Polyurethane Grouting Projects

By applying unique solutions to increase the safety and longevity of our environment.

Fire Station Floor Lifting

The Job

The concrete slab on the grade floor inside of a fire station on the North Neck of Virginia settled up to two inches. As part of the investigation into the cause, an engineer discovered voids up to 8″ below the slab and multiple broken sanitary sewer pipes below the floor.

The affected areas included a dayroom, kitchen & meeting hall.

The Challenge

In order to minimize disruption to the fire station’s operations, the proposed repair had to be quick, clean, and minimize uncertainty associated with the plumbing repair slab cuts.

The Solution

CJGeo performed ground improvement grouting of the underlying soils to 5′ below-grade utilizing plural component polyurethane compaction grouting. Shallow voids were filled using plural component polyurethane, which was also used for settlement correction.

Because polyurethane grouts cure very quickly, the floor was repaired the day before the plumbing work was scheduled. This allowed the plumbers a stable work surface and eliminated the risk of stuck saws or sudden collapse of the floor during floor sawing for plumbing access.

Pre & post-grouting DCP testing was done to verify grout travel.

14′ CMP Repair

The Job

During a real estate transaction, civil engineers walked a 1400LF run of 14′ diameter multiple tunnels running underneath a strip center in Asheville, NC.

A previous inspection had indicated impending section loss of the pipe due to corrosion and had recommended grouting of incidental voids, but no work had been performed at that time.

The pipe, which had up to 20′ of cover, bypasses a large stream and runs under 200LF of building footprint, the main entrance roadway, two out-parcels, and ties into an NCDOT box culvert to discharge.

The Challenge

Significant debris was present in the pipe, and access was exceptionally difficult. Because dewatering was not practical, all work proposed had to be performed underflow.

The Solution

CJGeo proposed polyurethane backgrouting using plural component CJGrout material, specifically CJGrout 35NHV61.

CJGrout 35NHV61 is a hydro insensitive, moderate mobility grout designed for backgrouting in wet environments, and is certified for potable water contact.

Despite a bear wandering into the pipe during repairs, CJGeo crews successfully backgrouted the pipe to address piping and erosion outside of the structure over a period of two weeks. More than 40,000 pounds of CJGrout 35NHV61 were needed to underseal the headwall structure and pipe.

Corporate HQ Stabilization

The Job

Starting immediately after construction was completed, the slab on the grade floor within the cafeteria, loading dock, and kitchen at a corporate headquarters building in Pittsburgh, Pennsylvania settled. Over the course of 12 years, the owner had four different grouting companies attempt to address the problem. Lime slurry injection below the slab was disruptive, and settlement always resumed shortly thereafter.

Compaction grouting was performed in one area but was so disruptive that despite the fact that it was the only method where settlement didn’t resume, the owner kicked the contractor off the site after nearly four months of not having access to their executive dining room.

The Challenge

Settlement progressed over time to be as much as four inches, affecting nearly 20,000 square feet of floor. A general contractor retained by the owner reached out to CJGeo about performing low-impact grouting to address the settlement.

Because settlement affected the entire kitchen, food prep, serving and majority of the dining areas, repairs had to be facilitated continued use of the facility. Additionally, due to the 24-hour staffing of the facility, the noise had to be limited, and there was zero tolerance for dust.

Video inspection of the extensive gravity sanitary and floor drains below the floor revealed six defects, including a 2″ offset in a sanitary drain line for a 6 stall restroom.

The Solution

CJGeo performed 17 DCP tests to determine the depth of uncontrolled fill, which was the presumed cause of settlement. DCP testing showed pockets of WOH fill down to 35′ below the finish floor, and voids ranging from 2″ to 18″ immediately below the floor.

Over the course of 7 nights onsite, CJGeo crews installed 12,000 pounds of CJGrout 20SDB into voids immediately below the floor, and 53,000 pounds of CJGrout 35NHV61 for polyurethane compaction grouting. Compaction grouting was performed up to 35′ deep, but to an average depth of 15′ over the entire area.

All work was completed off-hours. As soon as the kitchen shut down for the evening, CJGeo crews swung into action, grouting through the night until wrapping up in time for the food prep crews to get ready for breakfast at 0500.

To facilitate grouting under four walk-in freezers and refrigerators, over the course of a 24-hour shift, all cold contents were moved to reefer trailers, CJGeo grouted to 30′ under the freezers and refrigerators, which were then immediately turned back on, and then refilled.

Through careful coordination with multiple operational divisions for the owner, general contractor, flooring restoration contractors, plumbers, and remediation contractors, CJGeo successfully completed the project under budget and on time.

Sewer Collapse Sinkhole Repair

The Job

When the operators of a tire and auto shop noticed a sinkhole developing next to their building, they weren’t sure what to do. After an employee crawled into the hole and discovered that he could stand up underneath their building, the owner reached out to the city. City crews determined that a 20″ VCP combined sewer & storm pipe had collapsed under the structure, roughly 25′ below grade.

The Challenge

An on-call contractor for the city installed a new manhole and rerouted the pipe around the building, but addressing the sinkhole was out of their businesses’ scope. The project manager reached out to CJGeo, who visited the site and recommended DCP testing to better quantify the extent of the problem.

The Solution

DCP testing showed that outside of the large hole on the surface, there was little deep disturbance. Working with the city’s consulting engineer, CJGeo developed a grouting plan to install two different CJGrouts; 20SDB in the bulk voids near the surface, and 35NHV61 for soil grouting to address voids within the underlying ground near the failed sewer line.

