Irrigation Head Gate Void Fill Erosion Control Soil Stabilization

Problem

Erosion of support soils beneath this concrete head gate had happened over time caused by turbulent water eroding soils beneath the inlet floors and undermining the structure. The voids created beneath the inlet had grown large enough that the foundation of the structure was compromised. In high water events, the undercut of the water could potentially wash out the entire head gate.
FC Excavation, the general contractor responsible for repair of the head gate was hired to provide a permanent solution to stop water from undercutting and carrying soil away from beneath the floor of the structure. An in situ solution, that would not require excavation or ripping out and replacing the concrete was preferred. They were also looking to make the repair during the fall when water was not being diverted through the head gate and have it solid before irrigation started in the Spring.

Solution

Concrete Stabilization Technologies partnered with Josh Frappart of FC Excavation in designing a permanent solution to fill voids and create an impermeable curtain wall beneath the head gate to support the structure and prevent future erosion.

Upon investigation of the site, it was discovered that voids as large as 2 cubic yards exist-ed beneath the head gate. To create a stronger base, the FC Excavation crew first added rock and soil into the large voids. Injections were then made into the soil, creating support pressure and filling the voids.

The hydro-insensitive expanding structural polymer (ESP) consolidates and strengthens the weak base soil and lenses out to fill voids, reinforces and densifies the soil, and creates a permanent barrier against water erosion.

Once the crew had finished injections, the contractor brought in rip rap to be placed on top of the repaired area.

Result

The entire repair of this undermined head gate was completed in 6 hours.

The expanding structural polymer installed by CST’s technicians efficiently and effectively rehabilitated this irrigation head gate with ZERO EXCAVATION.

The ESP used to repair the head gate will effectively mitigate against future erosion. The impervious barrier created beneath the structure will divert water from forming a channel beneath the head gate.

CST’s expanding structural polymer repair process is highly effective for preventing seepage and controlling erosion caused by water. Because of its hydro-insensitive characteristics, the ESP can be installed in wet environments and does not degrade in water. This in situ repair process saves irrigation districts and land owners the high cost and downtime of rip out and replace while providing a permanent solution.

Challenges

  • Create a permanent solution to undermin-ing and channeling caused by water.
  • Fill voids without having to excavate the structure.
  • Consolidate the soil and rock material into an effective support system for the struc-ture.

Benefits

  • ZERO EXCAVATION in situ repair process.
  • Hydro-Insensitive material.
  • Easily reach areas where large equipment would cause damage, or unable to access.
  • Effective rehabilitation of existing infra-structure eliminates cost of rip out and replace.

City of Buffalo WY Swimming Pool Void Fill Soil Stabilization

Problem

The City of Buffalo Wyoming’s public pool had experienced large amounts of water loss due to leaks in the main fill lines beneath the pool. Cracks in the concrete floor of the pool had also contributed to the water loss.

The leaks were causing ponds of water to develop beneath the pool, weakening base soils and this massive structure’s support system.

The City needed a solution that would seal the leaks in the main lines and underseal the floor of the pool to stop water loss.

Because of the large size, tearing out the concrete to repair the leaks would be extremely expensive and would cause major disruption for the public with a lengthy closure.

The City was looking for an in situ repair that would seal the leaks, stabilize base soils and allow the pool to be returned to service quickly.

Solution

CST partnered with City of Buffalo Public Works Director Les Hook, and department staff to design an in situ repair to seal the leaks, stabilize and void fill the soils to support the pool.

Through a thorough investigation of the pool, it was determined that the ponding water was mainly collecting beneath the deeper end.

Injection holes were drilled, and the crew installed expanding structural polymer, starting at the shallow end, and working towards the deeper end of the pool.

The injection pattern was carefully designed to only void fill and underseal the bottom of the pool without lifting any of the concrete.

As injections were made, water was displaced and pushed out from beneath the pool and the saturated support soils.

Result

A total of 30,454 square feet area was successfully void filled and under sealed in a matter of a few days using CST’s expanding structural polymer injection technologies.

The repair did not require any excavation and the pool was immediately available to be refilled and put back into use following completion of CST’s polymer injection process.

The City saved thousands of dollars avoiding a rip out and replace scenario.

The hydro-insensitive characteristics of CST’s expanding structural polymer is ideal for rehabilitating leaking infrastructure. The Zero Excavation repair process is an ideal solution for repairing water lines, sewer connections, dams, inlets, irrigation structures, manholes and ground water cutoff walls. The high ten-sile strength of the material mitigates against channeling and is an ideal void fill and soil stabilization solution.

Challenges

  • Design a cost effective repair solution to void and seal beneath the pool without tearing out the massive con-crete floor.
  • Complete repairs efficiently without major disruption to the public or a lengthy closure.
  • Stay within the City’s maintenance budget.
  • Benefits

  • Zero Excavation, in situ repairs.
  • Highly effective soil stabilization, void fill, and undersealing process.
  • Hydro-insensitive material works well in saturated environments.
  • High tensile strength mitigates against erosion and channeling.
  • Carbon Fiber Structural Repair Exterior Block Wall

    Problem

    This concrete masonry building had experienced cracking damage at the corners and around window and door openings. The building was occupied by several different businesses, including a Montessori School, infant daycare, and retail storage area.

    Y2 Consultants of Jackson Wyoming conducted an assessment including an infrared scan of the building that revealed construction deficiencies. The structural assessment of the building noted that the cracks were due to differential loading and insufficient horizontal rebar at the corners to tie the perpendicular walls together.

    The differential loading and insufficient rebar had stressed the CMU to crack in these loca-tions. In order to allow safe occupancy of the building, it was determined that a retrofit of the deficient areas was necessary. Repairs would need to be coordinated with the businesses using the building, without a lot of disruption.

    Solution

    A Carbon fiber retrofit repair process to strengthen the walls at the cracked corner areas was determined to be a viable solution. CST’s carbon fiber repair system is comprised of high strength carbon reinforced fabric strips, applied over a clean and prepped surface, and adhered using a high strength epoxy. CST crews first prepped the surface using surface grinders to remove existing paint and get the surface profile required. A boom lift was used to help the crew safely reach areas above the awning. CST power washed the exterior of the building where the carbon fiber reinforcement would be applied. Moisture tests of the block surface were taken to ensure project specifications were met for the surface conditions necessary to achieve maximum adhesion properties of the material. Once dry, primer, then a tack coat, and then saturated carbon fiber was applied to the wall followed by a final grey UV exposure rated coating to protect the material.

    Result

    CST crews successfully reinforced deficient and cracked areas of this concrete block building in a matter of days.
    The carbon fiber retrofit allowed the owners to keep business running and provide additional support to extend the useful life of the building for many more years. Carbon Fiber repair options such as the method used on this concrete masonry building strengthen existing structures, and provide a higher safety factor.

    For many older structures, where reinforcement may not have been included during construction, carbon fiber retrofit helps to stabilize and reinforce areas of concern, bringing older buildings up to current code regulations and extending their useful service life.

    CHALLENGES

    • Perform the repair without disrupting tenants of this commercial building.
    • Prepping the surface to meet specification for maximum adhesion of the car-bon fiber material.
    • Accessing areas above the awning of this structure to prep surface and install carbon fiber material.

    BENEFITS

    • In situ, non-disruptive repair.
    • Increased safety factor through strengthening of existing structural deficiencies.
    • Meeting current code regulations, allowing older buildings to continue to be used.

    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.