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Polyurethane Foam Injection Cost-Effective Concrete Crack Solution

Over the past 20 years, much has changed in home construction, from intelligent HVAC systems to new building materials. However, one element of home construction has hardly changed: concrete for foundations, slab floors, garage floors, driveways, and patios. While concrete has no equal, it remains susceptible to shifting, settling, and cracking. Fortunately, repair techniques for cracked or uneven concrete slabs have evolved—significantly.

Gone are the days when cracks and settling within concrete mandated messy, invasive, time-consuming, and costly repairs with traditional pressure grouting or slab jacking procedures. Today, polyurethane foam injection can fix concrete fractures and settlement with little hassle and at a fraction of the historical cost. Adapting techniques from other shared applications, repairers make a series of small holes in the imbalanced flooring or cracks and inject them with polyurethane foam.

Polyurethane foam injection is a two-component, high-strength hydro-sensitive structural polymer that can be used to fill voids and cracks and seal leaks. The foam can also be used to lift warehouse floors and commercial walkways. The material is lightweight but strong enough to support industrial weight as soon as forty-five minutes after application!

Because it’s liquid, polyurethane foam flows into gaps or voids in either the base of the concrete or the top of the soil. The foam consolidates loose and soft soils, a natural consequence of shifting earth and fluctuating moisture density. This solidified base prevents additional movement and can even lift the settled areas of the concrete slabs.  

Polyurethane foam injection, essentially a type of pressure grouting, provides cost-effective repair solutions for cracks in house foundations or warehouse flooring. It requires small holes with diameters rarely larger than 5/8 of an inch, so minimal impact. Any excess foam that seeps out of the holes or seams is brushed away.

The technicians at Carolina Foundation Solutions have seen plenty of changes over a century-plus of work experience in the foundation business. Legacy aside, the company uses the latest technology to address shifting and sinking foundations and flooring. Watching a video of a Carolina Foundation Solutions commercial application of polyurethane foam injection demonstrates precisely how efficient and mess-free the operation is.

After Carolina Foundation Solutions sales technicians assess the problem and diagram the solution, company-trained experts drill a series of small holes. A custom-designed injection gun connected to the supply of polyurethane foam is then placed in each hole. Then, foam is released until maximum pressure is determined. This procedure is repeated at each spot until coverage is complete. A certain amount of foam will seep out of the holes in the flooring as the pressure mounts. This dry polymer foam is swept up with a push broom. After just 15 minutes, the floor can support large machinery, such as a fully loaded forklift or other commercial vehicles.

Carolina Foundation Solutions’ residential repair work looks very similar to its commercial work, obviously on a smaller scale. The polyurethane foam is injected into wall cracks and flooring, driveways, and patios. The foam seals cracks and spreads to solidify loose gravel and soils to prevent future heaving and potential eyesores—and even personal injury caused by tripping over an elevated seam.

Concrete may not have significantly changed in the past century. Still, modern expert repair utilizing polyurethane foam has created a cost-effective, swift solution to cracks and imbalances in foundations, driveways, patios, and other concrete surfaces. A good rule of thumb is that raising and leveling concrete is usually around 50%-80% less than the cost of replacement.

Carolina Foundation Solutions is a family-owned and operated foundation repair company of experts and professionals. For all your foundation repair needs, call us at (877) 770-7050 to schedule a FREE inspection.

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