While onsite for just 6 hours, a CJGeo crew completed the work with zero disruption to the businesses’ operations.

Coal Pier Sinkhole Grouting

The Job

With an annual throughput capacity of 48 million tons, Norfolk Southern’s Pier 6 at Lamberts Point in Norfolk, Virginia is one of the largest coal trans-loading facilities in the world. As an around-the-clock facility built around precision logistics, there’s little tolerance for disruption or downtime.

The Challenge

When two sinkholes opened up at the end of Pier 6 adjacent to the bulkhead, railroad personnel reached out to an onsite maintenance contractor. Steel plates were installed to provide temporary protection while a long-term solution could be implemented.

The Solution

CJGeo performed DCP testing at the site in order to quantify the depth of voids below the pavement adjacent to the sinkholes. The DCP testing showed that in addition to large voids visible from the sinkholes immediately below the pavement, there were large pockets of voids down to 15’ below the surface. 

CJGeo crews then used CJGrout 35NHV61, a hydro insensitive, NSF-certified geotechnical polyurethane to fill all voids and restore stability to the area. The grouting work took five hours onsite to install 3400 pounds of material, with zero disruption to operations.

PA Turnpike Undersealing

The Job

As part of a 24 lane mile mill & pave rehabilitation on the Pennsylvania Turnpike, slab stabilization was required. The Turnpike’s specification for stabilization is either liquid asphalt or polyurethane.

The Challenge

In order to keep MOT in place continuously, work had to be done 24 hours per day. Due to work on three bridges within the repair area, undersealing also had to be phased.

The Solution

CJGeo proposed undersealing with CJGrout 40NHL, a 4.0 lb/cuft free rise polyurethane grout formulated specifically for undersealing thick pavements in transportation environments. 40NHL is hydro insensitive, so performs well in wet environments, as confirmed with NYSDOT GTP-9 testing.

Using a double gang drill and single grout truck, CJGeo crews undersealed up to 1.8 lane miles per shift. Drilling was completed at night, and grouting during the day, to allow the general contractor to keep MOT in place continuously.

Tub Crossing Repair

The Job

The sandy soils of South Jersey are great for growing produce and mining pure silica sand. While most of the produce is shipped by truck, a lot of the silica is shipped by rail. The rails inevitably cross the roads, and many of the crossings are at grade.

The Challenge

A short-line railroad was experiencing significant settlement and pumping of multiple precast modular crossings in the Vineland & Millville areas. Each crossing saw significant truck traffic, primarily from aggregate mining, and also significant heavy haul rail traffic from transporting sand.

The Solution

Working with a rail maintenance contractor, CJGeo performed polyurethane grouting on a total of four precast tub crossings in the area. Each was done in a single day, with the immediate resumption of automobile traffic, and rail traffic. Supplemental bolting was performed to address the deterioration of the panels that had resulted from the extensive movement of the panels.

Industrial Short Line Tub Crossing Repair

The Job

Sparrows Point, in Baltimore, Maryland is a brownfield site being redeveloped from steel manufacturing to industrial and logistics use. From it says as a heavy manufacturing facility, there is an extensive freight rail network throughout the site, with many grade crossings subject to significant heavy truck traffic & heavy haul rail traffic.

The Challenge

A precast tub-style grade crossing on a road feeding a metals recycling plant developed a 2.5″ belly. The local FRA inspector instructed the railroad to correct the settlement.

The Solution

CJGeo performed structural polyurethane grout injection to fill voids below the panels, and then lift them back into their correct alignment. The work was completed in a few hours, without disruption to the rail or auto traffic.

NC Tub Crossing Repair


The 8′ long panels of tub-style grade crossing settled. As a result, a speed restriction was placed on the crossing, which affected passenger schedules. Three panels were affected, and the belly in the slabs was approximately 2 inches. Slight deflection with heavy truck traffic was noted, and significant deflection with rail traffic was present.


The repair had to be completed in just a few hours, to avoid disruption to rail traffic. The repair had to allow for immediate resumption of rail traffic, and tolerate tamping of the adjacent truck during the repair. Additionally, the tub crossing repair had to be done in a manner that did not disturb the adjacent asphalt pavement.


High-density geotechnical polyurethane grouting to stabilize and lift the affected modular grade crossing panels. Geotechnical polyurethane grouting is far superior to mudjacking, in that the process is faster, and can more easily ensure a complete filling of voids under the crossing panels. Lifting precision of fewer than 0.1 inches is standard.

A CJGeo modular grade crossing repair crew filled the voids and corrected settlement in a few hours. During the tub crossing repair, tamping was done by the rail system to address the settlement of the adjacent track.

Industrial Driveway Crossing Repair

The Job

MARC’s Brunswick Line’s Frederick extension passes through multiple industrial sites & driveways. This particular crossing served as the driveway of a ready mix concrete operation, so saw extensive high dynamic loading in a wet environment.

The Challenge

The repair had to be performed without disrupting either rail or industrial traffic. There was a four-hour window between the last morning train and the first evening train for performing the repair to the eight modular tub crossing panels. The settlement was up to two inches, with extensive spalling.

The Solution

CJGeo’s crew installed supplemental bolts due to replace the OEM center panel anchors, and then grouted the crossing in the mid-day window, without disruption to any stakeholder.