Granby Foundation Lift & Stabilization

PROBLEM

Located in the mountains of Colorado, this 15 year old residence had settlement occur in the foundation, and resulting damage to exterior facings, windows, doors and casings as well as interior damage to drywall and wall finishes. 

The owner had recently purchased the home and was referred to CST by a previous customer. CST was contacted to assess the issues with the foundation, and provide a solution to repair the settled foundation and mitigate against future settlement. The homeowner wanted the repairs made on the foundation prior to beginning additional mechanical and cos-metic repairs such as replacing cracked windows, doors, and interior/exterior finishings which needed to be completed soon as cracks and gaps were causing issues with keeping the cold winter air out of the home. 

SOLUTION

An initial site elevation survey conducted by CST revealed that the home’s foundation had experienced settlement of approximately 2 inches. 

The biggest area of differential movement had occurred in the great room and front entrance areas of the home. 

CST performed Soil Density tests in order to determine the weak soil zones and set benchmarks prior to designing the injec-tion plan. Once injection locations were determined, CST installed a high density expanding structural polymer into the soil, at determined depths. Working from the exterior, with crew members monitoring from the interior great room, the team lifted the settled areas back to original elevation. 

RESULT

The entire repair of this home’s foundation was completed in less than 2 days. CST lifted the settled foundation without causing additional damage to the home and adjusted windows enough that they were able to be latched where previously they had not. 

CST’s repair process is non-invasive and the residents were able to stay in their home during the repair. 

By stabilizing the foundation’s underlying soils, the home was protected against any future settlement or movement, allowing the owner to quickly move forward with completing the mechanical and cosmetic repairs to their home. 

CHALLENGES

  • Completing foundation repair in mid-December in order to protect the interior of the home and it’s occupants from winter elements. 
  • Lift the foundation without causing additional damage to the home’s finishes. 

BENEFITS

  • In Situ, no excavation foundation repair. 
  • Repairs are completed quickly, with very little disruption or mess. 
  • Families may stay in their homes during repair. 
  • Effective and efficient, long lasting protection for your assets. 

Drain Pan Void Fill Structural Support CDOT Region 1

A drain pan structure running adjacent to US-287 near Broomfield Colorado had experienced significant voids of varying severity beneath the structure. The drain pan was designed to move water away from the roadway during water events and run off; however, due to issues with the design of this particular structure, water was running beneath the concrete and eroding areas beneath the pan. The integrity of the structure was compro-mised due to the weakened and eroded supporting soil.

CDOT needed an effective solution to treat and repair the almost 800 foot long problem section of drain pan that would not only fill the voided areas, but also protect it against additional damage and structural failure that may also effect the safety of the adjacent highway.

A thorough evaluation of the site was conducted prior to design of the repair plan for the drain pan. It was determined that the more severe voids were located on the uphill slope area of the structure. Alternate solutions, including a flowable fill, were taken into account while determining the most effective way to treat the area. However, due to the advanced features of CST’s proprie-tary injection process, and the unique characteristics of the specialized expanding structural polymer, it was determined that filling the voided areas using this process would most effectively and most efficiently solve the problem. Injections were made directly through the drain pan, filling voids, and strengthening the supporting soils.

The entire stretch of affected drain pan was void filled and stabilized in four days without any disruption to traffic flow along the adjacent highway.

The treatment method allowed CDOT to extend the use life of the structure and avoid the expense of tearing out and replacing the structure.

The specifically designed repair not only eliminated the void space beneath the pan and strengthened the soils, but also provided protection to the structure against future erosion.

Repair costs came in under budget for this project.

Railroad Subgrade Soil Stabilization Lift, and Re-alignment

A 70 foot section of railroad track near Green River, Wyoming had experienced ongoing settlement issues. During springtime, and high water events, the area required weekly re-compaction and leveling. The replaced ballast would continually sink into the wet subgrade soils.

A factor that contributed to the problem, is that the area is located at a drainage point of the surrounding hillsides.

Settlement of the subgrade soils was a continual problem for the railroad as well as the unsafe conditions for freight trains and their personnel travelling over this section of track.

Keeping the track open and safe was a major concern for the Rail Company.

CST partnered with Watco Rail representative Neal Ward to design an effective repair solution for the settled areas of track.

An initial site survey was conducted on all areas of the settled rail. Areas for treatment were identified and a site specific injection design was created to lift the settled areas, and stabilize the subgrade soils beneath the track and ballast to mitigate against any future settlement.

CST installed a high density structural polymer at pre-determined depths to treat weak soil and lift the settled track sections. Crews alternated between sections to allow train traffic to continue through the area.

All sections of settled track and weak soil zones were stabilized.

Injections made into the weak soil zones effectively pushed water away from the areas, and provided a protective barrier beneath the ballast, to stabilize and protect the area against future settlement.

Railroad track was lifted, and realigned to provide a stable, safe passage of the company’s freight trains and personnel traveling across the tracks.

All work was completed in a matter of 3 working shifts without major closure or disruption to trains traveling through.

Concrete Slab Lift Asphalt Pavement Lift Soil Stabilization – Pueblo, CO

This highway roundabout located in Pueblo West, Colorado had experienced settling of between 2 to 3 inches in areas of the concrete panels. The settlement had occurred as a result of poorly compacted soils. The settlement of the slabs had created a negative drainage situation, causing water to pool against the curb and gutter instead of draining away from the structure as originally designed.

As part of a larger paving project, Martin Marietta, a heavy highway contractor working on the section of roadway that included this roundabout, needed a solution to lift the settled concrete panels and correct the drainage issues the settlement had caused without ob-structing traffic flow through the rounda-bout and connecting roadways.

