Severe Cracks Signal Foundation Issues
The back side of this barn was sinking several inches creating major cracks in the block foundation.
Less Severe But Still Concerning
The other side of the barn showed some smaller cracks but they were no less concerning.
This barn had a partial stone foundation and a partial block foundation, both of which were falling apart.
Rock Wall Crumbling
Several spots in the stone foundation were falling apart and failing.
Walls Falling Apart
Several sections of the wall looked exactly like this. The foundation was in major need of some new strength and reinforcement.
SmartJacks Support Floor Above
On the bottom level of the barn, SmartJacks were installed by digging a cube of soil out, filling them with compacted stone, and then placing the galvanized steel SmartJacks above that. This helps distribute the load deep into the ground.
Helical Piers Lift And Support
Helical piers were drilled down to competent soil and fitted with foundation brackets to permanently lift and support the sinking portion of the barn. Two piers were installed on each side.
The electrical panel for the barn couldn't stay on the existing wall since it would be covered in the new concrete. Our master electrician relocated the sub-panel to the upstairs.
Shotcrete uses compressed air and wet concrete sprayed concurrently through a sort of fire hose to blast concrete onto a deteriorating surface. The force of the concrete places and compacts the concrete at the same time making it incredibly strong.
As the concrete is still being sprayed, completed areas of the wall are smoothed as much as possible.
Prep Work Helps Shotcrete Adhere
To help the concrete stick to the wall, wire mesh was fastened to the walls as well as some metal c-channels. Some forms were also created around the ceiling and windows to protect and contain the concrete. Afterwards the window forms are removed.
New Wall On Surface Of Old
Looking at the wall from the outside gives a clear picture of the new wall that has been sprayed on the surface of the block wall.
The Final Product
The bottom level of the barn is brand new. The walls are incredibly strong, the SmartJacks provide great support for the floor above, and the new floor is smooth, strong, and reliable - a huge upgrade from what was there before.
Tuck Pointing Cleans Up The Exterior
As the project wraps up, tuck pointing helps to clean up the exterior of the barn and seal any cracks.
New Plank Floor
On the top level of the barn the concrete floor was removed and a new wood plank floor was installed.