What to Have Done with Your Sinking Slab and Why

Transcription

1 What to Have Done with Your Sinking Slab and Why

2 Published by: Foundation Supportworks, Inc Cary Circle Omaha, Nebraska st Edition Foundation Supportworks, Inc. All Rights Reserved. Reproduction of text or images in whole or in part without the express written consent of Foundation Supportworks, Inc. is not permitted and is unlawful according to the 1976 United States Copyright Act. 1

3 INTRODUCTION When confronted with having a concrete repair project completed, most people want to know what a foremost expert in the field would do to their own home. The intention of this booklet is to give you all the facts and ask all the questions you should be asking when undertaking a concrete leveling project. We ll present what is available, explore the advantages and disadvantages, and discuss why they are important. As with any choice in products and contractors, some are not what they promise, and it may be what you don t know that creates a problem for you if you purchase it. We hope you get value from this information no matter what you decide to do with your project. 2

4 Here are some good reasons: 1. The problem will get worse. Once a slab is cracked and sinking, it simply won t get better with time. In fact, it only gets worse, and as it gets worse, guess what? The solution costs more. 2. Resale value. Who wants to buy a house with an unlevel driveway, a stoop pulling away from the house, or floors that are cracked and sinking? Nobody. 3. Appearance. Concrete that is out of level can often cause ugly cracks not only in the slab itself, but also in any structure that is resting on top of that slab. That means cracks in brick, drywall, plaster, or any other material the structure is made from. 4. Safety. Have you ever taken a walk on a sidewalk and tripped over a section of concrete that was a different level than the rest? Those trip hazards can be dangerous and open you up to unwanted liability. 5. Water intrusion. Cracks in a concrete slab allow elements from the outside, inside. Cracks let in water, or at the very least moisture, which can damage your living space in a variety of ways. 6. Pooling water. As concrete cracks and settles, it creates a perfect environment for water to pool, and what happens to that pooled water when it becomes cold outside? That s right, ice forms, causing more safety concerns. 7. Structural damage. As a concrete slab begins to crack and settle, the structure above will crack and settle as well. This can cause doors to stick, windows to bind, and other structural damages throughout your home. 3 Sometimes when we live with a problem long enough, we can almost forget that it s there. But make no mistake, concrete that is out of level won t fix itself, and over time the additional problems and damages become more and more serious and costly. Doesn t it make sense to fix it now?

5 1 The problem will get worse 3 Appearance 7 Structural damage 4 Safety 5 Water intrusion 6 Pooling water 2 Resale value 4

6 You re Going to Pay for It Whether You Fix It or Not Consider this. We are all going to sell our homes one day. And when we do, the buyer will hire a home inspector to examine the condition of your home, and you will also be required to complete a disclosure form explaining any defects with the house. Let s face it, the damages caused by a settling slab are obvious, unattractive, and scary, so there s no hiding. It s simply unavoidable that the home inspector and potential buyer are going to know about the settling slab problems in or around your home. Will they say, Aww shucks, don t you worry about that. We ll take the problem off your hands and deal with it ourselves!? Not likely. In fact, they will probably walk away, and go look at the hundreds of other homes for sale out there. If they do still want your home, they will either make you fix the problem before they buy it, or they will take the price of the repair off the price of the house. There is no escape. So whether you get your settling concrete problem fixed now and enjoy the peace of mind for you and your family while you live there, or you don t, you are still going to pay for it -- and maybe more later as the problem gets worse. So, if you are going to pay for something whether you get it or not, doesn t it make sense to get it now? 5

7 When we are talking about slab settlement, we are talking about the concrete slabs that can be found in a number of areas in and around your home. These may include: Interior Floor Slabs Driveways Sidewalks Patios & Pool Decks Stoops & Porches Additions Each of these areas may sink and settle for different reasons, but before we can talk about the causes of slab settlement, it s important to first understand the process of how concrete is poured. Once these basic steps for concrete placement are clear, the reasons for why the concrete settles will be very apparent. So let s get to it. 6

