Can I Use Spray Foam to Lift Concrete in Houston, TX?

Houston’s shifting clay soils, heavy industrial traffic, and cyclical flooding can turn perfectly level concrete into a tripping hazard or a drainage nightmare. Yes, you can lift and level concrete by using polyurethane foam—in a technique called polyjacking, foam injection, or LEVELift—which outperforms traditional methods like mudjacking in speed, durability, and cost-effectiveness. Below, we examine why polyurethane concrete lifting is the preferred concrete repair method for ports, airports, refineries, and distribution centers across the Gulf Coast.

Key Takeaways

• High-density polyurethane foam expands rapidly, fills voids beneath the concrete slab, and re-levels uneven concrete surfaces within minutes, allowing critical infrastructure to reopen the same shift.
• Foam lifting weighs about one-tenth of cement slurry, so it won’t overload Houston’s moisture-sensitive clays, reducing the chance of future settlement compared with heavier traditional concrete repair methods.
• Polyurethane foam injection is clean and minimally invasive: crews drill ⅜-inch ports, inject foam underneath, then patch and polish—no noisy jackhammers, no concrete replacement, and no weeks of lane closures.
• The closed-cell structure resists water, petrochemicals, and erosion, so the integrity of concrete remains intact even during hurricane-induced flood cycles.
• Life-cycle ROI stays strong: minimal downtime, lower labor, and the long-term effectiveness of polyurethane mean a lifespan measured in decades—often rivaling brand-new concrete.

How Polyurethane Foam Lifts, Levels, and Stabilizes Concrete

Polyurethane foam concrete lifting—also known as polyurethane foam concrete lifting, polyurethane foam lifting, or polyurethane concrete raising—relies on a two-component liquid that becomes an expanding foam used to lift and stabilize concrete slabs precisely.

The Expansion Principle

When the two components mix, a controlled exothermic reaction produces expanding foam that can grow up to 25× its liquid volume. The strength of polyurethane foam applies uniform pressure, lifting the slab to the desired elevation while stabilizing concrete and filling voids beneath the concrete.

Closed-Cell Structure & Properties of Polyurethane Foam

Because the cells are sealed, the foam repels moisture, fuels, and salts. Polyurethane foam is generally chemically inert, ensuring long-term resilience of polyurethane in demanding petro-chemical environments.

Load Distribution & Strength

Cured foam reaches 100–150 psi compressive strength—ample for highways—yet its density (2–4 lb/ft³) keeps weight low. The foam cures within 15 minutes; rapid curing time of polyurethane means concrete is ready for use almost immediately, shrinking shutdown schedules.

Comparison Table: Foam vs. Mudjacking

Why Foam Outperforms Traditional Methods Like Mudjacking in Houston

Lower Added Load

Heavy slurry accelerates settlement on saturated clays. Using polyurethane foam adds negligible mass and keeps the concrete leveling needs of Gulf Coast facilities in check for the long haul.

Superior Moisture Resistance

Closed-cell foam blocks water pathways. In contrast, grout can re-soften and wash away, leaving gaps beneath the concrete that restart the sinking concrete cycle.

Faster Turnaround

Foam cures in minutes. Crews can lift concrete, level concrete surfaces, and reopen container yards or taxiways the same day, protecting revenue streams.

Ideal Commercial & Municipal Applications for Polyurethane Concrete Lifting Services in Houston

• Heavy-haul roadways and highways where overnight reopening is mandatory
• Port container pads subject to high wheel loads and hydraulic pounding
• Airport aprons, taxiways, and runways needing a smooth concrete surface quickly
• Manufacturing and logistics floors where forklift vibration causes sunken concrete slabs
• Energy-sector sites requiring chemical-resistant concrete repair solutions

Step-by-Step Foam Injection Process

1. Site Evaluation & GPR Scanning – Identify voids beneath concrete surfaces and map utilities.
2. Precision Drilling – ⅜-inch ports keep the appearance of the concrete virtually unchanged.
3. Controlled Foam Injection – Polyurethane foam is injected in timed bursts; lasers guide millimeter-level lift.
4. Patch & Finish – Color-matched mortar restores aesthetics; concrete is ready for use often within an hour.

Cost Drivers & ROI

• Degree of settlement and volume of sunken concrete
• Slab thickness, reinforcement type, and foam density required
• Site access, traffic control, and night shift premiums

Avoided demolition, debris hauling, and pouring new concrete typically generate 50–70 % savings. Add zero downtime, and polyurethane foam offers one of the most cost-effective solutions for concrete lifting and leveling.

How Houston’s Geology Affects Sinking or Uneven Concrete

Expansive clays shrink in droughts and swell in storms, creating voids beneath concrete slabs. High-density polyurethane foam fills those gaps and locks into the subgrade, lifting and stabilizing concrete against future washout.

Choosing a Contractor for Polyurethane Injection Services in Houston

Look for:

• Manufacturer-certified technicians trained in the field of concrete lifting
• Rigs with temperature-controlled proportioners to ensure consistency
• Case studies on industrial projects similar to yours

When your slabs settle, contact leveled concrete specialists who can deploy foam raising technology with precision and provide documented quality control.

Conclusion

Polyurethane foam lifting delivers a clean, fast, and durable answer to settled concrete. From refinery tank farms to airport runways, foam to lift, level, and stabilize concrete slabs remains the choice for concrete professionals who demand performance without prolonged shutdowns. 

Contact our leveled concrete specialists at Superior Polylift today to schedule an evaluation and keep your infrastructure performing at its peak.