How Much Does Polyurethane Foam Injection Cost?

Last Updated on May 14, 2024
Written by CPA Alec Pow | Content Reviewed by CFA Alexander Popinker

Polyurethane foam injection has emerged as an innovative repair technique for lifting and stabilizing concrete slabs and foundations. By injecting expanding polyurethane foam beneath concrete, voids can be filled, soils stabilized, and sunken sections raised back into place.

However, like any construction method, polyurethane foam injection comes at a cost. By understanding the factors that influence pricing, you can more accurately estimate costs and budget for your project.

This guide examines all the expenses related to polyurethane foam injection processes. We’ll look at materials, equipment, labor rates, permitting needs, and more. You’ll also learn how polyurethane injection compares cost-wise to alternative options like hydraulic lifting and traditional mudjacking.

With these insights, you can determine if polyurethane foam injection is the most economical choice for your particular concrete repair project.

How Much Does Polyurethane Foam Injection Cost?

The costs for polyurethane foam injection typically range from $3 to $40 (≈2.7 hours of labor required at $15/hour) per square foot for concrete slab lifting projects and $150 to $900 (≈1.5 weeks working every single day at $15/hour) per linear foot for foundation wall repairs, depending on the size of the project and complexity.

Some of the most common uses for polyurethane foam injection in construction and repair projects include:

Concrete Slab Lifting

For driveways, sidewalks, patios, pool decks, and other slabs that have settled or sunk, polyurethane foam can quickly lift and level them again.

Cost range:

• Small residential slab 100-400 sq ft: $500 - $2,000 (≈3.3 weeks trading your time for $15/hour)
• Large commercial slab 1000+ sq ft: $5,000 - $40,000 (≈1.3 years working to pay for this at $15/hour)

Foundation Wall Repair

Injecting foam can stabilize bowed or leaning walls, lift settled sections, and reinforce damaged areas.

Cost range:

• Typical residential foundation 100 linear ft: $2,000 - $7,000 (≈2.7 months of your career at a $15/hour job)
• Large commercial foundation 500 linear ft: $10,000 - $25,000 (≈9.5 months of continuous work at a $15/hour wage)

Soil Stabilization

Foam injection is used to stabilize and compact loose soils under slabs and foundations.

Cost range: $1 - $4 per square foot

Compared to traditional mudjacking methods, polyurethane foam provides longer-lasting repairs with less ongoing maintenance required.

According to Dalinghaus Construction, in Southern California and Arizona, the average price of polyurethane is $10 (≈40 minutes working at a $15/hour wage) per square foot/per pound, with a minimum fee of $2,500 (≈4.2 weeks of employment at a $15/hour wage) and a standard job average cost ranging from $2,500 to $5,000 (≈1.9 months of your working life at $15/hour).

The price for Polyurethane Deep Injection is $160 (≈1.3 days of non-stop labor at a $15/hour salary) per linear foot with a minimum of $2,500 (≈4.2 weeks of employment at a $15/hour wage) for 15.5 square feet, while the Void Fill After Lift/Stabilization Price is a minimum of $2,500 (≈4.2 weeks of employment at a $15/hour wage) plus $10 (≈40 minutes working at a $15/hour wage) x additional squared foot.

The Polyurethane Foam Injection Process

Before analyzing the cost factors, let’s quickly review how the polyurethane foam injection process works:

• Small holes are drilled into the concrete slab or foundation wall needing repair. Holes are placed strategically where foam needs to be injected.
• Two liquid components (isocyanate and resin) are pumped through hoses into the injection holes, often using a high-pressure pump.
• The chemicals rapidly react and expand into rigid polyurethane foam, filling voids and cavities beneath the slab, thereby lifting it.
• Once the slab is raised and stabilized, the injection holes are sealed up with concrete.

Polyurethane foam injection provides an efficient minimally invasive solution for concrete lifting and soil stabilization compared to traditional methods.

Cost Factors for Polyurethane Foam Injection

The price for any polyurethane foam injection project can be broken down into:

Polyurethane Foam Materials

The chemicals cost $600 - $1,200 (≈2 weeks dedicated to affording this at $15/hour) per cubic yard. More is consumed for bigger projects.

Injection Equipment

Specialized pumps and rigs are expensive rentals at $300 - $800 (≈1.3 weeks working without a break on a $15/hour salary) per day.

Labor

Trained technicians usually charge $50 - $100 (≈6.7 hours of continuous work at a $15/hour job) per hour for injection work.

Site Conditions

Accessing tight crawlspaces or basements increases labor time and difficulty.

Permitting

Some areas may require excavation or building permits costing $50 - $500 (≈4.2 days of your career at $15/hour).

You might also like our articles about the cost of a foam spray rig, concrete delivery, or concrete removal.

