Foundation Repair Photo Album: Shotcrete Saves Bath Township Barn

Robert called with a barn in crisis. The foundation was part poured concrete, part fieldstone, and all crumbling. We poured a new footing to create a stable base, and then used Shotcrete to create a new foundation - one that will stay in one piece.

Bath Twp Barn With Crumbling Foundation

Even from this distance, you can see that the foundation on the lower right side of the photo is struggling.

Barn Sits on Shaky Foundation

This is what's propping up an entire barn and keeping it from collapsing. Not very promising.

Crumbling Concrete Wall

In addition to the fieldstone wall falling apart, the walls that were poured concrete aren't doing so hot either.

Failing Walls in Bath Twp Barn

These walls don't inspire much confidence. For one thing, anytime there are gaps between a structure and its foundation, it's going to have issues as the elements wreak havoc inside. Secondly, the concrete itself is crumbling apart and threatening the integrity of the foundation.

Wall Surrounding Window Has Problems

I generally think of walls flat and in one piece. It looks like this wall was either built around the window, or cut into in order to install the window - either way, it's literally crumbling apart.

Dilapidated Wall in Barn Foundation

This is a mess. That's the only way to put it. You can literally see into the foundation in more than one spot, and the parts that are missing put the stability of the barn in danger.

Seeing Daylight Inside Foundation

You shouldn't be able to stick your hands through holes in a foundation and reach outside. At that point, it isn't doing half of its job - creating a barrier to the outside world. And it likely won't do the other half of its job - keeping the barn upright - much longer.

Preparing for Shotcrete

One potential downside - you have to say goodbye to your basement windows.

Creating a Support Structure for New Walls

We use rebar (short for reinforcing bar) to create a kind of frame for the Shotcrete to adhere to and form a new wall. It's directly attached to the existing walls so there's no chance of falling over.

Closeup of Rebar

Steel rebar creates a solid structure for the Shotcrete.

Rebar Installation

The rebar goes from floor to ceiling to ensure a stable wall construction.

Shotcrete Wall Construction in Progress

It isn't pretty - after all, it's concrete out of a fire hose - but Shotcrete application provides a structurally sound, reliable reinforcement to your foundation without the danger, expense, and inconvenience of pouring a new foundation.

Shotcrete Walls in Place

The Shotcrete does smooth out a little, as you can see here. And customers are often pretty unconcerned with the bumpy appearance of the walls when it means they have peace of mind.