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9 Basic Steps for Concrete Placement Site is prepared. The area where the concrete is poured will be cleared of grass, debris, rocks, etc., and the site is usually dug down about 4. Forms are set. Forms, typically made of wood, are set to act as a temporary mold when the concrete is poured. This approach is used when pouring concrete for driveways, sidewalks, patios, and so on. For the slab floor in your home, the footings and foundation walls serve as the form. Concrete is poured. Sometimes rebar is placed in a grid pattern to reinforce the strength of the concrete. However, this is very uncommon in older homes and almost never occurs when pouring concrete for sidewalks, pool decks, patios, and driveways. Concrete is then poured into the forms on top of the soil and is leveled. Concrete is finished. The surface of the concrete is finished using tools such as trowels and brooms. Concrete cures. The concrete rests and begins to cure (harden). This process takes several days or weeks. 8

10 WHAT IS SLAB SETTLEMENT? Simply stated, slab settlement is the movement a concrete slab experiences when the soil below can no longer support the weight of it. You may be asking yourself, Hey, the soil used to support my [driveway, patio, garage, slab floor] just fine. So what changed?! Most likely the soil changed. And while there are many reasons the soil may change underneath your concrete slab, let s focus on the three most common reasons: 1. Changes in the soil s moisture content 2. Wash-out of soil under the slab 3. Poorly compacted fill soil 9

11 Changes in the Soil s Moisture Content You probably noticed in Step 3 of the Basic Steps for Concrete Placement we mentioned that concrete is poured into the forms on top of the soil. So let s talk about soil and its relationship with moisture. Two very common soil types are sandy soil and clay soil. Sand Moisture does not have a big effect on sandy soil. When sand gets wet it doesn t expand in size, and when it is dry it doesn t shrink. But sand does wash out (more on this later!) Clay When clay is wet, it holds onto the water and expands in size. When it is dry, it shrinks. Look at this sample of moist clay soil. When this soil has been allowed to dry out, even the naked eye can see how much the soil shrinks. Imagine how dramatic this is when several feet of clay soil exists below your concrete slab -- whether it be your driveway, patio, or beneath the concrete floor in your home! Soil can dry out for several reasons, including drought conditions, tree roots drawing valuable moisture from the soil, and leaking HVAC systems under your floor slabs. In any case, as the soil beneath your concrete slab shrinks in size, it creates an empty space for the slab to settle into. The result? Cracked and unlevel concrete. 10

12 Wash-out of Soil Under the Concrete As water moves beneath your concrete slab, it can wash away the soil that s supporting the weight of the concrete. This can be caused by plumbing leaks, erosion, large rains, and a multitude of other reasons. We mentioned earlier that sandy soils are not typically affected by changes in moisture content. However, if there is a path for water to flow underneath a concrete slab, sandy soil, as well as other soil types, can flow right along with that water from beneath the concrete. Regardless of the reason, over time with nothing to support the concrete, the slab will begin to sink or cave in. 11

13 Poorly Compacted Fill Soil During the construction of a home, driveway, patio, or sidewalk, soil is commonly moved around or spread out to get to the desired grade level. Oftentimes, the concrete slab is poured right on top of these fill soils that have been moved around. If the fill was poorly compacted, the fill soil compresses and settles, and a void is created under the concrete. Again, with nothing to support it, the concrete cracks, breaks, and settles into the void. 12

