CASE STUDIES

To get an idea of what we can do for you, have a look at the following projects.

Sturgeon Bay Boat Launch Void

Problem:

Located on the Bay of Lake Michigan, this boat launch has survived many seasonal changes. Seasonal trends provide high and low
water levels, storm surges and ice shoves. From the surface, this appears to be a private boat launch. However what you see is not
the original boat launch slab. Under this visible slab is the original slab that had settled significantly and a new ramp was poured over
top. For many years, waves have crashed onto the shore line and drained back into Lake Michigan. With every wave more and more
soil was eroded. As the shoreline began to fail, it was built up with additional rip rap. These large rocks created a stronger barrier
against the waves and ice, but did not prevent water from shedding down and under the slabs. The homeowner watched year
after year as more shoreline eroded under the slabs. They knew the slab needed to be supported so they contacted FillRite for a solution

SOLUTION:

FillFoam™ was installed under the boat launch slabs. This material was pumped as a flowable foam. Six holes were drilled through this
thick three foot slab, around five feet apart. The crew started with filling the top of the boat launch and moved down towards the
water. While pumping through the bottom drilled holes, air was escaping through the cracks at the bottom of the launch under
water creating visible bubbles at the surface. While the FillFoam™ was pumped under the slab, the foam started flowing to the other
drilled holes. This process continued until the voids under the slab were effectively filled.

SUMMARY:

616 lbs or 88cu ft of FillFoam™ was pumped under the boat launch. This void project was completed in 2 hours and
the boat launch was ready to use immediately. FillFoam™ is hydroinsensitive, water does not impact how the foam
cures into a solid foam. After FillFoam™ cures, it is inert and will not changes shape. Now as the waves crash onto
the shore, the water can drain naturally, uninterrupted by the foam supporting this boat launch. Unlike the soils
that settled or eroded, FillFoam™ will hold strong and will not wash away. The homeowners are thrilled with this
permanent solution that will now support their property and hold up to the harsh conditions Lake Michigan can
present.

Railway Culvert Fill- Canada

Problem:

FillFoam Canada was approached by a Canadian rail company to assist with the abandonment of old culverts running under their
railways. Old culverts were made of corrugated steel which had begun to fail in certain locations under the tracks. The client wished
to fill these culverts to reinforce the structure ensuring the ground above them would not fail in the future. They also needed to ensure
that water was not able to flow through and continue to erode areas that were already failing. Once these culverts were filled, the
ends would be crushed and buried into the railway embankment.
Client concerns included the following: Traditional methods were time consuming, expensive, and complicated. Traditional abandonment products were not eco friendly and posed challenges during installation. For example, concrete slurry mixtures would “blow
out” during installation, requiring a major cleanup operation. They also require heavy equipment which when operating beside
highways would require extra resources for traffic control and other safety measures.

 

Solution:

FillFoam Canada presented a solution to the client that would provide all the benefits with none of the risks or complications. FillFoam
Canada built a 50 ft injection nozzle and capped the far end of the culvert leaving a single exhaust port. The 50 ft nozzle was placed
into the 75 ft culvert creating an injection point 25 ft from the end. Foam was pumped in from this point until it pressurized the far end
and began coming out of the port. The port was then plugged, and the nozzle was pulled roughly 10 ft back towards the open end of
the culvert. Each time the foam moved 10-15 ft back towards the injection end of the culvert, the nozzle was pulled back as well.
Keeping roughly 10 ft of foam between the open end (injection side) of the culvert and the end of the nozzle. This approach kept the
foam under positive pressure during installation allowing it to fill to the volume of the culvert. Once the foam reached the injection
side of the culvert, the nozzle was slowly removed while the pumps were still running to ensure that any void left behind was filled.
Once removed the pumps were shut down, a process that took roughly 2 hours per culvert.
FillFoam Canada’s approach removed the heavy equipment requirements as the only equipment required onsite was a ¾ ton truck
and trailer. This eliminated the need to shut down one lane of the highway and manage traffic as equipment was moved or
operated. This approach also eliminated concerns related to spills. The cleanup of concrete slurry is a much more involved process as the
product is highly flowable and often a leak leads to many yards of liquid concrete spilling into potentially sensitive areas. Fillfoam
cleanup is extremely fast, safe, and efficient.

 

SUMMARY:

FillFoam Canada put a plan together that successfully accomplished the client’s goal of filling and burying abandoned culverts.
This plan was completed faster and at reduced cost and complexity when compared to the slurry alternatives.

Sturgeon Bay, Seawall Repair

Problem:

Records water levels in Lake Michigan led to voids behind this 100
ft long seawall in Door County. High waters allowed water to wash
up and over the sea wall daily. When this water drains back into
the bay, it brings with it some of the soil under the slab. Without the
support of this soil, the walkway settled.
Because these levels could increase with high winds or additional
precipitation, it was important to replace the eroded soils and
support the concrete.

SOLUTION:
A series of holes approximately 5 feet apart were drilled into the
walkway. FillFoam™ was pumped as a flowable foam into one hole
until foam traveled up through the next hole. This process continued until the complete void was filled.

SUMMARY: This project was completed in 4 hours and required 900 lbs of
FillFoam™ to fill the void that was up to 4 feet deep. This produced
a volume of over 4 cubic yards of foam. This foam filled the void and
displaced the water collected under the walkway. The foam will
not change shape or wash away like the previous soils did.
FillFoam™ can relieve soils of access water, but will not interrupt
the natural drainage of water back into the lake. This lightweight
solution was also strong with over 20 PSI of strength.
After the foam was cured, crews returned to install polyurethane
foam to raise the walkway back to the original height. This project
was completed with a standard capacity FillFoam™ unit installed in
a trailer. 100 ft of hose was used to reach this area with limited
accessibility.

