Category Archives: Concrete Floor Repair

Concrete Leveling 101

Concrete leveling refers to correcting uneven or sinking concrete slabs. This is done through a variety of methods that alter the foundation that is beneath the concrete surface. It is less expensive to level concrete than to remove and replace the slab. Concrete leveling can be used in residential, commercial, and municipal applications. Homes, warehouses, roads, shopping centers, airports, and more can all be helped with concrete leveling.

concrete leveling 101, mudjacking, polyjacking, stone slurry

What Causes Concrete to Settle

There are several reasons that a concrete slab can settle. If the soil isn’t properly compacted during construction, it can compress or settle once the weight of the structure is placed on it. This could happen relatively soon or gradually over years. Another cause is soil that is either too wet or too dry. Oversaturated soil can swell and heave, putting tremendous pressure on the concrete. Soil that is too dry can shrink and crack, no longer providing strength and stability to the concrete above. If the area around the concrete doesn’t drain properly, the soil beneath the slab can erode, washing the support out from under the concrete. 

Other causes that can damage concrete are tree roots that push against concrete slabs and seismic activity. Both of these can cause slabs to crack, move, or otherwise be damaged.

Methods of Concrete Leveling

Just as there are several causes of concrete settling, there are different ways to stabilize and lift the slab. Although the methods are different in cost, application, effectiveness, and time, the result is a level concrete slab. These methods all fall under the category of “slabjacking”. The premise is to lift the concrete by pumping a mixture through holes in the slab, lifting the concrete from below. 

The initial injection fills the voids beneath the slab. Once the voids are filled, the remaining injection lifts the concrete. The holes are then patched and the project is done. All slabjacking methods take less time, cause less disruption, and cost less money than tearing up and replacing the concrete. Slabjacking is not an option if the concrete is too damaged. If there are too many cracks, you may be forced to tear up the old slab and replace it.

There are three types of slabjacking.

Stone Slurry Grout Leveling

This type of slurry is made from pulverized limestone, water, and Portland cement. This slurry is thick and pumped through holes that are around 1″ in diameter. The slurry is pumped below the slab, filling the voids below the concrete. Once the void is full, the slurry begins exerting pressure on the slab, lifting the concrete into place.  An expert operator can precisely lift the concrete to the desired height without cracking the slab. When the concrete is level, the hoses are detached and the holes are filled.

The stone slurry grout has a compressive strength of 240 psi. If Portland cement is added, the compressive strength jumps to an amazing 6000 psi. Once the slurry dries, it forms a near-solid stone foundation. This method has the highest compressive strength of all the methods described here. Stone slurry grout takes more clean-up afterward and uses bigger holes than polyurethane foam. The slab that is being lifted usually has to be within 200 feet of the truck that is pumping the slurry.

Mudjacking

Mudjacking uses a mixture of soil, sand, water, and cement that is injected through holes drilled in the slab. Other materials may be added to the slurry, including clay, limestone, fly ash, masonry cement, and pea gravel. The holes are typically larger than the ones used for stone slurry grout and polyjacking, coming in around 1 to 2″ in diameter. Like stone slurry grout leveling, the mudjacking slurry is injected through the holes beneath the slab. A portable pump is usually used, allowing better access to the slab than stone slurry grout leveling. When the void is filled, the remaining slurry builds under the concrete, lifting the slab. Once the concrete is level, the holes are filled and the project is complete.

The weight of the mudjacking and stone slurry grout can compromise soil that is already weak, causing more problems down the road. It also involves more clean-up than polyjacking and uses the biggest holes of the methods described here. This is also the slowest process of the three.

Polyjacking

Expanding Structural Foam Leveling, or as we call it, polyjacking uses an expanding polyurethane foam in its injection process. The polymer is a combination of two different materials, that, when combined cause the mixture to expand. The holes needed for the injection are around 5/8″, the smallest of all the methods. The expanding foam first compresses any weak soil it encounters, consolidating the sub-soil and causing it to become denser. The foam then fills any voids beneath the concrete. Lastly, once the void is filled, the foam will lift the slab to the height needed for it to be level and stable. 

