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Quality 1st Contracting Case Studies: Eagle Point Power Plant Concrete Repair

Wednesday, July 2nd, 2014 by Cassandra Santiago

Challenge

Eagle Point Power Plant faced numerous foundation settlement issues. The flooring in the administrative building had settled from 2” up to 5”.  The floors in the generator room sunk towards the generator causing uneven floor surfaces and cracks which made equipment moves extremely difficult. Our inspectors also noted additional damage including cracked tile and walls. Eagle Point employees were no longer able to safely use the administrative building due to the uneven floor.

Solution

Eagle Point considered full slab replacement but determined this method would take too long and be too disruptive. In addition, full slab replacement greatly exceeded their budget restrictions.

Eagle Point selected Foundation SupportWorks of NJ to install the PolyLEVEL® System to raise the concrete slabs across the facility. PolyLEVEL® is a two-part urethane that expands into a rigid foam used to fill voids, stabilize slabs and lift concrete. Once injected through small 5/8-inch drilled ports in a slab, a chemical reaction converts the liquid urethane components to a strong, rapidly-setting foam material. In its foam state, PolyLEVEL® is extremely light, weighing two to six pounds per cubic-foot (pcf). Other void-filling or lifting materials can weigh upwards of 120 pcf, adding significant weight to supporting soils which will contribute to further settlement issues. With a typical installed compressive strength of 100 pounds per square inch (psi), PolyLEVEL® can provide the necessary strength to support even heavy loads.

Foundation SupportWorks of NJ installed 9,800lbs. of PolyLEVEL® and returned the settled slabs to a safe and stable position throughout the facility.  The entire process was completed during normal business hours and the power plant staff was able to continue  normal operations.  Eagle Point was so pleased with the results, they are currently working to contract with Foundation SupportWorks of NJ on three other facilities.

Project Summary

System Design Specialist: Jessica Long

Foreman: Brian Way

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Serving NJ including the Greater Paterson area
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Cities in Bergen County, NJ
Allendale
Alpine
Bergenfield
Bogota
Carlstadt
Cliffside Park
Closter
Cresskill
Demarest
Dumont
East Rutherford
Edgewater
Elmwood Park
Emerson
Englewood
Englewood Cliffs
Fair Lawn
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Fort Lee
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Ho Ho Kus
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Saddle River
South Hackensack
Teaneck
Tenafly
Teterboro
Township Of Washington
Waldwick
Wallington
Westwood
Wood Ridge
Woodcliff Lake
Wyckoff

Cities in Burlington County, NJ
Beverly
Bordentown
Browns Mills
Burlington
Chatsworth
Chesterfield
Columbus
Cookstown
Delanco
Delran
Florence
Hainesport
Jobstown
Joint Base Mdl
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Maple Shade
Moorestown
Mount Holly
Mount Laurel
Palmyra
Pemberton
Riverside
Riverton
Roebling
Shamong
Southampton
Tabernacle
Vincentown
Willingboro
Wrightstown

Cities in Camden County, NJ
Pennsauken

Cities in Essex County, NJ
Belleville
Bloomfield
Caldwell
Cedar Grove
East Orange
Essex Fells
Fairfield
Glen Ridge
Irvington
Livingston
Maplewood
Millburn
Montclair
Newark
Nutley
Orange
Roseland
Short Hills
South Orange
Verona
West Orange

Cities in Hudson County, NJ
Bayonne
Harrison
Hoboken
Jersey City
Kearny
North Bergen
Secaucus
Union City
Weehawken
West New York

Cities in Hunterdon County, NJ
Annandale
Asbury
Bloomsbury
Califon
Clinton
Flemington
Frenchtown
Glen Gardner
Hampton
High Bridge
Lambertville
Lebanon
Milford
Pittstown
Ringoes
Rosemont
Stockton
Three Bridges
Whitehouse Station

Cities in Mercer County, NJ
Hightstown
Hopewell
Lawrence Township
Pennington
Princeton
Princeton Junction
Titusville
Trenton
West Windsor

