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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.

Challenge

  • Create a permanent solution to undermining 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 structure.

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 infrastructure eliminates cost of rip out and replace.
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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.
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    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.

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    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.

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    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

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    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.