PROBLEM

Milwaukee, Wisconsin- A park pavilion regularly used for youth programming and other activities was awarded a donation for an expansion to
be made on the 1970’s building. During the construction of the addition, the area was backfilled with ¾ crushed stone to prepare for concrete to be poured. A spread footing was built and the framing was constructed for the future wall. Unfortunately, the fill was improperly compacted and could not support the weight of the footing. The project engineers and contractor were concerned that the gravel would also settle under the weight of the slab after it was poured. So they contacted their local concrete lifting and stabilization contractor.

SOLUTION

The concrete lifting contractor team designed a plan to stabilize the gravel and increase the load bearing capacity. This plan consisted of
two parts. The first part was a layer of polyurethane foam to be installed to bind together the loose gravel. HMI HF 402 was chosen because of its unique foam characteristics.
The second and final stabilization technique was to install FillFoam™ to fill in around the stone and lock into place. Precision laser measuring equipment was utilized to monitor for movement and identify when foam was installed until refusal. It was very evident when installing pipes at depth that the lower layers of gravel were not compacted.
Various densities of FillFoam™ were installed throughout the project. Higher densities that were more fluid were installed where further flow was required. This allowed material to flow under the stairwell. In other areas, flow was limited by installing a lower density FillFoam™. With
HMI/FillFoam’s engineering support, the local contractor was able to successfully stabilize the gravel for the building addition.

SUMMARY

1,800 lbs of HF 402 Fast were installed for the top layer. 2,119 lbs equivalent to 8 cubic yards of FillFoam™ were installed into the loose gravel. The next day, crews poured the slab over the top of the stabilized gravel.

PROBLEM

A drink manufacturer facility was in the midst of building renovations when they realized there were many voids beneath the facility. Because this well known bottling plant was held to strict sanitary standards, the floor was washed daily and led to this void under a 20×30 ft area of 4-12 inches in depth. In order to save on
expense and downtime for the factory, they awarded this job to the local void filling company to install to install FillFoam™ under the
factory floor. This allowed them to keep the companies factory floor on its three shift schedule and they didn’t need to move the heavy
equipment.

SOLUTION

Test holes were drilled in various places to see the void in each area. FillFoam™ was safely installed through a 1 inch hose in a
20×30 area. Two different densities of FillFoam™ was installed to complete this void fill project. A total of 800 lbs of FillFoam™ was
installed. The FillFoam™ installation took 2 days in comparison to a week it would have taken with shutting down the equipment,
moving the equipment and removing the current concrete bring in backfill and repouring concrete.
Once installed, the small holes were patched. There was no mess left as the excess FillFoam™ was easily washed down with water or picked up and disposed of that flowed outside of the building while filling the voided area.

PROBLEM

This Midwest church has had drainage challenges since construction. Water shedding off of the building would flow under the slab
as it traveled to the drainage system. This created a channel for water to flow under the slab. Years of water flowing through this
channel eroded the soils supporting the parking. Within the past 15 years the congregation elected to mudjack the void to support the
slabs. Eventually the problem did arise again as the mudjacking grout eroded like the original soils, this time assisted by a leaking
fire hydrant and sprinkler system. Seeking a more permanent solution, the congregation contacted a local contractor for other
options.

SOLUTION

FillFoam™ was installed under the voided slab. The depth of voids ranged from 2-18”, additionally there were up to 4 feet of weak soils
below the slabs. The majority of the holes used to inject FillFoam™ under the slab were from the previous installation of mudjacking
material. This provided a 10 foot grid pattern. FillFoam™ was pumped under the slab until it started to come up through adjacent
holes and along the joints between slabs. The holes were then plugged and more foam was installed. This allowed the foam to
build pressure and flow further. It also helped compact the loose soils and fill the voids under the slabs. FillFoam™ will travel the path
of least resistance. FillFoam™ will not travel out other cracks, joints or holes until enough foam has been installed to build pressure and
push out past the slab.

SUMMARY

68 cubic yards of foam were installed under the parking lot to support the slab. This job was completed within 8 hours
with the Hi-Volume FillFoam™ System. The Church can now be confident that the material supporting their parking lot
will not wash away or interfering with drainage.

 

PROBLEM: Midwest Facility Void Fill

It was identified that there was a failure in the floor drainage of a food production facility. This slow drainage resulted in a major void and multiple pipe breaks. Because this facility was held to strict sanitation requirements, the equipment and floor was washed down regularly. Every time wash down occurred, water would drain into the compromised piping and more fill would wash away. What started with only drips of water and small particles washing away developed into a major problem.
The primary void was 60ft long and was a void size of 4’x4’feet at the worst area. The void ran perpendicular to the main forklift aisle. The worst part of the void was directly under the aisle. As soon as these voids were identified the entire factory was shut down. This factory shutdown cost the plant millions of dollars in downtime and loss of production.

SOLUTION

Prior to any repairs, the void needed to be filled to support the slab and construction equipment needed to install the new drainage system. Through two injection locations, 4,947 lbs of FillFoam material was installed, equaling a volume of 20 cubic yards. The complete void was pumped in 1 ½ hours. Within 24 hours a trench was dug through the cured foam to install new drainage pipes (picture below). Reinforced concrete was poured over the repair site and the plant was re-opened for operation.

SUMMARY

The speed of mobilization from the FillRite team and FillFoam installation helped the plant save significant money and avoid longer downtime.