The foam moves throughout the underside of the slab, expanding in all directions, filling the area below the concrete. The foam is also hydrophobic when cured, preventing heaving from occurring in freezing temperatures and avert erosion. The clean-up process is simpler than mudjacking or stone slurry grout leveling, uses smaller holes, and uses smaller equipment that can reach places trucks may not be able to access.

Contact the professionals at Polyjacking.com to learn more about the benefits and advantages of leveling your concrete with our method. 

 

 

Agricultural Concrete Floor Repair

Polyjacking.com makes its home in Kansas City, right in the middle of the Heartland. This portion of the country is home to the majority of agriculture in the United States, so it makes sense that would be experts in taking care of the needs of agricultural buildings.

agricultural building and polyjackingThere is a wide variety of soil in the area we cover from Minnesota to Texas, but the problems that we encounter are the same throughout the area. Whether its clay, black soil, or a little bit of everything, expansive soil can cause concrete to sink or heave, making the surface unstable and unsafe. Polyjacking.com has the tools and knowledge to restore the strength and stability of your agricultural building’s concrete floor.

Applying Polyjacking to Agricultural Buildings

If you find your concrete in need of repair, contact the pros at Polyjacking.com. The use of polyurethane foam takes less time and effort than other methods and is also cost-effective. Once we determine the best way to level your concrete, we will drill small holes around 5/8″ in diameter into the slab. The foam is injected into the holes, filling the voids beneath the surface. The foam expands, raising and stabilizing the concrete. Our experts can control the lift to within 1/10″ of an inch.

Not only does the foam fill the voids below the slab, but it also seals any cracks that are on the underside of the concrete. The expanding foam compresses any loose soil, making the base even more stable than it was originally. The foam is hydrophobic, so it won’t erode or allow water to penetrate. 

The foam hardens in about 15 minutes. Once the holes are filled and foam is set, you can use the surface and return to work. 

Agricultural Applications for Polyjacking

With a lifting capability of 900 tons, you won’t have to remove products or equipment to repair a slab using polyjacking. There are a variety of structures that we’ve polyjacked to restore stability to agricultural buildings.

  • Silo
  • Barn
  • Farmhouse
  • Coops
  • Stables
  • Machinery Sheds
  • Animal Enclosures
  • Garages
  • Driveways
  • Grain Elevators
  • Parking Lots

No matter the structure or usage, polyjacking is the right choice for stabilizing the concrete surface. 

Advantages of Polyjacking

When it comes to concrete repair and leveling, polyjacking is easily the best choice. Using polyurethane foam is much less expensive than removing and repairing the concrete slab. The entire process takes less time than other methods, so your downtime will be limited. Other methods can take days or weeks to complete. The foam is durable, the repair will last a long time and won’t shrink or erode like other methods. 

Contact the professionals at Polyjacking.com to stabilize and level your agricultural buildings and concrete slabs. We have the experience and tools to do the job right the first time. 

Industrial Concrete Repair

In an industrial setting, time is important. Some methods of concrete repair can make it difficult or impossible for your employees to do their job. With polyjacking, the concrete repair can be done in a short amount of time, with little disruption to the workplace. 

industrial concrete repairConcrete is a strong and durable material, but damage can occur from machinery, foundation issues, and water problems. Polyjacking.com and the team at Pro Foundation Tech can restore the concrete in your industrial setting. Cracked and unlevel concrete can cause injuries to people and damage to equipment, so you must have it repaired as quick as possible.

The Need to Repair Concrete

As stated above, damaged or deteriorating concrete can be risky for inventory, machinery, and people. The structure itself can be unstable and unsafe, not to mention problems that can occur with utilities located underneath the slab. Your products can be damaged, time may be lost to injury, and equipment may need to be repaired or replaced. 

The pros at Polyjacking.com can repair your concrete, restoring the stability and safety of the work environment. We work closely with you to make sure everyone knows what to expect and there are no surprises. Our repairs take less time than other methods and provide a long-lasting solution for our industrial concrete repair needs.

