Polyurethane Foam Concrete Lifting Repair in Middletown, VA

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    Challenge: Cracked and Shifting Slab at Belle Grove Maintenance Facility

    The Belle Grove Maintenance Facility in Middletown, VA, had long been operational when significant problems arose with its concrete floor. Deep cracks and shifting had created uneven surfaces, posing safety risks and threatening the building’s foundation. As the floor continued to settle, more damage was expected. The National Park Service (NPS) sought solutions from several contractors. Replacing the slab was an option, but it would be costly and cause long disruptions. Temporary fixes were also considered but wouldn’t solve the core issue. LUX Foundation Solutions provided the ideal solution: injecting high-density polyurethane foam to fill voids, lift the slab, and seal all cracks with Polyflex, ensuring long-term stability and protection against future damage.

    Cracked and shifted concrete slab showing uneven surfaces and damage that needs concrete repair in Winchester, VA.

    Solution: Polyurethane Foam Concrete Lifting in Middletown, VA

    We implemented several systems to resolve the concrete slab issues at the Belle Grove Maintenance Facility:

        1. Assessment of the Slab Using a Precision Meter
          We first assessed the extent of the slab’s shifting using a precision meter to identify the areas that required lifting.
        2. Drilling Strategic Holes
          Small holes were drilled into the slab to prepare for the foam injection. These holes were strategically placed in the most affected areas.
        3. Injecting Polyurethane Foam
          High-density polyurethane foam was injected through the drilled holes, which expanded to fill the voids beneath the slab. The foam lifted and leveled the concrete to its original position, providing a stable foundation.
        4. Monitoring Slab Movement
          We used a dial indicator to monitor the slab’s movement during the foam injection, ensuring precise leveling and optimal results.
        5. Sealing Cracks with Polyflex
          Once the slab was stabilized, we sealed all cracks with Polyflex, a silicone-based sealant that prevents moisture from entering and causing future damage.
        6. Clean-Up
          After the repair work was completed, we cleaned up the site, removing all debris and ensuring the facility was ready for immediate use.

      Outcome: A Stable and Reinforced Foundation

      The Belle Grove Maintenance Facility has a stable, level, and safe concrete slab. The polyurethane foam concrete lifting ensures that the slab will remain stable for years to come, and the Polyflex sealant will protect it from future cracks and moisture damage.

      Cracked and uneven concrete slab before foam concrete lifting in Strasburg, VA. Level and stable concrete slab after foam concrete lifting repair in White Post, VA.

      Need Concrete Repair Solutions?

      LUX Foundation Solutions specializes in polyurethane foam concrete lifting, crack sealing, and foundation stabilization. If you’re interested in learning more about our services or want to speak with one of our experts about your project, contact us at  540-508-8587 or complete our online form for a free estimate with our team today.

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