The concrete slab on 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.
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.
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.
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.
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.
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 hydroinsensitive, 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.