Project Overview of a Polyurethane Foam Concrete Lift
In the dynamic landscape of distribution and logistics, a seamless operation is paramount. Walmart, one of the world’s largest retailers, operates a vast distribution network to meet the demands of its customers. In this polyurethane foam concrete lift case study, we delve into a vital project at a Walmart Distribution Center, addressing a pressing issue that required a swift and efficient resolution.
The Challenge:
The distribution center faced a significant challenge: over 75 concrete pads were sinking within a 10,000-square-foot area that accommodated four lanes for tractor-trailers. With the onset of the COVID-19 pandemic (when this project was awarded), the importance of efficient distribution centers reached unprecedented levels. The need to keep goods flowing was non-negotiable, but addressing this structural problem was equally imperative. Only one lane was allowed to close at a time throughout the duration of the job.
The Approach:
The commercial division of Ram Jack Foundation Solutions was entrusted with this critical project. We devised a methodical approach that would address the problem without causing major disruptions to daily activities at the distribution center.
- Planning and Preparation for Polyurethane Foam Concrete Lift: The project was meticulously planned, taking into consideration the high priority of distribution during the pandemic. Ram Jack’s polyurethane foam solutions offered the ideal answer to this challenge. Designed to repair, fill, lift, and support a wide range of commercial applications without the need for heavy excavation or downtime, polyurethane foam was the perfect choice for this situation. The approach was to work on one lane at a time, ensuring that only one lane would be closed at any given time.
- Polyurethane Foam Installation: The installation process involved a straightforward procedure. Small holes were drilled through the concrete slab or structure to access the soil beneath. Specialized equipment was used to inject NCFI geotechnical polyurethane foam into these holes, granting control over the elevation of the slab and densifying the soil to secure it in place. An impressive feature of polyurethane foam is its rapid expansion and hardening, taking only about 30 minutes to raise the slab back into position. Ram Jack coned off one lane at a time addressing each pad to lift and secure before clean up and lane transition.
- Clean-Up and Lane Transition: After securing each pad, a quick clean-up was carried out to remove any traces of the work. This efficient process meant that lane transitions could occur swiftly, minimizing downtime.
The Outcome of the Polyurethane Foam Concrete Lift:
Ram Jack’s approach led to a highly successful outcome for Walmart’s distribution center:
- Efficiency and Minimal Disruption: The area was brought back to a level surface without disrupting daily activities. The team’s ability to work on one lane at a time, combined with the rapid curing time of the polyurethane foam solution, allowed traffic to flow almost immediately after the completion of each section.
- Time and Cost Savings: The entire project was completed within just two days, an extraordinary accomplishment given the scale of the work and the challenging conditions posed by the pandemic. This approach not only saved time but also significant costs, offering a solution that minimized disruptions and kept operations running smoothly.
This case study underscores the power of innovative solutions and efficient project management. Ram Jack’s polyurethane foam solutions offer a fast and cost-effective way to address complex structural issues in critical environments. With the ability to lift, secure, and protect concrete slabs while minimizing downtime, polyurethane foam has become a go-to choice for facility managers, property managers, contractors, and engineers looking for a permanent, versatile, and reliable solution.
In a time when distribution and logistics are paramount, this success story underscores the importance of implementing smart, cost-effective, and timely solutions to ensure the continuity of essential services.
For more information on how Ram Jack’s polyurethane foam solutions can benefit your commercial or industrial setting, visit Polyurethane Injection.