A Journey Through Innovative Foundation Restoration in Arizona: Rising Stronger

2023-12-07T00:00:00.05Z

A Journey Through Innovative Foundation Restoration in Arizona: Rising Stronger

Recognizing the Significance of Foundation Repair in AZ

When dealing with significant structural issues like a sinking building, the importance of residential foundation repair contractors near you cannot be overstated. In a recent project in Arizona (AZ), a colossal industrial building faced a dire situation—a sinking foundation that posed a threat to its stability and safety.

Assessing the Challenge: The Foundation's Distress

The building, spanning an impressive 300,000 square feet, had experienced a staggering 15-inch subsidence. This unsettling decline was not static; it continued at an alarming rate of over 1/2 inch per month. The consequences were profound—tilt panels showed large gaps reminiscent of a series of leaning bookends, while the floors exhibited worrisome 2-inch gaps and noticeable slopes.

The Complexities of Foundation Repair in Arizona: Soil Composition and Unknown Variables

Situated on solid landfill filled with concrete, asphalt, and dirt, the project encountered a fundamental challenge—the variability and unknown nature of the subsurface. The soil composition, shaped by deep dynamic compaction before construction, added a layer of complexity to the repair process.

Exploring Repair Strategies: Overcoming Subsurface Obstacles in AZ

Initial attempts to gauge the subsurface through a test pile were thwarted by the presence of concrete debris, rendering it impossible to penetrate. The use of micropiles faced challenges due to downward drag caused by surrounding soil friction. These micropiles necessitated deeper drilling, compounded by their non-end-bearing design.

Tailoring a Solution: Repair Protocol and Innovative Techniques

The repair protocol, meticulously crafted, involved a multi-step approach. The team opted for a process involving the pre-drilling of the subsurface using a TEI 350 rotary and down-in-the-hole hammer, subsequently complemented by Supportworks 288 push piles. The strategy further incorporated the application of compaction grouting to reinforce floors and parking areas.

Overcoming Uncertainties: Navigating Reinforcement Variables

The nature of the concrete debris beneath the surface remained uncertain, posing a challenge to drilling. The potential presence of reinforcing steel added complexity, casting doubt on the effectiveness of the drilling equipment in penetrating these subterranean obstacles.

Embracing Methodical Testing: Validating Equipment Performance

To ascertain the efficacy of different drilling methods, multiple test holes were drilled. The comparison between the down-in-the-hole hammer and the top-hammering TEI 260HT drifter revealed the former's superior performance, showcasing its efficacy in navigating challenging subsurface conditions.

In conclusion, addressing foundation repair necessitates a meticulous understanding of the structure's distress, a tailored repair protocol, and a readiness to adapt to unforeseen variables in the subsurface. Stay tuned for the next installment, where we delve deeper into the intricacies of executing a comprehensive foundation repair plan.

Remember, when it comes to safeguarding a building's integrity, seeking the expertise of foundation specialists near you becomes an imperative step towards ensuring lasting stability and safety.

Addressing Foundation Challenges: Restoring a Sunken Industrial Building in Arizona

2023-12-06T00:00:00.05Z

Addressing Foundation Challenges: Restoring a Sunken Industrial Building in Arizona

Excavating the Foundation Heartaches in AZ

In the realm of industrial buildings, structural integrity forms the bedrock of operational success. One such daunting challenge emerged when we encountered a sprawling 300,000 square foot industrial building in Arizona, grappling with a sinking foundation.

Recognizing the Urgency for Intervention

Upon initial assessment, the dire state of the structure was unmistakable. Elements crucial to its stability were perilously close to failure. The joists and girders were on the brink of disconnection, while connections to wall pockets were also compromised. Compounded by a broken perimeter ledger, the building's integrity was under severe threat.

Swift Action and Strategic Stabilization in Arizona

Immediate measures were imperative. We swiftly bolstered the roof and tilt-up walls with shoring jacks to prevent further deterioration. Engaging in extensive exploratory work, test piles were installed, prioritizing the southeast corner, the area most susceptible to movement. To counter the pressing need for support, piles were filled with grout, incrementally elevating the building to redistribute the load – a process vital despite its time-consuming nature.

