Category Archives: Polyjacking

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. 

 

 

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 a Bridge Approach

The team at Pro Foundation Tech and Polyjacking.com recently completed a project lifting the slab on a bridge approach. The bridge is located in Butler County, Kansas. Below you can view a gallery of pictures from the project.

Polyjacking has been used by DOTs all over the country for years. The success of the application, combined with the cost and effectiveness, makes it an easy choice for lifting slabs in a wide variety of situations and locations. We’ve worked with residential, commercial, industrial, and municipal applications from Minnesota to Texas and everywhere in between. 

Contact us if you have any questions regarding polyjacking for your projects. 

Bridge Approach

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Lifting a slab for a bridge approach in Butler County, KS

Polyjacking.com Video

Steps Lift

Steps Lifting in Missouri

The crew at Polyjacking.com recently lifted some steps in Missouri. The steps had sunk and were beginning to pull away from the rest of the home. This was not only unsightly but could be dangerous. Additionally, the crack in the steps could allow water to enter the foundation of the home. 

We used polyurethane foam to lift the steps to their original position, protecting the home from damage and the occupants from being injured.

Check out the gallery below to see the difference between before and after.

sunken steps in Missouri

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Driveway Lift

 

Driveway Lift in Harrisonville

We recently lifted a driveway around 6 inches in Harrisonville, MO. One of our clients in Harrisonville, Missouri had a driveway that had sunk a fairly good amount. We ended up using polyurethane foam to raise the sunken driveway slab about 6 inches. The customers were happy to have a level and safe driveway once we were done.

Check out the before and after pictures in the gallery below.

Sunken driveway in Harrisonville, MO

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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.

 

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