Background
Our customer is a highly regarded contractor operating in the southern California region. They specialize in overseeing facility upgrades and new construction projects for a diverse range of building owners and clients. They were contracted by a leading transportation service provider to help with a critically urgent situation in one of their facilities.
The Problem
A fire riser line had malfunctioned in the client’s facility, releasing a high volume of pressurized water beneath one of its maintenance bays. This caused water and debris to shoot through fractures in the concrete, elevating the concrete slab by 4 inches.
After shutting off the water and conducting a facility inspection, the city inspector deemed the site unsafe and issued a red tag notice. The inspection revealed that the high-pressure water had created voids across the slab and localized footings had been undermined. Both issues posed a serious threat to the structural integrity of the building.
Repairing the facility became an urgent priority. The compromised state of the building left our customer with the pressing need to restore operability, as their client was incurring substantial daily losses in operational costs while shutdown. The downtime not only jeopardized the financial interests of the contractor but also posed a risk of service delays.
The Alternative
Our client assessed the situation and considered several options. The primary alternative involved a hybrid approach that would include demolishing the concrete slab in areas where voids had formed beneath the maintenance bay. Subsequently, helical piers would be installed beneath the compromised footings to stabilize the building. This method was not only expensive but also time-consuming. Demolishing the slab or foundation would necessitate excavation, soil recompaction, rebar installation, and the pouring of new concrete.
This entire process would require structural engineering drawings, multiple city inspections, and permitting. The same would apply for the installation of helical piers. All these steps added significant costs to the facility repair. This solution was not favored, as obtaining the necessary structural drawings, permits, and city inspections would take months, leaving the client exposed to the financial risks associated with prolonged operational downtime.
The Geobear Solution
Geobear mobilized to the site within 24 hours to conduct an inspection, review available information, and walk the project site with the client. Subsequently, Geobear devised a plan, beginning with enabling work to identify the problem. This involved determining the depth and extent of voids underneath the slab, utilizing dynamic cone penetrometer (DCP) tests. Following the completion of these tests, Geobear’s expert engineering teams analyzed the data and formulated a treatment plan aimed at restoring the building to a viable state for use.
Results
Geobear crafted a tailored treatment plan that precisely addressed the client’s needs. Initially, we focused on resolving the issue of voids beneath the concrete slab. We developed an injection plan, utilizing Geobear’s Void Fill solutions to address the affected areas. This approach ensured the maintenance of a structurally stable concrete slab without the need for complete removal and replacement.
The second concern involved the footings affected by the fire riser failure. Geobear implemented its globally recognized Ground Improvement solution to densify the areas surrounding the footings. This process rendered them stable and firm, effectively repairing and reinstating the structural integrity of the impacted soils. This approach not only saved time but also proved cost-effective compared to industry standards like helical piers, which would have required months for design and city approval
