Foundation Repair Photo Album: Foundation Repair In Eagle, MI

This barn was nearly 100 years old, with a partial stone foundation and partial block foundation. Cracks and deterioration were present in each. The back of the barn had actually sunk several inches. In order to save this barn, we used three main tactics. First we used SmartJacks to add support down the center beam of the barn. These SmartJacks are galvanized steel jacks. They're installed by removing a cube of earth below the jack, filling it with compacted stone, and then placing the jack over top. This helps to distribute the load deep into the earth allowing these jacks to support an incredible amount of weight. Next, we used helical piers to lift and support the sinking portion of this barn. Helical piers are drilled deep into the ground to competent soil and are then fitted with a foundation bracket on the top to permanently support the weight of the structure. Finally, Shotcrete was used to blast concrete onto the surface of the deteriorating wall and essentially form a new and incredibly strong wall on its surface. We laid a new concrete floor on the lower level of the barn as well and installed a new wood plank floor on the upper level to complete the space. This barn should last for many years to come and may be passed down to the next generation, hopefully surviving another hundred years.

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.

Mixed Foundation

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.

Sub-panel Moved

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 Applied

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.

Concrete Smoothed

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.