14 Mudjacking Mudjacking is an old fashioned method for leveling concrete. It involves drilling a series of holes throughout the concrete slab, and a cement slurry, or mud, is pumped beneath the slab to fill in the void and attempt to lift the slab. One of the biggest drawbacks to this approach is that the high-pressure grout is very messy. It is not uncommon for the cement slurry to spew out of the holes and cracks in the slab, making a huge mess that is almost impossible to clean up. Mudjacking also requires that large holes (about the same size as a can of soda) be cored in the slab on a 2 to 3 foot grid pattern. These large holes detract from the look of the slab once the job is complete. Another thing to consider is that the cement slurry used for mudjacking is heavy, (weighing in at a whopping 120 pounds per cubic foot!) and adds a significant amount of weight to the soil that supports the slab. This additional weight often makes the problem worse than it was to begin with and causes the slab to sink even more in the future. The cement slurry in mudjacking also takes several days to cure, meaning that you can t drive or walk on it for several days after it s installed. 13

15 Large 2-3 holes cored throughout slab Multiple holes in small area detract from visual appeal of slab Cement slurry can create splattered mess on home belongings 14

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17 Concrete Replacement In order to replace concrete, the existing concrete slabs must first be removed. Typically a jackhammer is used to break the existing concrete slabs into pieces. And then all of those chucks of concrete are hauled away. In the case of an exterior slab, like a sidewalk or driveway, heavy equipment (such as a backhoe or skid steer) is often used to remove and haul the concrete debris away. This equipment can cause major damage to the lawn and landscaping. In the case of interior slabs, all of the home furnishings, floor coverings and interior partition walls must first be removed. Then a new floor is poured and allowed to cure for at least two weeks. Then interior partition walls can be re-built, floor coverings re-installed, and home furnishings brought back in. This solution is obviously disruptive and expensive, but the real problem is that it doesn t address the issue. The concrete slab isn t the problem; the soil supporting the slab is the problem. When you install a new concrete slab over the same troublesome soil, you can expect your new slab will sink just like the old one! Another problem that people often forget to consider is that the color of new concrete doesn t match the color of the original concrete. This creates a major eye sore around your property. Additionally, it takes several weeks for new concrete to cure, meaning that you cannot drive or walk on it for several days or weeks after it s installed. 16

18 PolyLEVEL System The PolyLEVEL System is a state of the art approach to repairing sinking concrete. PolyLEVEL takes the original concept of mudjacking and combines it with modern knowledge and technology. Rather than using a mixture of concrete and mud, this method utilizes high-density polymers to raise slabs back to a desired level. This is done by drilling small holes (smaller than a penny) in the slab and then specially designed equipment is used to inject structural grade polymers into the void. After the void is filled, the expansion of the polyurethane allows for a precise lift and stabilization of the slab. 17

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21 ADVANTAGES OF POLYLEVEL Less holes and smaller holes than other repair options. Holes in the slab are virtually unnoticeable once complete. Plus, there are no mismatching concrete colors. Lightweight. Less than 4lbs per cubic foot compared to 120lbs for concrete or mudjacking! Quick cure time. PolyLEVEL can be driven on within 15 minutes after installation. Material is waterproof and will not wash out beneath the slab in the future. High capacity lifting strength. Typical lifting force ranges from 2,000 to 4,000 pounds per square foot. In other words, it can lift very heavy structures! Reduces trip hazards and restores property value. Environmentally friendly material that will not rot or deteriorate underground. 20

22 SLAB REPAIR APPLICATION CHART Choosing the Right System Based on Your Situation and Goals Solution Condition PolyLEVEL Replacement Mudjacking Ready to support traffic in 30 minutes or less Lightweight material Waterproof subgrade that will not wash out Clean installation No dust, grout overflow, or concrete splatter Uniform appearance Minimal patchwork or discolorations Addresses thin / brittle and severely broken slabs Precise lifting capability (reduced risk of over lifting) Long-term warranty 21

23 DID YOU KNOW? Engineers and architects across North America trust the PolyLEVEL technology so much that they regularly specify it to support major interstates, highways, and commercial structures? Roads & Bridges Grain Bins & Other Heavy Structures Industrial Buildings & Warehouses Railroads & Infrastructure Repairs 22

