CASE STUDYCase Study: Forklift Slab Restoration & Soil Stabilization at Pier 77 Seawall

Site Issues Identified:

• Significant voids beneath the 18” thick slab
• Cracks and uneven surfaces across the concrete pad
• Soil loss due to water intrusion behind steel sheet piles
• No foundational support—slab was reliant on eroded soil

A traditional demolition or rebuild would have caused costly downtime and operational disruptions. Safe Harbour needed a fast, efficient, and non-invasive solution.

Inspection & Diagnosis by Seawall Savers™

Team Leader: Charlie Garcia, licensed marine contractor
Seawall Savers™ conducted a comprehensive site assessment, including geotechnical testing and structural evaluation.

Diagnosis Highlights:

• Core Drilling & Probing: Confirmed deep voids and slab settlement (up to 4 inches).
• Seawall Inspection: Found water bypassing the seawall, eroding the soil behind the sheet pile toe.
• Foundation Review: No pilings under the slab, meaning weight was being transferred to unstable soil.

Conclusion: A multi-phase polyurethane injection approach was necessary to stop erosion, stabilize the soil, and lift the slab to its original position.

Engineered Solution: Two-Phase Polyurethane Foam Injection

Seawall Savers™ implemented a dual-foam injection system that was custom-designed for the high-moisture conditions of the Florida coast, executed without excavation and with minimal operational downtime.

Phase 1: Soil Stabilization (Single-Component Foam)

Objective: Stop erosion and restore the load-bearing capacity beneath the slab and seawall.
Method: Hydrophobic polyurethane foam was injected into 30 strategic points, reaching depths of 2 feet beneath the slab and up to 2 feet under the sheet pile toe.
Result: Created a bonded soil curtain with 2,000+ psi compressive strength, halting water migration and densifying the eroded sub-base. This phase addressed the root cause—soil washout.

Phase 2: Slab Lifting (Two-Component Foam)

Objective: Lift and realign the forklift slab to its original elevation.
Method: A grid of 40 foam injection points was used to inject two-part foam beneath the slab. The foam expanded, lifting the slab in real-time, monitored with laser levels for precise alignment.
Result: Achieved up to 4 inches of lift across the 400+ sq. ft. slab, fully restoring the forklift pad without the need for demolition.

Project Results:

Client Testimonial

“The Seawall Savers™ team lifted our slab and stabilized the soils faster than expected—with zero downtime for our operations. Extremely professional.”
— Marina Operations Director, Pier 77

Why Choose Seawall Savers™?

• ✔️ Non-invasive repairs – no excavation or concrete removal required
• ✔️ Marine-grade materials – designed for coastal durability
• ✔️ Minimal business interruption – rapid, quiet installation
• ✔️ Eco-conscious solutions – protect Florida’s natural coastlines
• ✔️ 28+ years of marine infrastructure expertise

Don’t Let Subsurface Erosion Sink Your Operations

Seawall Savers™ provides fast, non-destructive, and long-lasting repair solutions that restore structural integrity and keep your waterfront business running smoothly.

Serving Florida’s coastal communities for over 28 years
📞 Call (239) 284-6830
🌐 Visit www.seawallsavers.com to book your FREE site assessment.