1. 1 Pavement Lifting & Soil Stabilization Control SOIL STABILIZATION, LIFTING OF PAVEMENT STRUCTURES AND UNDERGROUND INFRASTRUCTURE REPAIRS USING DEEP INJECTION (DI) HIGH DENSITY POLYURETHANE (HDP) Joe Kindler URETEK USA of Ohio

2. 2 AGENDA WHAT IS HIGH DENSITY POLYURETHANE APPLICATIONS TESTING AND MEASURING CASE STUDIES QUESTIONS

3. 3 WHAT IS HIGH DENSITY POLYURETHANE Composition Resin & Hardener 1:1 mixing ratio by volume Exothermic chemical reaction generates CO2 CO2 gas causes expansion of material and creates up to 8000 psf lifting pressure Fast reaction – complete in < 1 minute No shrinkage during curing

4. 4 WHAT IS HIGH DENSITY POLYURETHANE Characteristics Lightweight – 3 to 10 pcf As material cools Rigid Structural Polymer Spread is limited due to speed of reaction High Compressive & Tensile Strength Compressive Strength and Tensile Strength are directly proportional to Density Chemical resistance / Ultraviolet radiation

5. 5 WHAT IS HIGH DENSITY POLYURETHANE Quality HDP Material Characteristics Hydro-insensitive in that it contains water insoluble diluents - can be injected into wet soils and even standing or flowing water NSF 61 Certified - can be used with potable water systems Environmentally Inert - material has no impact

6. 6 APPLICATIONS Settled Pavements Roadways Dams Runways, Taxiways, Aprons Bridge Approaches & Departures Asphalt, Concrete or Composite Dips or Faulted Joints Underground Infrastructures - Leaking / Settled Settlement in Buildings

7. 7 APPLICATIONS Pavement or Structure Settlement Due to: Voids Poor Soil Conditions in Sub-base Undersized Pavement Structure for Current Mission Leaking Underground Drainage System Causing Loss of Soil Support

8. 8 URETEK DEEP INJECTION UDI

9. 9 DEEP INJECTION PROCESS Compaction Displacement Grouting Process Densification of soils is achieved by the controlled expansive force of the polymers Adequate densification confirmed by movement of bearing load and field testing (e.g., DCP and FWD)

10. 10 DEEP INJECTION PROCESS Drill 5/8” holes in pavement Hole pattern is 3’ to 4’ on center Insert injection tubes to proper depth Holes can be drilled up to 2” to accommodate multiple tubes for multiple injection depths Typical injection depths within -10’ Can inject down to 40’

11. 11 DEEP INJECTION PROCESS Can inject full range of soils: Injection into sandy soils creates sandstone Stiff clays – inject above and/or below layer Highly organics – material consumption will be high – currently studying techniques to minimize consumption by creating honeycomb “confinement cells” structural support

12. 12 HDP DI INTO SANDY SOILS

13. 13 Forensic Excavation of HDP DI Stabilized Peat Deposit

14. 14 Forensic Excavation of HDP DI Stabilized Peat Deposit

15. Sample taken from minus 12 feet. 2’ x 1 ½’ x 1’ and weighed over 80 pounds.

16. The Polymer is very dense.

17. Precast Concrete Panels for Rapid Repair of Airfield Rigid pavements REZA ASHTIANI, PHD ATHAR SAEED, PHD, PE Applied Research Associates, Inc. MICHAEL HAMMONS, PHD, PE Air Force Research Laboratory

18. 18 Summary Three pre-cast PCC slab installation techniques were investigated in this research effort High Density Polyurethane (HDP) foam was used for leveling and installation of Slab#1 and Slab#2. Flowable fill was used for Slab#3 Performance of the repaired sections were assessed through analysis of: Load Transfer Efficiency Based on Deflections (LTE  ) Load Transfer Efficiency Based on Stresses (LTE  ) Load Transfer Based on FAA Design Criteria (LT) Analysis of Joint Stiffness based on MEPDG criteria [log (J c )+R] Analysis based on Dissipated Deformation Energy to Subgrade Analysis of Responses of Pre-Cast Panels using FE Rank 3 Slab#3 Flowable Fill Conventional Method Rank 2 Slab#1 HDP Foam Direct Injection Method Rank 1 Slab#2 HDP Foam Deep Injection Method