Site Preparation

Leveling, grading, and ductwork may be needed to access injection sites, at a cost of $500 - $2,000 (≈3.3 weeks trading your time for $15/hour) or more.

Concrete Patching

Sealing drilled holes and resurfacing repaired slabs adds $200 - $2,000 (≈3.3 weeks trading your time for $15/hour) typically.

Individual expenses

Polyurethane Foam vs. Other Methods

Polyurethane foam injection costs moderately more than slabjacking but less than full replacement:

• Mudjackinguses concrete pumped beneath the slab for lifting, at $2 - $8 per square foot.
• Hydraulic jacking lifts slabs with water pressure for $250 - $700 (≈1.2 weeks of salary time at $15/hour) per pier.
• Slab replacement is far more extensive at $8 - $15 (≈1 hour of uninterrupted labor at $15/hour) per square foot.

While more affordable upfront, mudjacking and hydraulic lifting may need repeated repairs, while foam injection provides longer-lasting stabilization and leveling in most cases.

Return on Investment Analysis

The moderate upfront investment in polyurethane foam injection pays dividends over time:

• Long-lasting repairs: Foam injected repairs last 10-15 years compared to 5 years for mudjacking.
• Less demolition: Foam injection is minimally invasive compared to full slab replacement.
• Soil stabilization: Polyurethane stabilizes loose soils and prevents further sinking.
• Added resale value: Level foundations and slabs add property value.

Considering these substantial benefits, polyurethane foam injection provides excellent value and return on investment for the right applications.

Polyurethane Foam Injection Process

To understand where costs originate, let's look closer at each step of the polyurethane injection process:

1. Site Evaluation - An initial site visit is done to assess damage and plan the repair approach at a cost of $200 - $500 (≈4.2 days of your career at $15/hour).
2. Site Preparation - Any excavation, ductwork, or grading will need to be completed ahead of time, if necessary, from $500 - $5,000 (≈1.9 months of your working life at $15/hour).
3. Drilling Injection Holes - Typically 3/8” holes are drilled on a grid pattern for optimal foam distribution, at $5 - $10 (≈40 minutes working at a $15/hour wage) per hole.
4. Equipment Setup - The pumping unit and rig are delivered and set up, with technicians spending 2 - 4 hours at $50 - $100 (≈6.7 hours of continuous work at a $15/hour job) per hour. Rental fees are $300 - $800 (≈1.3 weeks working without a break on a $15/hour salary) per day.
5. Polyurethane Foam Injection - Technicians inject the foam through the holes which can take several hours or days depending on scope, at $50 - $100 (≈6.7 hours of continuous work at a $15/hour job) per hour. Materials may cost $600 - $6,000 (≈2.3 months locked to your job at $15/hour).
6. Cleaning and Sealing - Holes are sealed with concrete and the area cleaned up, taking 2 - 4 hours at $50 - $100 (≈6.7 hours of continuous work at a $15/hour job) per hour.
7. Finishing and Resurfacing - As needed, new coatings or overlays are applied to restore the appearance, at approximately $2 - $4 per square foot.

Final Words

While costs for polyurethane foam injection can seem high compared to other methods, the value derived from long-lasting repairs, minimized demolition, soil stabilization, and added property value make it a wise investment for the right applications.

Expect to pay more for larger commercial projects and those with difficult access or extensive prep work. Carefully considering the project’s scope and getting multiple bids ensures you get the most competitive pricing for quality results.

For homeowners and businesses needing concrete or foundation repairs, polyurethane foam injection often provides excellent return on investment thanks to its efficiency, longevity, and performance.

Frequently Asked Questions

What are the issues with polyurethane foam?

Potential issues with polyurethane foam include chemical sensitivity to isocyanates for some people, flammability if exposed to open flames, and moisture absorption in some types. Proper protective equipment for installers and keeping foam sealed mitigates these risks.

Can you injection mold polyurethane foam?

Yes, injection molding is commonly used to form polyurethane foam parts and products. Liquid components are mixed and injected into temperature-controlled molds where they quickly expand and cure into the final shaped parts. The process is highly automated and reproducible.

What are the safety precautions for polyurethane foam?

The main safety precautions when working with polyurethane foam include wearing protective gloves, clothing, and respiratory gear to avoid skin and inhalation exposure. Work areas must have adequate ventilation. Appropriate fire extinguishers should be on hand. Safety training is critical for installers.

How does polyurethane foam cure?

Polyurethane foam cures through a chemical reaction between polyol and isocyanate components mixed together before injection. Once combined, the reactive ingredients expand rapidly. The curing process continues for 24-48 hours, hardening the foam fully into a solid plastic. The cure times can be adjusted with formulation.