Strategic Maneuvers and Operational Challenges in AZ

Operational intricacies dictated our approach. Given the unoccupied status of the building, simultaneous interior and exterior work ensued. Meticulously staggering the piles, we sidestepped eccentric loading concerns, strategically mitigating risks. However, logistical hurdles loomed in areas where the foundation stepped down, necessitating external pile installations due to safety considerations.

Unforeseen Hurdles and Mysteries Unveiled in Arizona

The journey to restoration was not devoid of peculiarities. Unexpected interference arose from the landscaping team, inadvertently jeopardizing our excavations by reinstating irrigation during off-hours. Resolving this issue was paramount, compelling us to sever the source line to safeguard the building from further peril.

The plot thickened with yet another enigma. Water inundating the excavated holes from inadvertent irrigation began revealing an inexplicable interconnectedness, spanning over a hundred feet, unraveling an underground anomaly that left us astounded.

As the restoration efforts surged ahead, each discovery unfolded a new layer of complexity, promising more mysteries to unravel in the quest to resurrect this sunken industrial colossus.

Foundation Repair in Arizona: Overcoming Challenges in Industrial Building Restoration

2023-12-05T00:00:00.05Z

Foundation Repair in Arizona: Overcoming Challenges in Industrial Building Restoration

Raising a Sunken 300,000sf. Industrial Building by 15" in Arizona

The task of salvaging an industrial building facing foundational issues involves intricate steps and unforeseen challenges. In the case of this 300,000 square feet property, the foundation repair process uncovered a series of obstacles that demanded innovative solutions and expert intervention.

Addressing Predrilling Challenges and Push Piles in AZ

The initial phase involved predrilling holes for the installation of push piles, crucial for stabilizing the sinking structure. Unexpectedly, some drilled depths revealed openings lacking resistance, posing concerns during the installation of the push piles. Despite the lateral integrity provided by sleeved push piles, the absence of tension connections raised the possibility of pipe sections dropping into voids during installation.

To tackle this concern, a solution emerged: welding each pipe section during installation. This added complexity to the project but significantly bolstered confidence in the pile contiguity, ensuring a more secure foundation.

Navigating Varied Depths and Construction Conditions in Arizona

The depth of some piles reached extraordinary measures, spanning between 200 to 300 feet. Ordinarily, such conditions might trigger worries about pipe section separation. However, the welding technique implemented during installation mitigated this concern, ensuring structural integrity.

The strategy of utilizing dock doors for predrilling proved effective in certain sections. However, limitations arose in areas devoid of these doors, especially near man doors and fire system risers. In these locations, piles had to be installed four inches away from the tilt wall face, presenting unique challenges in the construction process.

Initiating Building Elevation in AZ

Following months of meticulous drilling, the stage was set to commence the building's elevation. Over 100 lifting jacks were positioned for simultaneous lifting, marking a significant phase in the restoration. The initial attempts, while witnessed by a sizable audience, yielded a modest lift of only half an inch in the first few hours. Subsequently, when the onlookers departed, additional progress of a few more inches was achieved.

The lifting process commenced at the building's corner most affected by foundation settlement. However, as progress ensued, signs of stress surfaced in the piles, a concerning anomaly in the restoration process. Upon reevaluation and thorough calculations, it became evident that the initially provided weight of the building was underestimated, prompting the hiring of an external engineer, Tony Polusny PE from Pangolin Structural.

Redefining Load Calculations and Further Pile Installations

With the expertise of an additional engineer, the true weight of the building was accurately determined, necessitating a substantial increase in the number of piles required to support the revised loads. This realization redirected the focus back to extensive drilling and additional pile installations, ensuring the necessary support for the building's structural integrity.

The journey of salvaging this sunken industrial edifice showcases the complexities of foundation repair and the critical role of accurate calculations and innovative techniques in successful restoration endeavors.

Arizona's Landscape and Foundation Work: Challenges and Solutions

Arizona's unique terrain poses distinctive challenges for foundation repair. The arid environment and soil composition can significantly impact the stability of structures, requiring specialized solutions for effective repairs. Residential foundation repair contractors in Arizona must navigate these challenges while adhering to industry standards to ensure durable and lasting solutions for homeowners.