19. 19 2011 TRB PRESENTATION BY AFRL ABSTRACT Many airfield pavements are constructed with Portland Cement Concrete (PCC). Scheduled maintenance helps restore performance of deteriorated PCC slabs allowing optimal flight operations. Severely deteriorated PCC slabs require a well formulated plan to efficiently and effectively restore damaged slabs. This study investigates the feasibility and the efficiency of using different precast concrete panel installation techniques. High density polymer (HDP) foam and flowable fill were selected as the leveling materials after the literature review. The precast panels were installed using three installation techniques (conventional injection, deep injection and flowable fill) to study their impact on the performance of the repaired sections characterized by load transfer efficiency, joint stiffness and deformation energy dissipated through the pavement foundation. Heavy Weight Deflectometer and F-15 gear simulator were used to determine the stiffness properties and accumulation of plastic deformations after each load interval. Decay of joint stiffness and load transfer efficiency as well as increase in deformation energy were calculated as a function of the number of load applications. The results indicate significant increase in the deformation energy and considerable loss of joint stiffness with number of load applications for slabs installed using flowable fill. Precast slabs installed with HDP foam performed better than those installed using flowable fill. HDP deep injection installed slabs performed better than those installed with HDP conventional method. This study suggests that precast concrete panels leveled with high density polyurethane foam and installed using deep injection method performed best compared to other design permutations.

20. 20 DOD TRANSPORTATION PROJECTS Andrews AFB MD – Soil Stabilization and Pavement Lifting under Air Force One Runway (repair in place August 1999 until December 2010) Tyndall AFB FL – Soil Stabilization and Void Filling under the Drone Recovery Dock (repair in place February 2004 until present) MacDill AFB FL – Void Filling under an Apron (repair in place April 2004 until present)

21. 21 DOD TRANSPORTATION PROJECTS NAS Corpus Christi – Soil Stabilization under a Runway (2010) Lackland AFB TX – Joint Alignment and Soil Stabilization under an Apron (2011) NFESC – Develop an Airfield Damage Repair (ADR) system for US Navy Reference: TR-NAVFAC ESC-EX-1201, Cody M. Reese, Jan 2012 AFRL – Alignment and Stabilization of Pre-cast Slabs for USAF repair system Reference: TSW 2012 Paper # 89 (Ashtiani, Saeed, & Hammons) to be presented Thu 8 Mar 12, 1015, in the San Antonio Room

22. 22 NAVFAC ADR PROJECT - CONCEPT Perform expedient repair of craters on airfields by injecting polyurethane into loose backfill (underlying a rapid set concrete cap) to achieve soil stabilization

23. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Injection inside steel reinforced, plexi-glass box so material flow could be observed

24. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Stabilized soil mass was free-standing after box removed

25. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Vertical load applied using an excavator

26. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Soil mass would not crush, but excavator was lifted 11 inches

27. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Loose soil and concrete rubble used to fill the second crater

28. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Excavation revealed polyurethane compacted the backfill material and filled the voids

29. EXPEDIENT REPAIR OF ANDREWS AFB RUNWAY 01L/19R Crater repair was removed intact after forensic examination

30. 30 ANDREWS AIR FORCE BASE JOB LOCATION: 89 CES/CECE 3710 FETCHET AVE. ANDREWS AFB, MD 20762 Runway 01L / 19R

35. 35 ANDREWS AIR FORCE BASE JOB LOCATION: 23,000 Pounds 89 CES/CECE 12 Days 3710 FETCHET AVE.$125,000 ANDREWS AFB, MD 20762 Runway 01L / 19R

36. ODOT8 1-71SB MM58 42” Bored Gas Line 9’ Below 7.5” Asphalt, 9” Concrete & 6” Base DCP 8’ Weak Soils 10hrs 9-2pm 2 days

37. DCP TESTING

38. TUBE INSERTION

39. BACK TO GRADE 2000 Pounds 12 Hours $15,000

40. UNDERGROUND INFRASTRUCTURE

45. 45 ADVANTAGES of HDP DI Cost * 75%85% Invasive * 90% Disruption and Time * 100%90% Strength in 15 Minutes Control & Accuracy Soil Densification Soil Stabilization Deep Void Fill Water Displacement Void Fill

46. 46 ANY QUESTIONS? Available on State Contract and GSA Schedule Thank You Joe Kindler URETEK of Ohio 866-849-6017