CST partnered with Martin Marietta to create a repair plan that would allow traffic to continue to flow through the roundabout while the panels and adjoining asphalt were lifted back to original profile. CST’s technologies were used to repair the settled slabs and pavement. The process employs injecting an expanding structural polymer that densifies and compacts soil, fills voids, and lifts settled concrete and asphalt. A rubberized barrier was used to assist injection crews in staging and protecting injection hoses across the roadway which allowed traffic to safely continue through the roundabout during the repair process. Martin Marietta used a water truck to wet down the roadway and panels to assist CST’s injection crew in locating and correcting the areas of settlement prior to beginning injections.

The settlement and soil compaction issues were efficiently and effectively addressed and corrected while allowing traffic to continue use of the roundabout and roadways during the repair. The con-crete panels and adjacent asphalt pavement were lifted back to original design profile which corrected the drainage problem.

The repair was completed in less than a day, preserving the existing concrete, correcting drainage, and guarding against future damage erosion, settlement, or damage to this roundabout structure and adjacent roadway.

CHALLENGES
Maintaining traffic flow during repair.
Safely staging injection equipment in the roundabout area.
Restore drainage away from the concrete panels.

BENEFITS In situ, no excavation repairs
Little to no downtime
Fast, cost -effective, permanent
Preserves and extends the life of existing structures & pavement

Union Pacific Railroad Crossing Lift Realignment and Soil Stabilization

A Union Pacific Railroad Crossing at the entrance of the Mountain Cement plant located in Laramie Wyoming, had experienced settlement of the precast panels beneath the track.

A soft spot beneath the panels and the presence of water had exacerbated settlement and caused the crossing panels to become misaligned.
Ed Hinker, Union Pacific Track Maintenance Manager, contacted CST to analyze and create a repair plan to provide in situ stabilization and realignment of the crossing.

Due to the location of the crossing, it was imperative that repairs be made quickly, without a lot of disruption to both truck and train traffic utilizing the crossing.

CST partnered with UP maintenance personnel and designed a site specific injection plan to stabilize the soft soils, lift, and realign the precast crossing panels, as well as beneath additional areas of track.

A thorough site investigation was first conducted to identify areas and depths for repair.

CST’s technicians placed injection probes into predetermined locations and depths, installing a high density, expanding structural polymer to stabilize the soft spots in the soil, and lift to realign the settled crossing panels.

Additional areas of subgrade soil were also treated in adjacent track sections leading up to and away from the crossing.
The railroad crossing precast panels were lifted, realigned, and stabilized in a matter of hours. The subgrade soils beneath the panels and areas of track were stabilized to mitigate against additional settlement.

Repairs were made with zero excavation and very little disruption to vehicles accessing the cement plant, or trains utilizing this section of track.

All areas were immediately available for use following the repair.

CST’s soil stabilization and concrete lifting technologies are an efficient and effective way to provide long term, precision repairs without the added expense of lengthy downtime or costly tear out and replace alternatives.

Mine Shaft Head Frame Footer Foundation Stabilization

The head frame support leg foundation on one of the Tronox Alkali Corporation mine shafts had experienced settlement. As a result, movement of the footings had caused the head frame and shaft bucket to shift from center. The issue was discovered as crews and equipment were being lowered and retrieved from the mine shaft.

Tronox Mine Foreman Todd Jackson contacted John Eddins, P.E. with JFC Engineers and Surveyors to investigate the problem. The goal was to find a solution that would effectively align the shaft and mitigate the issue of potential future tilt or settlement.

Stabilizing the foundation of the head frame support and correcting the tilt to safely allow mine crews to use the equipment to access the mine shaft was critical.

JFC Engineers contacted CST to help deter-mine the best solution to stabilize and realign the structure.

CST partnered with JFC Engineers and performed a thorough site investigation. It was determined that the back leg of the head frame foundation would be treated using the Uretek Technologies to stabilize, lift, and realign the structure.

Dynamic Cone Penetrometer tests were performed to determine the condition of soils below the frame’s legs. The tests and analysis revealed that the soil would need to be treated at two depths to lift and to stabilize the soils to assure no future settlement would occur. Injections were made at two depths under the foundation and at the toe of the foundation to mitigate potential slide or settlement in the soils. The treatment was to obtain the target realignment of the structure and the foundation stabilization with minimal disruption to the structure or operations.

Injection probes were placed through the asphalt and into the soils at depth. Injections were made while closely monitoring elevations for movement.

The mine shaft footer foundation was stabilized and the shaft frame vertically realigned. Due to the surgical precision of the injection process, no additional stress to the structure or horizontal movement occurred during the lift. Voids were eliminated beneath the footings, ensuring a strong and stable base to support the heavy load.

The project was completed with minimal disruption and without having to take the equipment off line during the repair. The equipment was immediately put back into use with all repairs done in only two shifts. Most importantly, stability was restored quickly and efficiently, extending the safe use-life of this industrial structure.

“The project was well planned and executed. The back leg foundations were lifted to the established target elevations which brought the head frame structure to verti-cal plumb. The client expressed their ap-preciation and satisfaction with the results” -John Eddins, P.E., JFC Engineers & Surveyors

CHALLENGES
Stabilize the soil beneath this large piece of equipment without having to take the shaft offline or deconstruct the head frame.
Correct the tilt of the head frame to bring the shaft bucket operation back to center.”

BENEFITS
In Situ, Fast, No-Dig Process
Ability to Lift Heavy Loads with Surgical Precision
Long Lasting Repair
Extends Use Life of Existing Structures