Eagle Point Power Plant Foundation Settlement Repaired in Westville, NJ

Challenge

Eagle Point Power Plant faced numerous foundation settlement issues. The flooring in the administrative building had settled from 2” up to 5”. The floors in the generator room sunk towards the generator causing uneven floor surfaces and cracks which made equipment moves extremely difficult. Our inspectors also noted additional damage including cracked tile and walls. Eagle Point employees were no longer able to safely use the administrative building due to the uneven floor.

Solution

Eagle Point considered full slab replacement but determined this method would take too long and be too disruptive. In addition, full slab replacement greatly exceeded their budget restrictions.

Eagle Point selected Quality 1st Basement Systems to install the PolyLEVEL® System to raise the concrete slabs across the facility. PolyLEVEL® is a two-part urethane that expands into a rigid foam used to fill voids, stabilize slabs and lift concrete. Once injected through small 5/8-inch drilled “ports” in a slab, a chemical reaction converts the liquid urethane components to a strong, rapidly-setting foam material. In its foam state, PolyLEVEL® is extremely light, weighing two to six pounds per cubic-foot (pcf). Other void-filling or lifting materials can weigh upwards of 120 pcf, adding significant weight to supporting soils which will contribute to further settlement issues. With a typical installed compressive strength of 100 pounds per square inch (psi), PolyLEVEL® can provide the necessary strength to support even heavy loads.

Quality 1st Basement Systems installed 9,800 lbs. of PolyLEVEL® and returned the settled slabs to a safe and stable position throughout the facility. The entire process was completed during normal business hours and the power plant staff was able to continue normal operations. Eagle Point was so pleased with the results, they are currently working to contract with Quality 1st Basement Systems on three other facilities.