and exterior footings had produced cavities or voids in the underlying subsurface soils. Stress on the slabs had not only produced significant cracking in the interior and exterior walls and floor slabs, but also caused problems with waste lines and exterior walkways of the units. Three options were considered for repairs. Helical Piers. Micro Piles, and the patented URETEK Deep Injection process®.

Solution

The foundation remediation for the Fox Hall Apartments utilized injection of URETEK Expanding Structural Polymer in the top 5 to 7 feet of sub grade soil beneath the exterior continuous wall footing and interior slabs. The injection of the URETEK ESP densified the soluble silty sands and clays in the top 5 to 7 feet of sub grade soils beneath the load bearing foundations and the result was lifting of the load bearing foundations. Additionally, areas under the distressed slab were injected with URETEK ESP to lift and re-level the concrete floor slabs, and densify those areas of the subgrades that had low densities and porosities (voids). The process filled the voids without adding additional weight. The ESP works to interlock soils in place, and the impervious nature of the product helps to prevent future water migration into the soils which would prevent any future extension of soil collapse.

Areas of low density beneath the slab were determined by using a dynamic field penetrometer. The process was coordinated to minimize cracking in the floor slab and to ensure that the floating foundation was not lifted off the exterior continuous wall footings interior notch.

Multiple locations and depths were injected and voids filled beneath the floor slabs. Full time observation and monitoring of the injection and lift were necessary to ensure no additional cracking of the floor slabs in the units.

Results

Three apartment units were successfully repaired with one corner of the foundation being lifted 6 1/4 inches and another corner lifted 3 1/2 inches. Voids were filled and soils stabilized beneath the concrete slabs. Slabs were realigned and lifted to original grade with minimal disturbance to tenants and landscape features. The original integrity of the uniform foundation system was maintained by utilizing the URETEK Technologies. Work was completed in less than a week and the owner and manager of the property was very pleased with the result.

Benefits

Time Savings: Repairs were made quickly. The non-intrusive nature of the repair process resulted in minimal disturbance to landscaping & tenants of the apartment complex.

Longevity: The integrity of the original uniform foundation system was maintained by using the URETEK Technologies. The foundation lift and stabilization were made without mixing a deep foundation design with the original spread foundation. The migrating nature of URETEK Expanding Structural Polymer not only filled voids, but interlocked soils, helping to increase stability of sub grade soils. The impervious nature of the material will prevent future water migration into the soils & prevent extension of soil collapse.