Initial Assessment

The management team at a corn syrup plant faced significant challenges with sinking concrete slabs supporting critical infrastructure, including water tanks and raw material tanks. The uneven slabs posed risks of tank instability and potential structural failure. A geotech contractor was engaged to perform void filling and stabilize the affected areas, ensuring a solid foundation for plant operations.

Proposed Solution

The technical team recommended using AP Lift 475, a two-component polyurethane foam that is ideal for void filling and slab stabilization. This material was selected for its high compressive strength, controlled expansion, and ability to effectively fill voids while providing robust support for heavy loads. The approach ensured minimal disruption, as it required no extensive excavation.

Procedures

1. Established a grid pattern to guide the placement of injection points in the affected areas beneath and around the water and raw material tanks.
2. Drilled holes through the concrete slabs at predetermined injection points to access the voids beneath.
3. Injected AP Lift 475 polyurethane foam into the drilled holes to fill voids and stabilize the soil beneath the slabs, ensuring comprehensive void coverage.
4. Patched drilled holes to restore the surface integrity of the concrete slabs.

Results

The void-filling project at the corn syrup plant was a success. The application of AP Lift 475 effectively filled all identified voids, stabilizing the concrete slabs and restoring a solid foundation. The stabilized areas now securely support the water and raw material tanks, eliminating concerns about sinking or tipping. The facility can resume full operations with confidence in the structural integrity of the tank foundations.

Want more information on geotech products?