Port Shed Floor Stabilization

Baltimore, MD


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.


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.


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. A high density (3.3PCF free rise, 4PCF in place) TerraThane 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.

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