Using a minimally invasive structural resin, Uretek Mid-Atlantic was able to increase the load bearing capacity of existing foundations for a factory expansion.

1. A Low Impact Solution for
Increasing Existing Structural
Loads
Originally Presented by Bryan Honeycutt,
Technical Sales Manager
South Carolina & Charlotte
Edited & Designed by Katherine Witt,
Marketing Assistant

2. Background
A reputable automobile manufacturing plant in Greer, SC was in the
process of expanding its facility. Plans called for the addition of a
penthouse and an additional wing. Consequently, existing column
foundations were subjected to significant load increases. The additional
weight necessitated the increase of load bearing capacity for the
existing foundations.

3. New Loads on Existing Columns
Increased loads required column
modifications

4. Effects of New Loads on Foundations
o Soil Bearing Pressure increase due to new vertical loads applied at
top of columns from penthouse addition.
o Soil Bearing Pressure increase due to new lateral loads applied at top
of columns from penthouse addition; higher moments at bottom of
columns and foundations.
o Soil Bearing Pressure increase due to increase in column stiffness.

5. Penthouse
Expansion
Existing
Penthouse
New
Penthouse
o New Penthouse Structure Tying into
Existing Penthouse Structure
o 50’x50’x23.75’ Bay
o Roof trusses and floor framing
above existing roof; column
extensions
o Replacing Equipment in Existing
Penthouse Structure

6. o Replacement of existing
foundation
o Conventional foundation
modification / enlargement
o Installation of New Columns
to reduce loads on Existing
Columns
o Micropiles
o Subgrade modification
Options
There were several viable
options to increase the load
bearing capacity of the
foundations.

7. Considerations
o Cost
o Invasiveness
o Impact on factory production
o Associated time relative to fast track
schedule

8. Conventional options were relatively expensive and time consuming.
Uretek Mid-Atlantic was contacted to investigate an alternative solution. After
reviewing the proposed structural design criteria and geotechnical data regarding
existing subgrade capacities, Uretek determined that subgrade enhancement would
be an overall better solution.
Uretek designed and implemented a solution to increase the capacity of existing
structural foundation support soils utilizing their patented High Density
Polyurethane Resin and Deep Injection™system.
An Innovative Alternative

9. High Density Polyurethane Resin
(HDPR)
o Hydrophilic, Hydrophobic and Hydroinsensitive* (URETEK 486 Star)
o Two Component Polymerization Process
o Injected as a liquid, chemical reaction expands and changes the liquid
into a solid
*“Hydroinsensitive”, meaning it will react in a saturated environment as it does in dry
conditions; traditional polyurethanes require some degree of moisture to react properly

10. Benefits of Using HDPR
o Increased Properties of Unconsolidated Soils
o Increases bearing capacity by increasing density or internal angle of
friction or both
o High Expansive Forces
o High lifting capacity to weight of material ratio
o Addresses Inflow and Infiltration (I&I)
o Seals underground structures

11. Benefits of Using HDPR, cont…
o Minimal Disruption:
No Digging Develops 90%
Strength in 15 minutes
Fully cured in 24 hours
o Return to service in 1 hour
o Excellent Chemical Resistance
o Long Term Structural and Dimensional Stability
o Environmentally Benign

12. Product Testing
HDPR injection to soil.
Congealed HDPR and soil after
application.

13. Deep Injection
Minimally invasive injection
ports.

14. Deep Injection
Injecting material while
monitoring the structure to
avoid any undesired
movement.