In conclusion, the intricate process of raising a sunken industrial building exemplifies the expertise and adaptability required in foundation repair, emphasizing the significance of accurate assessments and innovative strategies in resolving structural issues.

The ongoing journey of revitalizing this structure underscores the importance of diligent planning, expert collaboration, and adaptability in overcoming unforeseen challenges in foundation repair projects.

Grout and Glory: The Art of Pressure Grouting for Pool Stabilization

2018-06-20T00:00:00.05Z

Grout and Glory: The Art of Pressure Grouting for Pool Stabilization

When it comes to grout and pressure grouting for foundation repair and soil stabilization, the world of construction and pool maintenance is often fraught with misconceptions. Many people mistakenly believe that grouting underneath pools to achieve pool stabilization is impractical, primarily due to the perceived risk of damaging the intricate network of pipes below the pool. However, modern pools, especially those featuring negative-edge water features, demand a high degree of precision and levelness to function optimally.

At Arizona Foundation Solutions, our dedicated team has not only embraced the challenge of pressure grouting beneath pools but has also excelled in this endeavor for numerous years, all without causing any plumbing damage. How do we accomplish this feat? Let's delve into the intricacies of our process, highlighting key steps and techniques.

Precision Matters: The Potholing Technique in Pool Grouting

1. Advanced Reconnaissance:

Our journey begins with a thorough assessment of the pool's structural integrity. Using Ground Penetrating Radar (GPR) location methods, we pinpoint all the reinforcing elements within the pool shell. This critical step allows us to avoid disrupting the rebar reinforcing and any surface irregularities on the pool's interior.

2. Precise Coring:

To maintain the structural integrity of the pool, we carefully core the pool shelf, ensuring that it avoids interfering with the rebar reinforcing. This precise coring process minimizes any potential damage to the pool's structural elements.

3. Potholing for Safety:

Safety is paramount in our process. We excavate potholes to a depth of two feet, ensuring that we steer clear of any existing piping infrastructure beneath the pool. This precautionary measure significantly reduces the risk of damage to plumbing components.

4. Reinforcement Encounters:

As we proceed, we drive our casing to a depth where we encounter refusal. This depth ensures that the ground is stable enough to support the loads of the pool, enhancing its overall stability.

5. Low Mobility Compaction Grouting:

Our choice of grout mix is critical. Instead of opting for an intrusive grouting mix that might pose a risk to pipes, we use a low mobility compaction grouting mix. This choice minimizes the chances of the grout traveling to nearby pipes, safeguarding the pool's plumbing infrastructure.

From Thin Cement to Compaction Grout: Evolution in Pool Repair

In a previous article, "Grouting Smoke and Mirrors Part III: Compaction Grouting," we explored the differences between compaction grouting and thin cement grouting, delving into the intricacies of grout rheology. Successful low mobility grout mixes are designed to minimize travel once injected into the soil. This not only prevents soil fracturing and promotes successful soil densification but also greatly reduces the risk of unintended travel—a crucial consideration when working beneath pools with extensive pipe networks.

Over the years, the teams at Arizona Foundation Solutions have successfully grouted numerous pools, achieving pool stabilization and adjusting pool elevations as needed to ensure optimal performance. This includes pools featuring the challenge of negative edges, where precision and stability are paramount.

Preserving Paradise: The Secret to Safely Stabilizing Pools

In conclusion, pressure grouting for pool stabilization is not only practical but also achievable without causing damage to the essential plumbing infrastructure. By following a meticulous and well-planned approach, like the one employed by Arizona Foundation Solutions, pools can be stabilized, leveled, and ready to deliver years of enjoyment to their owners, all while maintaining the integrity of the pipes below.

Pressure Grouting in Arizona's Pool Repair and Soil Remediation

2018-06-20T00:00:00.05Z

Pressure Grouting in Arizona's Pool Repair and Soil Remediation

This article delves into a complex pool repair and soil remediation project in the arid landscapes of Arizona, where the use of pressure grouting techniques became pivotal. In this collaboration with Alpha Geotechnical, a renowned local soil engineering firm, we tackled the challenging task of addressing a settled indoor swimming pool that had not only damaged lines but also posed a looming threat to the surrounding soil stability.