The Benefits of Polyjacking for Industrial Concrete Repair

It’s possible that you’re not familiar with the term “polyjacking”. This method of concrete repair has been used by municipalities and Departments of Transportation for years and is quickly becoming more popular in other applications, both commercial and residential. 

Polyjacking uses a polyurethane foam that expands below the concrete surface, raising the slab and restoring the strength and stability of the area. The polyurethane foam has a compressive strength of 500 psi. This compressive strength is more than enough to withstand the weight of vehicles, industrial equipment and machinery, warehouse shelving and inventory, and other items that you’ll find in an industrial setting. Polyurethane foam has a lifting capability of 900 tons, allowing it to be used without having to remove machinery or inventory.

Although the foam is strong, it is easy to adjust. The foam can lift the slab to within 1/10 of an inch of the desired height. The foam won’t shrink with time and, since it is water-resistant, it won’t erode, providing stability where other methods may wash away.

The foam expands evenly, lessening the stress on your concrete floor. The foam seals the underside of the slab, filling voids and cracks, preventing water from coming up and damaging the concrete.

In addition to being highly effective, polyjacking is also economical. Polyjacking costs are around 70% less than repouring the floor and is 80% faster than other industrial concrete repair methods, such as mudjacking.

The Polyjacking Process

The process of polyjacking is simple. Small holes around 5/8 of an inch in diameter are drilled into the concrete. The foam is injected into the holes, using only one vehicle to deliver the polyurethane. The foam expands below the slab, filling voids and sealing cracks. The slab is lifted to the desired height and the holes are sealed. The foam cures in about 15 minutes, allowing to quickly get back to work. Other methods can take days or weeks to be completed.

The foam not only fills the voids, but it compacts any loose soil under the slab. This will further strengthen the base that the concrete is built on. The foam is hydrophobic, so it displaces and repels any water it encounters, without being compromised or watered down. The foam replaces any missing sub-base with a strong, solid material that won’t erode or shrink.

Applications for Industrial Polyjacking

We have experience in using polyjacking to help a wide variety of locations and applications. Some of the ways we’ve used polyjacking to help in industrial settings include:

Contact the industrial concrete repair experts at Polyjacking.com. We can help you in the Kansas City area and throughout the country. We look forward to helping you restore your concrete’s strength and stability.

Leveling a Floor with Polyjacking

The Polyjacking crew recently leveled floors at Phenix Label Company in Olathe, KS. This was the second time we have worked with this organization. The first time we lifted some aisles in their warehouse that had settled due to poor soil compaction. This time we worked in another area of their building that had also had some concrete settling due to poor soil compaction.

We worked over the weekend, so we didn’t interfere with the company’s production schedule. Also, Phenix Label Company did not have to move any of their card stock or labels off of the shelves, as we were able to level the floors without them having to remove anything. They stated that this alone saved them thousands of dollars. 

The first phase of the project took around seven hours to complete and the second phase took around four.

We were proud of the results and Phenix Label Company was happy with their new stable and level slabs.

Check out the pictures below to see this project.

Phenix Label Company, Olathe, KS

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Polyjacking.com Video

KU Edwards Campus Repair

The professionals at Polyjacking.com were recently called in to help with some floor leveling repairs that were needed on the campus of KU Edwards in Overland Park, KS. The campus was opened in 1993 and offers programs for undergraduates, graduates, and certificates along with professional and continuing education courses.

Floor Leveling and Void Filling on KU Edwards Campus

We were called in to take a look at an unlevel floor in one of the on-campus buildings. Upon inspection, we discovered that the floor needed to be raised by an inch due to voids that had formed under the building that had caused the floor to sink. The voids were around five feet below the surface and caused by a broken water line. Our experts leveled the floor and filled the voids, providing a stable foundation for the building and a safe environment for students and faculty members. 

Please view the gallery below with some pictures from the work site. If you have any questions or would like more information, please contact us at Polyjacking.com.

