Project: TFP Nutrition
Location: Nacogdoches, TX
Asset: Extruder-room equipment foundation pads, 1,680 SF area in a 24/7 animal-food processing facility
CHALLENGE
TFP Nutrition produces a variety of animal foods, running 24 hours a day, 7 days a week. A 1,680 SF extruder room houses several large pieces of equipment that are central to the process, all mounted on concrete foundation pads. The pads had begun experiencing a high degree of vibration that would eventually lead to equipment failures and lengthy downtime, which was not acceptable. Taking the equipment out of service was itself a significant concern. The general contractor that manages TFP's construction projects, already familiar with Superior's work, reached out looking for a solution.
SOLUTION
Superior first drilled inspection holes to check for voids and assess soil conditions, and confirmed that voids existed throughout the extruder room beneath the pads. Superior proposed injecting expanding polyurethane to fill those voids and stabilize the foundation pads in place, using High-Density Polyurethane injection. The process fit every constraint the facility had. It was clean, which is essential in a food-processing environment. It was fast, keeping downtime to a minimum. The material reaches 90 percent of its strength in 15 minutes, so cure time was not a bottleneck. Injection was done through small 5/8-inch holes in the concrete foundation, and the lightweight material weighs only 4 pounds per cubic foot, adding negligible load to the subgrade.
RESULTS
2,500 pounds of High-Density Polyurethane injected to fill the voids and stabilize the foundation pads.
Equipment vibration was stopped, protecting against future equipment failures and downtime.
Work was performed over the weekend, minimizing disruption to 24/7 operations.
A very clean environment was maintained throughout, as required in a food-processing facility.
