Commercial & Industrial

The Job

This office floor settlement repair project is located near Norfolk, Virginia. The slab floor inside of a grain import/export facility office sank both differentially and globally. All exterior walls are on driven timber piles, but the floor floats independently of the foundations. Slab settlement up to 3 inches affected approximately half of the building footprint.

The Challenge

Over the roughly 15 years that the floor was settling, maintenance crews were constantly repairing various systems. These repairs were including tuckpointing CMU walls, moving/shimming HVAC ducting, and rerouting water lines.

The foundation repair work on this building couldn’t impact operations. Ship loading and unloading could not be disrupted for any reason. The settled building houses many operations critical to ensuring timely loading and unloading.

The Solution

CJGeo proposed polyurethane grouting for this slab foundation repair project. Polyurethane grouting is safe, fast, and economical for floor settlement repair. Structural polymer grouting is another name for polyurethane grouting. The material of choice was CJGrout 28FDL. 28FDL is optimal for lifting light duty commercial floors experiencing both global and differential settlement.

CJGeo mobilized two polyurethane grouting crews to the facility on a Saturday morning. The 4,000 square foot repair only took nine hours start to finish. There were zero disruption to operations. During lifting, previous cosmetic repairs were undone to facilitate lifting. This included removing extensive patch material from the CMU walls, loosening plumbing connections, and adjusting HVAC ductwork.

By mobilizing multiple crews with multiple equipment redundancies, CJGeo was able to ensure that the repair had zero disruptions to the facility and its operations.

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Facing a similar challenge to this office floor settlement repair project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

THE JOB

This port shed floor stabilization project is located in Baltimore, Maryland. The 11″ thick slab floor of a storage shed at a port facility settled up to 6 inches. Exploratory coring & non-destructive imaging (GPR & microgravity) indicated there were extensive voids below the floor.

Previous work on the adjacent bulkhead uncovered extensive voids below the exterior footings (pile-supported) and multiple abandoned, but unfilled, pipes under the floor.

THE CHALLENGE

Due to relatively thin voids, which were all less than 6 inches, and void filling grout had to be highly mobile. However, this posed environmental challenges due should the grout make its way into an unfilled abandoned pipe and into the adjacent waterway. The owner did not want to lift the floor, so grouting had to be sufficiently low mobility to prevent runaways, but also fill all voids at an economical hole spacing.

THE SOLUTION

CJGeo proposed polyurethane grouting for this slab foundation repair project. The original design was for a 50/50 mix of polyurethane and cement grouting. CJGeo proposed a valued engineering proposal to perform all grouting with polyurethane. CJGrout 35NHV geotechnical polyurethane grout was proposed to balance mobility for completeness of fill and reaction time to avoid any runaway loss into the adjacent waterway.

CJGeo mobilized a two-reactor polyurethane grouting rig and installed approximately 6300lbs of polyurethane grout over a three-day period. Pneumatic rock drills were used to speed drilling.

Speak With An Expert

Facing a similar challenge to what CJGeo addressed on this port shed floor stabilization project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.

THE JOB

This commercial floor void fill project is located in Manhattan. During a Local Law 11 inspection, the owner of a coop building’s first floor asked the GC to investigate a settled slab floor inside part of the building. The contractor began opening up a 2′ square hole in the floor. During this, all the debris was disappearing. After opening the hole it was apparent why. There was a 2′ to 3′ deep void around the entire perimeter of the building footprint.

THE CHALLENGE

Filling a 90CY void under the floor of an operating business can be a challenge anywhere. Complicate it with a 40′ x 10′ laydown area, Mid-Town Manhattan traffic, and cold winter temperatures, and you’ve got quite the challenge.

The cause of settlement was the consolidation of poorly placed fill, which was primarily construction debris. Lightweight void filling material is best to minimize future settlement of the underlying fill material.

THE SOLUTION

At the suggestion of an on-staff structural engineer, the general contractor’s project manager reached out to CJGeo about performing polyurethane grouting to fill the voids. CJGeo proposed using a low-exotherm, high mobility bulk void filling foam to fill the voids. 3′ deep voids are too deep to fill with most polyurethane grouts. A true low exotherm foam is needed for efficiently and safely filling any voids thicker than about 6″. High mobility foams are also critical when filling voids in order to ensure complete coverage.

CJGeo mobilized a two-reactor polyurethane grouting rig. The CJGeo crew installed approximately 4800lbs of CJGrout 20SDB geotechnical polyurethane grout over a two-day period. CJGeo pulled continuous negative pressure on the void through the floor. This was to allow for continuous operation of the facility during grouting. CJGeo’s work didn’t disturb operations at all. All of the voids were completely full of grout at the end of the project. The polyurethane grouting process used here for slab foundation repair is sometimes also called slab jacking or structural polymer grouting.

Speak With An Expert

Facing a similar challenge to this commercial floor void fill project? Give us a shout or shoot us a text. Click the state marker for the location of your project for contact info for the appropriate rep.