KU Edwards Sunken Floor

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April Showers Bring May…Showers

Pretty much our entire service area has been the victim of non-stop rains and long-lasting flooding this spring. This weather is taking a toll on buildings, roads, fields, and people. The rain has to come to an end, eventually, right?

The Weather’s Impact on Concrete Slabs

You can do everything right when it comes to downspouts, gutters, and other drainage solutions, but when it rains this much for this long, every system can be overwhelmed. If you already had a water issue, the problem can be even greater.

rain can damage concrete slabsWhen the ground becomes as wet and saturated as it has this spring, bad things can happen to your home or business. Basement walls can begin to bow or lean, due to pressure from the water-logged soil. Foundations can shift or sink as the soil weakens from all the water. Driveways, sidewalks, and patios can sink or buckle. These problems can range from being annoying to being a danger to peoples’ safety.

Small cracks may not seem like a big deal, but water doesn’t take much to be able to enter your home or business. In addition, a crack may be small on the side you can see, but the other side may be much bigger.

You may not have a problem right now with sinking or settling slabs but when the soil dries out, you might. The soil expands when it is saturated, then when it dries out, it will shrink, possibly removing the support your concrete surface needs.

Slabs can sink, not allowing water to drain correctly or causing tripping hazards. Voids can open under the concrete, causing the soil to wash away even more, creating dangerous situations.

If you suspect that your concrete is being damaged by rain problems, you don’t want to wait. The damage won’t heal itself and the needed repairs will only take more time and money the longer they go undone.

Polyjacking Solutions Work the Best

Fortunately, you have options available to help restore your concrete’s stability and strength. Some options are better than others, so make sure you take the time to choose the one that will provide you with the best benefits.

We believe that polyjacking is the answer for many types of concrete problems. In this method, polyurethane foam is injected beneath the slab. The foam expands, lifting the concrete to within 1/10th of an inch of the desired height. In addition, the foam is water-resistant, so it won’t wash away like the slurry used in mudjacking. The foam hardens and seals the bottom of the concrete, preventing any cracks from allowing water to seep through and filling any voids below the surface. The expanding foam also compacts any loose soil that may be under the slab.

The foam is lightweight (about 3-5 pounds/cubic foot) compared with mudjacking grout (over 100 pounds/cubic foot). The added weight of mudjacking can cause problems down the road as it combines with the weight of the concrete and whatever traffic is using the surface.

The installation process is another benefit that polyjacking has over other methods. In mudjacking, the holes that are drilled into your concrete are 3 inches or bigger in diameter, whereas the polyjacking holes are only 5/8″ wide. No heavy equipment is needed, so your lawn won’t be driven over with tractors and trucks and the area won’t be full of construction pieces. The foam takes about 15 minutes to cure, so as soon as that’s done, you can use the slab. Other methods may require days or weeks to allow you to use the concrete slab.

Stay Solid

Don’t let Mother Nature’s temper tantrums damage your concrete slabs. Let us keep your driveways, patios, sidewalks, and more level and strong. Contact us to learn more about how polyjacking can help you and your home or business.

Can I Polyjack in the Winter?

polyjacking in the winterWe won’t lie, the winter is usually a slow time for us. People get busy with family activities, dealing with the weather, and frankly, just hibernating. Also, people may not know that they can polyjack their concrete during the winter months. We understand, there are a lot of winter days where outdoor activities are the furthest from our minds.

There are several reasons why you may want or need to have your concrete leveled. If the problem is dangerous or damaging your house or business, or you’re looking to sell the property, you may not be able to wait until the weather warms up. The reasons may override your schedule.

Is It Too Cold to Polyjack?

The temperature does factor into the success of your concrete lifting, but you may be surprised by other factors that come into play during the winter.  Extreme cold can cause the ground to freeze solid making the concrete lifting difficult or downright impossible. The frozen earth can hold onto the concrete, sticking to the bottom of the slab and possibly causing the cement to break before it can even be raised.

