Liquor Warehouse Slab Lift – Cheyenne, WY

The Customer

Built in 1976 over an old creek bed, this warehouse once served as an electronics distribution center for over 20 years. It now is the sole storage and distribution hub for imported liquor in the State of Wyoming.

In 2012, the State of Wyoming purchased a warehouse that was used as an electronics distribution center for over 20 years, turning the facility into a storage hub stocking Wyoming’s liquor inventory for statewide distribution.

Shortly after the state purchased the warehouse, installation of newer, higher shelving was erected to store over $18 million worth of liquor inventory. The shelving exceeded 15 feet in height allowing additional inventory to be stored for future statewide distribution.

The Challenge

Soon after liquor inventory was stocked on the warehouse shelves, warehouse managers noticed cracks appearing and growing larger in the floor slab. The additional weight from liquor inventory combined with constant pounding and vibration from forklift traffic expedited the weakening of the sub-base and floors. Warehouse management quickly recognized the topple hazard of the uneven shelving and trip hazards created by uneven floor slabs, as a huge safety concern for employees working in the facility.

After a complete evaluation of the pre-construction and existing conditions of the warehouse, results showed 1) numerous areas of differential settlement in the slab, 2) high spots caused by poor finishing techniques, 3) unraveling joints in several locations, and 4) cracks in the concrete slab ranging from hairline to 1/4” in width.

The Solution

With the goal to improve the ride and extend the useful life of the warehouse floor, the following solutions were applied to treat 12,000 square feet of warehouse floor:

  • The CST method was used to underseal, stabilize, and realign mismatched and uneven slabs
  • Joint sealing and crack repair to protect surface
  • Grinding/smoothing high spots in rolled joints
  • Remove and replace unrepairable concrete sections

The Results

Concrete Stabilization Technologies successfully treated approximately 12,000 square feet of warehouse flooring. CST completed the undersealing, slab lifting and realignment, and overall stabilization of the entire warehouse floor in 3 ½ days.

In addition to CST injections, approximately 6,300 square feet of concrete was ground down and a special concrete hardener was applied to protect the surface from future damage.

Timely completion of the warehouse stabilization allowed this important liquor inventory distribution hub to continue operations with minimal disruption and downtime.

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 CST 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.

Distribution Warehouse, Slab Stabilization and Joint Fill – Pueblo, CO

A large retailer distribution center, a 1,270,000 square feet warehouse and storage facility located in Pueblo Colorado, underwent a large renovation and rehabilitation project in September of 2015. The building was acquired in 1986 and has had several additions to the original warehouse area.

The Problem

In July of 2015 a site survey revealed a large array of structural deficiencies including drainage issues, spalling issues of interi- or concrete surfaces, water infiltration, settlement of concrete floor slabs, building movement, problems with doors not shutting, cracking in the precast wall panels above bay doors, and joint filler deterioration. Roche Constructors, a highly reputable Commercial Contractor located in Greeley Colorado was awarded the contract to coordinate and provide rehabilitation of the building. CST partnered with Roche to perform the slab lifting, soil stabilization, structural repair and joint filler portions of work.

Settlement of close to 6,000 square feet of floor slab had created a bird bath in the main north/south runway at the east side of the building near the busiest loading dock bays. This area is continually pounded by loaded forklifts carrying product to and from storage areas. Soil testing determined a weak soil zone 10 to 12 feet below the slab in this area that likely contributed to the settlement. The joint sealant in the control joints in a large portion of the floor slabs had lost cohesion and needed to be replaced as well.

15 areas in the precast walls located above the large overhead dock doors had developed cracks due to impacts from large semis unloading freight.

Factors for Consideration

There were many factors CST had to consider while planning and executing the stabilization and repairs of the distribution center. Roughly 25% of the floor area that needed lifting was in the main runway. Injection hoses would need to be run along this area, but not interfere with forklift traffic. Due to the approaching holiday season, the warehouse was receiving more inventory than usual and areas had to be accessible for unloading and storing freight. Because of increased shipments and need for access to the additional storage areas, the work window was reduced to accommodate receiving personnel and provide access to the additional storage areas of the warehouse.

The original joint fill compound used in the floor slab control joints had lost cohesion in a large portion of the slab area. In order to find the most effective and long lasting solution that wouldn’t require re-application, the product specified for sealing would need to be analyzed to ensure durability.

The sheer size of the warehouse itself posed a problem with communicating between crews and warehouse personnel. Two-way radios were issued which allowed easier communication when a question arose during repairs and attributed to a successful and smooth running project.

Method/Process Applied

The CST technologies were used to lift the warehouse floor slabs and stabilize the soils beneath the slabs. In addition, 3 columns were also stabilized and lifted to match the slab elevation. The CST process uses a high density expanding structural polymer that is injected through small probes into the soils below the concrete slabs. The polymer fills voids, increases bearing capacity of the soil, and lifts the concrete. Soils were also stabilized at depth of weakness to ensure no future settlement of the area. Careful monitoring at the surface was performed during injections to control the stabilization and lifting process with surgical accuracy. The CST soil stabilization and concrete slab lifting processes provide a permanent solution for settled concrete slabs because they treat the real problem, the underlying soils.

CST worked with the retailer’s engineering staff to determine a more effective and stronger compound than what was originally specified to ensure a more permanent adhesion and performance of the joint filler for the control joints. Areas were sectioned off and treated as to not disrupt warehouse traffic. Old material was removed from the joints, backer rod and sealer were then installed with areas marked off and allowed to cure before traffic was allowed back on the area which ensured good adhesion and strength of the treated joints.

To address the cracks in the precast walls , CST employed a composite repair system designed to provide shear and flexural strengthening to compromised and damaged buildings and infrastructure. The system uses an extremely strong carbon fiber matrix that was applied to the cracked and deteriorated areas of the precast walls. The repair system is significantly faster and less expensive than traditional repairs or replacement. Interior and exterior repairs were made to strengthen and protect the precast walls from further deterioration.

Result

The entire 6,000 SF slab area was lifted back to near original elevation and columns were stabilized and lifted to align with stabilized floor slabs, control joints were treated and filled and cracks in the precast walls were repaired in the time frame required. Soils beneath the distribution center warehouse were permanently stabilized, the concrete slabs and columns were realigned eliminating trip hazards and excessive wear and tear to equipment traveling over the areas. The structural integrity of the precast walls was restored. All processes were done with zero excavation and very little disturbance to the operations within the warehouse. Work was completed while leaving one lane open at all times to fork lift traffic. Due to the fast curing time and non-disruptive CST processes, traffic was allowed back onto the treated areas within 15 minutes following stabilization. The owner of this project and the owner’s representative, Roche Construction were very pleased with the professional, quality repairs performed by CST on the distribution center warehouse.

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 CST 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 prior to injection of CST 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 required 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

CST Deep Injection Method – The CST 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 stabilized using in-situ methodology.

The CST 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 CST 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.