Challenges and Solutions:

The project posed a myriad of challenges, demanding innovative solutions that hinged on the effective use of grout and pressure grouting technology. Among these challenges was the delicate task of achieving soil compaction near a retaining wall without inducing any undesirable lateral movements. Our team, armed with expertise in grout injection, meticulously controlled the grout slump, preventing unwanted flow into rock drains while maintaining the stiffness necessary to prevent wall displacement. This combination of precision and technique was key to the project's success.

Grout Pumps and Soil Stabilization:

To execute this intricate task, specialized grout pumps and a state-of-the-art grout machine were employed. These tools allowed us to administer grout injection with unparalleled accuracy, ensuring the integrity of the retaining wall and the soil stabilization process. The use of pressure grouting equipment played a pivotal role in achieving the desired results.

Implementation:

With the fill depth plunging to approximately 10 feet below the pool deck, we embarked on a carefully orchestrated plan. We began by verifying the cut fill line by driving the grout casing, ensuring precision at every step. The process commenced with the pressure grouting of the holes nearest to the retaining wall at lower pressures for initial protection, strategically adjusting patterns to safeguard the infrastructure. As we progressed, we increased the pressure for holes farther away, achieving a seamless lift of approximately 1/2" and effectively closing the cracks at the grout line. This precise approach, rooted in the principles of compaction grouting, not only addressed the pool's settlement but also improved soil compaction, all without the need for additional lubricants.

Project Conclusion:

In a remarkable testament to meticulous planning, precise execution, and the power of pressure grouting techniques, the pool repair and soil remediation project was successfully completed in just about two weeks. The holes in the pool area were meticulously patched, and new decking was seamlessly installed. This case study underscores the paramount importance of grout technology, pressure grouting, and soil stabilization techniques in achieving not just satisfactory but exceptional outcomes for pool repair and soil remediation projects. It stands as a testament to the efficiency and reliability of modern grouting methods in ensuring the structural integrity of essential infrastructures.

Industry Case Study: Summit at Copper Square-Phoenix Weitz Company

2022-03-31T23:51:49.05Z

Situation: The 23 story concrete shear wall residential building had 35 spandrel beams that were cored for pipe sleeves below the approved zone per criteria given by the engineer of record. This caused a 35 kip loss of capacity in downward shear. They need to regain the capacity lost by the cores.

Challenges: Using structural steel was not an option because it would lower the ceiling height in the hallways. Exterior post-tension cables would not work because the span was not wide enough and there was inconsistency in the location of the pipes. Many of the cores had pipes already installed. This created issues installing the carbon fiber. The solution was to cut the fiber, allowing the installers to wrap the fiber around the pipes.

Industry Case Study: Peoria Sports Complex

2022-03-31T15:27:55.05Z

Solution: Arizona Ram Jack was able to mix on-site a low-density cellular grout engineered mix design that met the requirements of the project. By providing an air bleed-off hole at the end of the pipe we were able to monitor the flow of the grout and assure that there were no voids.

Conclusion: Both the General contractor and the Special Inspector were impressed with our team and our proprietary mix design that they had not seen used before. the project was completed in one day.

Industry Case Study: PCCP Pipe Repair-San Juan Power Plant

2022-03-31T14:58:31.05Z

Situation: Wire breaks in the 10' diameter pipes severely limited the capacity of the pipe to withstand internal pressure. The goal was to restore the capacity of the pipeline.

Challenges: All work needed to be done within the time frame of the shutdown of 3 weeks for the # 3 circline and 3 days for the #4 circline. The replacement was far too costly and too much downtime. Steel lining would reduce the flow, cause future corrosion, and would have high mobilization costs.

Industry Case Study: Moman Residence-Scottsdale Grouting

2022-03-31T13:49:46.05Z

Situation: Existing subsurface soil conditions facilitated the foundation movement of the existing residence. Previous grouting and subsurface rocks made driving grout tubes impossible in some locations. Water infiltration was suspected under the house with high moisture contents observed. Stabilizing the house and stopping future movement in the floors and foundations was the ultimate goal.

Challenges: Much of the required work was inside the house, precluding the use of large equipment. Compaction grouting with high slump materials was tried in the past with poor results. Underpinning would have proven ineffective because the rocky/grouted soils and chemical grouting proved too expensive.