It is almost impossible to perform mudjacking during the winter. The mud slurry that is used to raise the concrete can freeze inside the pump or hoses, making it impossible to move the slurry. Water is used to remove excess slurry, which isn’t an option in below-freezing conditions. Due to the mess and danger of mudjacking, most projects are done outside, so the winter prevents that from being a common option for concrete lifting during that time.

sports arena concrete repairPolyjacking can be limited by extremely cold temperatures, however, the limits are much less than those that impact mudjacking. The polyurethane foam that is used for polyjacking is created by combining two liquids. These liquids are heated in a temperature-controlled environment, then injected through a heated hose. The foam is largely unaffected by outdoor temperatures, so it can be used effectively in cold weather.

Just Ask!

If you need concrete lifting and aren’t sure if it’s too cold out, just give us a call and ask! As you know, the weather could be below zero one day, then in the 50s the next. We’ll be able to let you know when we’ll be able to safely lift your concrete. We don’t want to cause more problems than you already have, so we’ll be upfront and honest with you in regards to the best time for your particular project.

Contact us today to learn more about polyjacking your concrete at any time of the year. We look forward to providing you with a safe and strong concrete surface.

Polyjacking > Mudjacking

Concrete surfaces such as basement floors, driveways, patios, and more are all impacted by soil movement and weather that can cause damage and weakness. The slabs can also sink if the surrounding soil no longer supports it. These problems won’t repair themselves, the longer you wait to fix the problem, the bigger the issue and damage will be.sunken concrete repair, mudjacking and polyjacking

If your foundation sinks, it can cause damage throughout your business or home. Walls and floors can crack or lean, floors can slope or warp, and doors and windows may not stay open or closed. The worst-case scenario is that the foundation collapses and brings your structure down with it. If the soil that supports the foundation or concrete becomes oversaturated, too dry, or isn’t compressed correctly, it will no longer give the slab the stability that it needs.

Luckily, there are solutions to keep your concrete and foundation stable and level.

Polyjacking and Mudjacking Solutions

Sinking concrete usually occurs because a void has formed under the slab. Unless the void is filled and the soil stabilized, the concrete will continue to sink. If left unaddressed, the repair may have to be done with underpinning, greatly raising the time, money, and effort needed to fix the problem.

When it comes to the task of filling in voids, mudjacking and polyjacking both are up for the job. Mudjacking uses a mud slurry to fill the void and lift the concrete, whereas polyjacking utilizes a polyurethane foam to fill the void. In both methods, holes are drilled into the concrete above the void and then the slurry or foam is injected, filling the cavities below the concrete. The slab will be lifted to a level plane and the drilled holes will be filled. Mudjacking uses bigger holes than polyjacking (3-4″ compared to 3/4 to 1″).

Both forms of concrete lifting can be used for a variety of concrete surfaces including foundations, sidewalks, warehouse floors, tennis courts, and swimming pools.

Pros and Cons of Both Concrete Lifting Solutions

Though both methods are similar at face value, there are some pretty big differences between mudjacking and polyjacking.

Mudjacking Pros

  • polyjacking vs mudjackingComparatively inexpensive
  • Time-tested
  • Naturally occurring materials

Mudjacking Cons

  • Doesn’t fill the void completely
  • Short-term results that have to be repeated every couple of years
  • Slurry material is 30-50x heavier than polyurethane
  • Slurry material is prone to erosion
  • Large holes must be made in the concrete
  • The slurry can take days to set and hardenpolyjacking filling in a void

Polyjacking Pros

  • Long-lasting results
  • Lightweight materials
  • Polyurethane foam density fills the voids
  • Soil mixes with the foam to bond securely and gains strength
  • Small injection hole
  • Doesn’t wash away
  • Able to adjust leveling to within 1/100″
  • Polyurethane foam sets within 15 minutes

Polyjacking Cons

  • Costs more than mudjacking
  • Not as well known

Polyjacking.com Swears by Polyurethane Injections

We want to offer the best repair methods to our clients. We have been using polyjacking for so long that we coined the name! In the past, only commercial properties and municipal projects used polyjacking, but we have learned over the years that it is a great solution for residential repairs, too.  We’re dedicated to providing the residential and commercial owners an affordable and lasting repair for sinking and damaged concrete slabs and foundations.