Cities in Middlesex County, NJ
Avenel
Carteret
Colonia
Cranbury
Dayton
Dunellen
East Brunswick
Edison
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Helmetta
Highland Park
Iselin
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Kendall Park
Metuchen
Middlesex
Milltown
Monmouth Junction
Monroe Township
New Brunswick
North Brunswick
Old Bridge
Parlin
Perth Amboy
Piscataway
Plainsboro
Port Reading
Sayreville
Sewaren
South Amboy
South Plainfield
South River
Spotswood
Woodbridge

Cities in Monmouth County, NJ
Allenhurst
Allentown
Allenwood
Asbury Park
Atlantic Highlands
Avon By The Sea
Belford
Belmar
Bradley Beach
Brielle
Cliffwood
Colts Neck
Cream Ridge
Deal
Eatontown
Englishtown
Fair Haven
Farmingdale
Fort Monmouth
Freehold
Hazlet
Highlands
Holmdel
Howell
Keansburg
Keyport
Leonardo
Lincroft
Little Silver
Long Branch
Manasquan
Marlboro
Matawan
Middletown
Millstone Township
Monmouth Beach
Morganville
Neptune
Oakhurst
Ocean Grove
Oceanport
Port Monmouth
Red Bank
Roosevelt
Rumson
Sea Girt
Shrewsbury
Spring Lake
West Long Branch

Cities in Morris County, NJ
Boonton
Budd Lake
Butler
Cedar Knolls
Chatham
Chester
Denville
Dover
East Hanover
Flanders
Florham Park
Gillette
Green Village
Kenvil
Lake Hiawatha
Lake Hopatcong
Landing
Ledgewood
Lincoln Park
Long Valley
Madison
Mendham
Millington
Mine Hill
Montville
Morris Plains
Morristown
Mount Arlington
Mountain Lakes
Netcong
New Vernon
Parsippany
Pequannock
Pine Brook
Pompton Plains
Randolph
Riverdale
Rockaway
Stirling
Succasunna
Towaco
Wharton
Whippany

Cities in Ocean County, NJ
Barnegat
Bayville
Beach Haven
Beachwood
Brick
Forked River
Island Heights
Jackson
Lakehurst
Lakewood
Lanoka Harbor
Lavallette
Little Egg Harbor Twp
Manahawkin
Manchester Township
Mantoloking
New Egypt
Ocean Gate
Pine Beach
Point Pleasant Beach
Seaside Heights
Seaside Park
Toms River
Tuckerton
Waretown
West Creek

Cities in Passaic County, NJ
Bloomingdale
Clifton
Haledon
Haskell
Hawthorne
Hewitt
Little Falls
Newfoundland
Oak Ridge
Passaic
Paterson
Pompton Lakes
Ringwood
Totowa
Wanaque
Wayne
West Milford

Cities in Somerset County, NJ
Basking Ridge
Bedminster
Belle Mead
Bernardsville
Bound Brook
Bridgewater
Far Hills
Franklin Park
Gladstone
Hillsborough
Kingston
Manville
Martinsville
Neshanic Station
Raritan
Rocky Hill
Skillman
Somerset
Somerville
South Bound Brook
Warren
Watchung

Cities in Sussex County, NJ
Andover
Augusta
Branchville
Franklin
Glenwood
Hamburg
Highland Lakes
Hopatcong
Lafayette
Layton
Montague
Newton
Ogdensburg
Sparta
Stanhope
Stockholm
Sussex
Vernon

Cities in Union County, NJ
Berkeley Heights
Clark
Cranford
Elizabeth
Elizabethport
Fanwood
Garwood
Hillside
Kenilworth
Linden
Mountainside
New Providence
Plainfield
Rahway
Roselle
Roselle Park
Scotch Plains
Springfield
Summit
Union
Vauxhall
Westfield

Cities in Warren County, NJ
Belvidere
Blairstown
Columbia
Great Meadows
Hackettstown
Oxford
Phillipsburg
Port Murray
Stewartsville
Washington

Cities in Philadelphia County, PA
Philadelphia

Cities in Pike County, PA
Matamoras

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