How the Concrete Poly Foam Leveling Process Works
Understanding Polyurethane Foam Concrete Leveling & Repair Process
Concrete Leveling With Foam, commonly called foamjacking, is a modern repair technique designed to address uneven concrete caused by shifting or settling soils. This method serves as a foam leveling solution. During the foam expansion process, small injection holes are precisely drilled into the sagging concrete area.
A specialized injection gun is used to deliver a high-density polyurethane material through these holes. The mixture expands beneath the slab, filling voids and raising the concrete to its correct level. The Poly foam method might seem quick and easy, but it has some serious downsides.
The fast curing time can lead to concerns about how well the slab will stay stable in the long run. Even though the drilled holes are filled with concrete, the surface can still look patched up and less attractive.
On top of that, the Poly foam method is expensive. While some claim it lasts longer because it resists moisture and decay, these promises don’t always hold up. Many people feel the high cost isn’t worth it, especially since the foam might not prevent future repairs or the need to replace the slab entirely.
Attempting foam leveling as a do-it-yourself project can present notable challenges. Specialized equipment, such as the injection gun and a seasoned hand, are required to dispense the polyurethane solution and foam evenly and accurately.
The injecting process is intricate and necessitates a precise methodology to avoid inconsistent foam expansion due to the sensitivity to temperature and pressure. Seeking the expertise of professionals skilled in polyurethane work is advised.
Mudjacking Versus Poly Foam Concrete Leveling – Fact vs. Fiction
If you came here because you are interested in concrete leveling methods to raise your sunken concrete slab, you came to the right place. With over 40 years of experience, the Concrete Chiropractor® is here to help you make the right choice when searching for concrete foam jacking near me. We spent years researching this concrete repair method, and although we could offer it, we decided NOT to offer it in our service lineup for concrete raising.
While there may be some very limited circumstances for raising concrete slabs with foam where foam may be applied in commercial repair settings, we do not recommend its use in 99% of the applications.
The risk, liability, recyclability issues, and costs associated with injecting foam offset any minimal benefit to “you,” the customer.
Below are some reasons why we strongly suggest you use a Mudjacking cement grout to raise your concrete, not poly foam.
Concrete leveling using poly foam is a newer process added to concrete raising. A man-made, petroleum-based product, chemically known as poly isocyanate, is injected through a 5/8” hole. The foam then expands, raising the settled or sinking concrete slab.
This differs from the eighty-plus-year-old original process called mudjacking. Mudjacking uses a slurry of earth-based material such as sand, clay, or limestone.
These natural products are mixed into a Portland cement grout. This grout is then injected through holes drilled through a concrete slab roughly the size of a quarter, or
The concrete patio, pool deck, floor, or sidewalk slab will then float back to its original position as part of the patio leveling project.
Advantages of Mud-Jacking Grout for Use in Slab Leveling White Paper
Poly leveling foam is marketed based on claims that the product offers several benefits over traditional Mudjacking. Civil and environmental engineers have scientifically studied these claims. Considering the potential safety hazards associated with slab leveling, rigorous testing is essential.
When the poly foam product claims are evaluated through mathematical and scientific investigation, they are deficient in multiple areas. Furthermore, this method does not require extensive excavation or demolition, which minimizes the risk of debris and subsequent cleanup.
Flammability:
Mud-jacking grouts are non-flammable and do not produce toxic gasses and are generally safe to the surrounding environment. Polyurethane foam-based leveling systems, however, have experienced spontaneous combustion during and shortly after application, illustrating one of the significant hazards of using this polyurethane solution. Most notably, a project in Vancouver, BC, Canada, witnessed this concerning event when poly foam caught fire during curing.
Toxicity:
The study also illuminated the health concerns related to isocyanates, typically found in poly leveling materials. Understanding these chemicals’ hazards is crucial as they can affect both workers and the environment.
Recyclability:
Moreover, the inability to recycle concrete slabs efficiently due to the adherent nature of poly foam suggests a larger carbon footprint and higher costs associated with demolition and debris removal, drawing attention to the environmental hazards of this approach.
The traditional method of concrete repair in NJ and nationwide for sinking concrete, with its over 80-year history, has been mudjacking. This is the only way to raise concrete without the unknown history of poly leveling or Polyurethane foam concrete raising and void filling.
It’s also noteworthy that mudjacking does not suffer from the same moisture resistance concerns that can plague other materials over time. Here at Concrete Chiropractor, we are experienced specialists and one of the original companies in the field of mudjacking and slabjacking in NJ.
Concrete Chiropractor® is a leader in the foundation repair industry in NJ, providing top-tier mudjacking services to remedy sinking concrete, effectively managing moisture and ensuring stability. As part of our commitment to safety and quality in leveling sinking concrete, we attend events like World of Concrete to stay up-to-date with technological advancements that could transform our industry. However, despite the purported advantages of Poly leveling foam, our analysis of the associated risks and safety hazards has validated our preference for mudjacking.
We back our tried-and-true method with our long-standing reputation and our personal guarantee. Concrete Chiropractor is your go-to service provider if you want to raise concrete safely and economically with a reputable company that stands behind its work.
Polyurethane Foam vs. Mudjacking Concrete Raising: Separating Myths and Facts
Poly foam is lightweight and will not cause settlement like Mudjacking grout
Facts show that the main cause of concrete settlement is due to disturbed soils during initial home and building construction and not due to weight. Main building structures far exceed the weight of concrete slabs on grade and are footed on undisturbed soils. These soils generally do not settle. However, concrete slabs that surround a structure such as concrete pool decks, garage floors, patios, porches, and walkways that are prone to settlement failure.
A know fact is the difference of 100 pounds per cubic foot between Mudjacking grout and poly foam is insignificant as undisturbed soils generally support 1500 to 3000 pounds per square foot.
Poly foam is environmentally friendly
Poly-Isocyanate, the chemical name for poly foam is a two-part product consisting of a part A and part B. When mixed there is a chemical reaction. This reaction is known to off gas and generate heat. This poly foam product which has been used for concrete raising has a history of flammability and self-combustion. There are documented cases in which these poly foam fires have resulted in health-related lawsuits and the National Institute of Safety and Health, NIOSH, requires the use of a respirator and gloves along with skin and face protection. The CDC has stated that poly foam has a history of reactions including death.
In addition to separation costs and added recycling costs during concrete replacement, poly foam cannot be accepted at concrete recycling facilities.
Poly foam products have been shown to come with a long-term environmental impact. The use of poly products such as plastic bags, bottles, Styrofoam’s have resulted in plastic reduction and bans. Further use of these products is predicted to come at a much higher financial and environmental cost going forward.
Poly foam does not wash out like mudjacking grout
It is a known fact that poly foam products do no biodegrade and can take hundreds of years to break down. However, tests have shown that a properly mixed and tested Mudjacking grout with Portland cement can withstand long term water resistance. Cements have a time-proven history of durability against weather dating back thousands of years.
The actual concern with all concrete leveling repairs regardless of the product used is to correct all water issues. A down spout discharging next to a slab, roof water, or a lack of drainage from poorly pitched grade will not only result in washout of any base soils but can also increase the possibility of frost damage in colder climates.
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