We know that you don’t have the time to have your place torn up with heavy equipment and then having to wait for the slab to be ready to be used. Polyjacking uses only one truck for the foam and the slab is ready to use within 15 minutes of completing the injection. We won’t tear up your landscaping or disrupt your business while getting your slab repaired. You can rest easy knowing that your concrete will be stable when it comes to sinking, heaving, or cracking.

Contact the concrete lifting experts at Polyjacking.com to learn more about how our polyurethane foam can lift your concrete and provide you with a stable and strong surface, protecting your property, equipment, and people.

 

Rain, Rain, Go Away

rain and floodingMost of the service area covered by Polyjacking.com has had a lot more rain this summer than usual. In addition to ruining a lot of outdoor plans, the rainfall may have wreaked havoc with the foundation of your home or business.

If your building wasn’t flooded, why should you be worried about the amount of rain in your area?

Water and Soil

When there is a lot of rain, it has to go somewhere. Some of it may run into storm sewers or creeks or other planned run-off areas. Most of the time, though, it goes into the soil until the ground is saturated. The water-soaked soil can cause problems for concrete slabs and foundations.

Hydrostatic Pressure

When the soil is oversaturated, it can exert a tremendous amount of pressure on its surroundings. This is called hydrostatic pressure and it can damage a foundation wall completely. If the foundation of your building is under the strain of hydrostatic pressure, the walls may begin to bow or lean. Walls and slab floors may show cracking as the soil and water pushes against the rigid concrete.

Erosion

Water will take the path of least resistance and can erode the soil around it. When the soil gets washed away, it removes the support from around the foundation or slab. Voids can open underneath the concrete, allowing the slab to sink or crack.

Flooding

If the rain falls too fast or the ground is saturated, the water can flood buildings or enter cracks no bigger than a hair. Water can weaken concrete and put your slab or building in danger.

Water Damage Prevention

There are steps you can take to help keep your home or business dry. You can make sure that your gutters and downspouts are clear and emptying at least 10 feet from the foundation. In addition, companies like Pro Foundation Technology, Inc. can provide you with waterproofing techniques to keep the water out of your building.

Surface Drainage

Some options that can help with surface drainage include drywells, gutters, and French drains. It is important that you have good surface drainage or the water you keep out of your building will just come right back, trying to enter your foundation.

Exterior Drainage

To properly install exterior drainage, the outside of the building will have to be excavated, exposing the footing. Most reputable contractors will roll on or spray a polymer waterproofing product. A drain pipe system should be installed for continuous drainage. The drain can empty to a sump pump system or to daylight.

Interior Drainage

One of the most important parts of a waterproofing system is the implementation of a sealed interior drain tile system. Since the system is underneath the foundation, it is important that it is installed correctly from the start. Cracks in the walls and floor will need to be sealed with epoxy or polyurethane.

Sump Pump System

A sump pump system can move water out of the building, keeping water from flooding the structure. The system consists of a sump pump, a sump pit, and we recommend a battery back-up sump pump.

My Slab is Damaged, Now What?

industrial floor repairSo after all of the rain this summer you may be facing a damaged concrete slab or foundation, so what can you do? Before you call in someone to have the slab torn up, contact the experts at Polyjacking.com. We will come out and look at your property and determine if polyjacking is the solution you need. Polyjacking a slab is a LOT cheaper than destroying it and replacing the concrete.

The process is relatively easy and doesn’t require heavy machinery. Small holes are drilled in the concrete and polyurethane foam is injected under the slab. The foam expands, lifting the concrete and filling in any voids and cracks underneath the slab. The foam is water-resistant, so it won’t erode and the foam compacts the soil, making it more stable. By the time the equipment is removed and the area is cleaned up, you can use the slab. Curing time is about 15 minutes, so you won’t have to wait long to get back to business.

Contact the pros at Polyjacking.com to learn more about how using polyurethane foam to repair your concrete is the most cost-effective and long-lasting solution available.

 

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