Micro Pile Case Study: Gogte Residence: Horizontal micro piles, FRP and soil grouting

2022-03-31T12:48:08.05Z

Solution: Build temporary walls for equipment access. Reinforce walls with FRP. Install 30mm Titan Epoxy Coated Hollow bars, and grout the soil behind the walls. Break down temporary walls at the conclusion of the work and restore natural habitat.

Conclusion: The work was accomplished ahead of schedule. Pull testing of micro piles exceeded requirements by double. The environment was restored to its original condition.

Industry Case Study: Figueroa Ave. Water Pollution Control Plant Yuma, AZ.

2022-03-31T12:15:24.05Z

Solutions: The amounts and types of repairs needed were estimated from an earlier shutdown and adjusted as the work began. AZRM worked closely with the engineer and product manufacturer to develop a repair system that would be utilized in high heat. By working closely with the general contractor & scheduling work around others, and by working some long days we were able to complete the repair work prior to the required start-up date.

Conclusion: The repairs were completed ahead of schedule on both phase 1 and phase 2 shutdowns. Both the general contractor and the owner were very pleased with the repairs, safety awareness, and completion time.

Industry Case Study: DEMA Project-Tempe Caliente Construction

2022-03-31T11:44:01.05Z

Situation: On this renovation project ten 6" Pre-cast hollow-core floor planks had numerous penetrations through them for utilities. Many of them were existing penetrations as well as several new penetrations were created for new plumbing. In many cases, these penetrations had severed the post-tension cables. Our dilemma was to replace the flexural strength with hollow-core planks.

Challenges: In the areas where the new penetrations were there was plumbing going through the openings. Because of this, we were not able to install continuous runs of laminate strips where the pipes were protruding.

Industry Case Study: Marriott Camelback Inn Adobe Restoration

2022-03-31T10:56:55.05Z

Situation: Marriott wanted to save and restore the adobe lodge building, which was built in the 1930s, back to its original look. Additions that had been added through the years were removed, and much of the adobe was damaged in the process. Major repairs were needed to bring this historic building back to its original charm.

Challenges: The largest challenge was locating the correct materials to make the repairs. The original bricks were hand-made from a mixture of clay, sand, and straw. The repairs needed to be made with similar material for both structural and aesthetic reasons.

Industry Case Study: Gilbert Water Treatment Plant

2022-03-30T14:37:21.05Z

Solution: We installed helical piers at each of the 5 pipe locations to raise them back into position. Then we mud jacked the slab back into position by injecting grout into 61 locations in the slab. We core drilled the slab and used potholing to locate the underground infrastructure.

Conclusion: This solution was much more cost-effective than using piers to raise the pipe supports and the slab, saving the owner several thousand dollars. The pot-holing before drilling prevented additional costly repairs if an electrical line had been damaged during the installation of the piers. The owners and the contractor were both very pleased with the cost savings and the time savings. The end result was a successful job and another happy customer.

Industry Case Study: Imagine Schools

2022-03-30T13:59:16.05Z

Situation: Imagine Schools, a charter school with locations throughout the United States, received funding to construct a brand new MS/HS next to their existing Elementary School in Coolidge, AZ.

Challenges: The land that Imagine School purchased was built on an old landfill. Geotechnical reports showed that soft landfill soil existed anywhere from 7 feet to 12 feet below grade. Over excavation to this depth would have been too cost-prohibitive. Due to the school having to open in time for the new year, helical piles were only given an 8-day window to be installed.

Grouting Case Study: Cornerstone-Grouting and Underpinning to Rehabilitate Building

2022-03-30T12:42:31.05Z

Situation: We received a call from a client about a vacant unit that had a settlement. When we went out to look at the unit, we found out that it had actually sunk 24’’ in the center of the floor. The client had been monitoring this movement, and in the past 3 months it had sunk 6’’.

Challenges: The previous tenant had power washed the floors every night for years to clean up, causing a significant amount of water to be underneath the structure. It was also discovered that the unit had been built over a wash, further complicating the soils underneath.

