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

Crescent Electric Supply – Gillette, WY

Structure Characteristics: The building is a single story structure approximately 80 feet by 125 feet in size and consists of wood post and beam framing, such as a pole building. The walls are constructed of wood posts, embedded in concrete piers at approximately 8 feet on center. The posts provide the vertical and lateral support for the walls and roof. The roof is framed with preengineered wood roof trusses. The floor of the building consists of a 6 inch thick reinforced concrete slab on grade. A septic tank and a leach field are situated along the west side of the building.

Problems That Prompted Repair: The building and concrete slab on grade were experiencing settlement. The settlement had caused cracks in the concrete slab on grade and interior finishes of the office area of the building. The majority of settlement occurred along the west side of the building and the concrete slab on grade in the warehouse were cracked the entire length of the building. Cracking ranged 3 to 8 feet east of the west wall. A slab construction joint existing in the center of the building and spans north/south. The joint appeared to have separated as a result of the slab settlement along the building.

Inspection/Evaluation Methods: A structural Observation and Geotechnical Soil Study were performed. Field investigation also performed with the use of a Dynamic Cone Penetrometer (DCP). The primary purpose of this tool is to locate the weak zones in the soils and quantify the comparative degree of ground densification improvement achieved by the deep injection process, as exhibited by the increased number of percussive blows required to penetrate the treated soil mass, when compared to a pre-injection test performed within the confines of the treated mass.

Test Results: The geotechnical study and structural observation indicated that the soils underlying the foundation and concrete slab on grade consisted of soft clays with considerably high moisture content. These soils are notorious for settlement and collapse upon wetting. It was determined that the settlement had high potential to continue if the problem was not addressed. Separation of the slab joint was determined to have been caused by the settlement of underlying soils. DCP Test results indicated weak soils at depths of 7 feet.

Causes of Deterioration: Deterioration was caused by a leak from a collapsed water tank in 2008 west of the building, effluent from the septic system, surface runoff, or a combination of these influences. Soft clay soils surrounding and beneath the structure and slab contributed to the settlement and associated damaged slab and interior finishes of the building.

Repair System Selection: Selection of the repair system was based on recommendations resulting from structural evaluation of the building. Due to the soil conditions and probability of future settlement, “Deep Injection”, using expanding structural Geo-Polymer, was chosen for correcting the settlement issues.
Site Preparation: Penetrometer testing was performed and reviewed. Mapping of the warehouse floor was completed. Profiles for settlement and finish target elevations were performed.

Demolition Method: No demolition of the existing concrete slab on grade was necessary due to
the utilization of the “internationally patented Geo-polymer injection system”. All soil remediation work was completed “In Situ”.

Surface Preparation: Surface preparation of the slab, and soil surrounding the outer perimeter of the building, prior to injecting was unnecessary. This is due to the unique nature of the expanding Geo-Polymer technology utilized. Minimal cleanup of the joint area was performed before epoxy was injected and caulking repairs were performed in the west joints and wide joint in the center of the warehouse. The crack repair and joint sealing was performed in the floor slab. Cracks were mechanically routed and gravity fed structural epoxy was injected into the cracks. Caulking of the joints was completed using a urethane sealant as specified by the engineer. Approximately 136 linear feet of cracks and approximately 124 linear feet of control joints were primed and caulked.

Application Method Selection: Repairs required utilization of a specialty technique. The foundation type (posts embedded in shallow concrete piers) does not lend itself well to helical pier stabilization. Stabilization of the underlying soils, individual concrete piers, and the concrete slab on grade itself needed to be modified in order to arrest future settlement. Therefore, the best method of application and method of repair was determined to be the injection of expanding structural Geo-Polymer.

Repair Process Execution: Initial testing of the soils were performed and analyzed to determine injection depths necessary to stabilize the underlying soil structure. Areas to be addressed were mapped and injection ports were prepared beforehand to accommodate frozen soil conditions at the time of repair. The injection of the patented Geo-Polymer material was used to penetrate deeply into the sub grade at depths of an estimated seven feet. Voids beneath the slabs were filled, and slabs lifted back to original elevations. Sub grade soils were stabilized using this Internationally Patented Technology. Deep Injection permanently altered the soil structure, thus stabilizing and preventing future settlement. Once soils were treated, the slab joints were sealed and caulked with epoxy as specified by the project engineer.

Structural floor repair: Sub contractor, gravity fed low viscosity epoxy into the floor cracks to re- establish the original monolithic strength.
Control joint sealants: Sub contractor mechanically cleaned the sides of the existing control joint and caulked with urethane primer and sealant.

Unforeseen Conditions Found: The work was performed in January which added concern for frozen ground and cold temperatures. The settlement originated below frost line. The Project Superintendent made additional efforts to keep equipment warm. The exothermic reaction of the Geo-polymer materials provided further protection against frozen conditions.

It was decided to perform the work on the client’s preferred schedule if possible. One of the unique characteristics of the Geo-Polymer is that it will not freeze during injections (it is not a water based material). Since unit weight was minimized and polymer did not add burden to weakened sub- grade, frozen ground and cold temps did not interfere with the work schedule.

Special Features and benefits of Geo-Polymer Deep Injection Repair Process:

  • Eliminated cause of settlement and future potential settlement resulting from the water spill.
  • Raised building and slabs to original elevation.
  • Saved concrete slab, and interior finish from further damage.
  • No downtime to business, timely, safe, clean.
  • All work done from above ground without excavation, In-Situ.
  • The Business was able to remain fully open during repairs with very little disruption to activities.
  • Floor sub-grade was restored to give full support for heavy forklift traffic.
  • Structural repair of floors was completed with full co-ordination of warehouse use.
  • Project was completed using permanent and economical, “Deep Injection” of Geo-Polymer.

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.

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.

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.