24 APPLICATIONS FOR POLYLEVEL There are a wide variety of applications where PolyLEVEL is the perfect solution to repair sinking concrete. The following are examples of some of the more common uses. It is common to find driveways that have settled in comparison to the garage floor. PolyLEVEL can easily lift this concrete, making the transition from the driveway to the garage smooth to drive on. 23 Before

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26 Settling sidewalks near and around your home can pose significant trip hazards for those who walk on them on a daily basis. The PolyLEVEL system can quickly eliminate these trip hazards without the headache of removing and replacing the concrete. 25 Before

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28 It is common to experience concrete settlement on patios and pool decks. Oftentimes, the soil surrounding the pool walls is only lightly compacted out of fear of causing damage to the pool walls. Unfortunately, over time that poorly compacted fill compresses, causing the concrete that surrounds pool deck to settle. Because PolyLEVEL is both lightweight and won t result in mismatched concrete colors, it is the perfect solution for patios and pool decks. 27 Before

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30 Often, portions of the brick facing of a home sit directly on the front stoop. As the stoop begins to settle, so does the brick facing, as you can see here in the separation between the window framing and brick façade. As the power of PolyLEVEL lifts the stoop, these cracks and gaps begin to close, improving the overall attractiveness of the home. Settling stoops can also create dangerous trip hazards for those entering the home. PolyLEVEL easily creates a level surface between the stoop and entry level of the home. 29 Before

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32 A porch is often one of the first things a person sees when visiting or entering a home. You can see how easily PolyLEVEL fixes trip hazards and enhances the beauty and impression a person has of a home. 31 Before

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34 The exterior steps of a home are utilized by both the home s inhabitants and guests every single day. Doesn t it make sense to make sure they are safe and attractive-looking? PolyLEVEL can close cracks, fix gaps, and raise the position of the steps back to their original elevation. 33 Before

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36 When interior floor slabs, such as garage floors and the concrete floor on the lowest level of your home, begin to settle, there are very few viable options. Many first turn to concrete removal and replacement, but quickly realize the major disruption, expense, and time commitment is overwhelming. The good news is that PolyLEVEL can easily raise these floor slabs quickly and with minimal disruption. 35 Before

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38 37 Before As concrete slabs settle, any structure on top of that slab settles right along with it. In this case, a small shed was placed on a concrete slab. You can see the gap that was forming between the shed and the home itself. Once PolyLEVEL was installed to raise the settling slab, the shed was raised right along with it back to its original position.

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40 39 THE POWER OF POLYLEVEL MORE BEFORE AND AFTER EXAMPLES

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42 WHAT DO I DO NOW? To get your concrete slab repaired, you ll need to know exactly what YOU need at your home. Finding out is simple contact your local PolyLEVEL dealer if you haven t already. You can find your local dealer by visiting You can expect a trained, concrete leveling expert to come out to your property for a complete inspection, consultation, and a free written proposal including cost. Then you can have the work completed and feel good knowing your slab has been stabilized. 41

43 WHO IS SUPPORTWORKS? Supportworks is a leading designer, manufacturer and distributor of foundation stabilization and leveling systems for residential, commercial and industrial structures around the world. While the words integrity and quality are used by most these days, Foundation Supportworks is a special company where these virtues are reflected in everyday decision making and behavior by our talented and dedicated staff and network of independent dealers throughout North America. The PolyLEVEL dealer network consists of more than 100 of the most experienced concrete leveling contractors in North America. Training our dealers is a vital function at our company, and we host literally thousands of individuals at our training events each and every year to ensure best practices for our dealers and their employees. Purlift, Your local PolyLEVEL dealer may have given you this book. Photo Contributions Provided By: 42

44 There are 110 million single family homes in the United States and Canada - each one surrounded by and relying on a concrete slab to hold up the home s promise to its occupants. But what if the slab is failing? Can it be fixed? How? As with any problem, there are a number of approaches to a solution - some good ones, and some not so good ones. This book brings you the collective wisdom of hundreds of concrete leveling experts who restore integrity to homes like yours everyday. This book is full disclosure for your consideration.