Industry Case Study: Lincoln Towne Centre

2022-03-30T12:21:18.05Z

Solution: Drill through the upper soils using a TEI rock drill to the 30' level. Drive the grout tubes through the looser 30-45 foot deep level and inject high slump materials. Potholing around the infrastructure was done to minimize damage to it. Monitors were set at the walls near grouting operations to avoid structural damage to the walls. The waterproofing at the tunnels consisted of stabilizing the tunnel structure with grouting to keep it from moving at the connections. Urethane foam injection at the moving concrete joints, exposing the outside to apply urethane flex coating, backfill, and injection of the soils with more foam urethane

Conclusion: Some voids encountered took much more material than was anticipated. In addition, the movement of the pressure on the walls, as noted by the monitors, prevented the grout team from completely filling those larger voids. The team developed a pattern of injecting lower pressures near the wall followed up with higher pressures away from the wall, using the previous grout as a wall to protect the existing infrastructure. The project was repaired and stabilized. The structures were lifted and brought back into acceptable tolerances.

Industry Case Study: Munds Park Caisson Remediation

2022-03-30T11:35:04.05Z

Solution: The voids were cleaned out using a combination of directed air and water using the various ports that were installed in various sequences. The cleaning was verified using a snake camera. Several sequences of cleaning and verifying were required before grouting could begin. Euco Tremie Grout was used to avoid washing out from the water in the voids.

Conclusion: The voids were cleaned out over a several-day period until the return water was clean, and there was good communication between cores that reached each void. Grouting was installed with the same communication requirements between core holes. Grout pressure was maxed at 300 psi.

Industry Case Study: Apache Gold Casino

2022-03-30T10:58:12.05Z

Solution: Arizona Foundation Solutions team worked with the project engineers to design a deep foundation system using Helical Piles for the construction of the new swimming pool. The piles were driven to depths of 50 to 60 feet to reach solid bearing strata. Rebar was then attached to the pile brackets, and the grade beams were poured. This provided a foundation system that would prevent the settlement issues that the old pool had experienced.

Conclusion: Helical Piles again prove to be the best solution when compressible soils present a construction challenge. Another successful project that created another happy client.

Industry Case Study: Desert Storm Elite Dance Studio

2022-03-30T10:43:18.05Z

Solution: Excavate a shallow footing and install 88 pre-construction Helical Piles to depths of 10 ft. to 15 ft. The piles installed were 2 7/8” round shaft piles manufactured by Foundation Supportworks. Cut each pile 6” above the bottom of the excavation and attach a pile cap. This provided a deep foundation system that would support the load of the new structure.

Conclusion: The helical piles provided a foundation that allowed the structure to be constructed to the original footprint without compromising the existing retaining wall and keeping the project on schedule.

Adaptive Reuse and Brownfield Development with Helical Technology

2022-02-04T00:00:00.05Z

One of the many challenges and opportunities in today’s market is to make use of infill properties and reuse existing structures. These kinds of projects, with many challenges including soil challenges and unknowns of existing buried infrastructure. Many times the structures are located in close proximity to functioning footings of existing structures that preclude either disturbing by digging below or overburdening by putting footings on top.

We have been a key player in developing cost-effective strategies and solutions for dealing with these challenges in making it possible for these Brownfield developments to take place. Helical piles and micro piles can provide gravity and uplift solutions for the support of new or existing structures without disturbing footings in close proximity. In addition to that these piles can be installed with little or no spoils making it ideal for sites that have contaminated soils.

One of the many challenges and opportunities in today’s market is to make use of infill properties and reuse existing structures.

We have worked on many of these sites in the past... some of which we have won awards for. One of which is the Franklin high school on McDowell and 17th Ave. where we installed new piles on an existing abandoned structure with contaminated soils.

Another such project we are currently working on has automobile fluff buried on-site with contaminants in it as well as the soil. Because of these challenges, the team has elected to minimize any haul off of excavated soils. As a result helical piles were selected to support the new building structure. An additional challenge of this particular site was the lack of any soil information to design the pile system as well as the large variability of the conditions that included voids and impenetrable solids.

Our design team after conducting several tests on-site developed a unique technology of helical piles that are continuously grouted while they are installed. It is highly unlikely that this site could ever be developed without that technology.