What Is The Difference Between Polyurethane Foam Leveling & Mudjacking?

Concrete leveling can be accomplished using two methods: polyurethane foam leveling & mud-jacking. Both are effective at fixing problems like uneven sidewalks, sinking driveways or settling patios but do so in very different ways.

Polyurethane foam leveling is a concrete lifting process that utilizes lightweight, high density foam to raise and stabilize concrete by filling the voids in the soil under the concrete. It is utilized for its toughness, quick cure time and water resistance. Foam is strong enough to withstand large commercial vehicles such as semis and forklifts as well as lifting high traffic areas such as highways.

Mud-jacking is another traditional method that involves pumping a heavy cement, sand, and water mix under the slab. Although often more economical upfront (typically about 20-40% less than foam leveling), it adds extra weight to the soil, which is not always ideal under all conditions. Additionally, Mudjacking does not have the power to stabilize areas that require more pressure such as highways, foundations, and other commercial areas.

Exploring Polyurethane Foam Leveling vs. Mud-Jacking

When it comes to concrete repair, the method matters. Among the most common are polyurethane foam leveling and mud-jacking. Although both aim to fix uneven or sunken concrete, they differ in materials, processes, and benefits. The key differences among these methods will be explained and you can decide which is right for you.

Key Differences Between Polyurethane Foam Leveling and Mud-Jacking

The Process

Polyurethane foam leveling

Done by injecting an expanding foam under the concrete. Foam fills in voids by being injected as a liquid, stabilizes the base, and raises the slab back to the original position by turning from a liquid into a solid foam. This process is very accurate and requires special equipment.

Mud-jacking

Uses a slurry of cement, sand, and water. The slurry is pumped under the concrete to raise it. Although effective, it requires larger quantities of material and is less precise than polyurethane foam leveling.

The noticeable difference between the two is that polyurethane foam requires more specialized equipment and is a smaller drill hole size into the concrete so it's less noticeable than a mudjacking hole. In our experience, we can patch polyurethane holes where it's not noticeable where as mudjacking holes will always be noticeable.

Hole Size and Appearance

A difference between these 2 techniques is the dimensions of the holes in the concrete.

Polyurethane foam leveling

Needs tiny injection holes of approximately 5/8 of an inch in diameter. These smaller holes make the surface look cleaner after repair.

Mud-jacking

Needs larger holes (1 to 2 inches in diameter) that will be more obvious after the work is completed.

Weight and Soil Displacement

Cure Time

Time is an important factor when selecting a repair method

Polyurethane foam leveling

Offers a rapid curing process. Most repairs are ready to support weight within 15 minutes, minimizing downtime.

Mud-jacking

Takes longer to cure, often requiring up to 24 hours before the area is fully usable.

Both options are great compared to other options such as concrete replacement which can take multiple days to multiple weeks depending on the project.

Durability and Waterproofing

The longevity and resilience of the repair are critical for ensuring lasting results

Polyurethane foam leveling

Resistant to water and moisture, making it ideal for areas prone to flooding or excessive rainfall. It also maintains its structural integrity over time without breaking down. The foam can last as long as 5-15 years depending on the underlying issue as to why the concrete settled.

Additionally, at KW Concrete Leveling we can utilize different types of foams for unique projects. We have foam that reacts and holds better in water compared to mud-jacking which only offers a single solution.

Mud-jacking

Can absorb moisture, leading to potential degradation. This makes it less durable in wet or unstable environments, while not as great as polyurethane, mudjacking can offer a solution to concrete lifting that can last for multiple years.

Environmental Impact

Environmental considerations are increasingly important

Polyurethane foam leveling

Uses environmentally friendly materials and reduces the need for extensive concrete replacement, making it a sustainable choice.

Mud-jacking

Relies on natural materials that is pumped into the ground to stabilize the concrete. Both options serve as a more eco-friendly way to level concrete.

What is Polyurethane Foam Leveling?

Polyurethane foam leveling is a modern, innovative approach to concrete repair. It involves injecting a two-part foam beneath the surface.

The foam expands, filling voids and lifting the concrete slab with precision. This method is highly effective for sidewalks, driveways, patios, and industrial floors.

The advantages of polyurethane foam leveling include its lightweight nature, rapid application, and superior durability. Additionally, its resistance to water makes it suitable for environments where moisture is a concern.

What Is Mud-Jacking?

Mud-jacking is a traditional method of concrete leveling that has been used for decades. It involves pumping a thick slurry mixture under the concrete to raise it.

While cost-effective and time-tested, mud-jacking is less precise and requires more invasive preparation.

This technique is commonly used for projects or situations where budget constraints are a priority. However, its heavier material and slower curing time make it less ideal for modern applications compared to polyurethane foam leveling.

When to Choose Polyurethane Foam Leveling vs. Mud-Jacking

The decision between polyurethane foam leveling and mud-jacking depends on several factors:

Choose polyurethane foam leveling when:

• Speed and minimal disruption are priorities.
• The repair area is in a moisture-prone location.
• A cleaner, more aesthetic finish is desired leaving you with a smaller hole size that is much less noticeable.
• Durability and long-term performance are critical.

Choose mud-jacking when:

• Budget is a primary concern.
• The repair involves smaller-scale projects such as sidewalks or patios. Not ideal for industrial application for highways, airport runways, and more.
• The appearance of larger holes is not an issue.
  

Which Concrete Repair Method Is Right for You?

Selecting the right repair method depends on your specific needs and priorities. Consider the following questions:

• How quickly do you need the repair to be completed?
• Is the area prone to water exposure?
• What is your budget?
• Are you concerned about the aesthetic appearance of the repair?

Polyurethane foam leveling often emerges as the better option for most homeowners and businesses due to its speed, precision, and durability. However, mud-jacking remains a viable solution for certain situations, particularly when cost is a limiting factor.

How to Address Concrete Cracks

At KW Concrete Leveling, we specialize in delivering high-quality concrete repair services that meet the different needs of our clients. Here’s why we stand out:

1. Faster and Easier Solutions

With our advanced polyurethane foam leveling techniques, repairs are completed quickly and with minimal disruption. You can expect your space to be ready for use within hours, not days.

2. Versatile Applications

Whether you need to fix a driveway, patio, or industrial floor, our methods are adaptable to various projects.

3. Lightweight Materials

Our polyurethane foam is lightweight yet strong, ensuring a long-lasting solution without adding extra stress to the soil beneath.

4. Long-Lasting Results

Durability is at the core of our services. Our materials resist moisture and wear, offering repairs that stand the test of time.

5. Environmentally Friendly Practices

We prioritize sustainability by using eco-friendly materials and minimizing waste. Choosing our polyurethane foam leveling services means making a greener choice for your property.

Professional Concrete Crack Repair

Sunken or uneven concrete can be repaired with polyurethane foam leveling and mud-jacking. 

KW Concrete Leveling, we offer fast, reliable and sustainable solutions for your needs. Contact us online today to learn more about restoring your concrete surfaces.