Can Foam Lifting Fix Concrete Cracks?

Concrete surfaces are built to be durable, but over time, they can develop cracks, uneven sections, and sunken areas due to shifting soil, water erosion, and general wear. If left unaddressed, these issues can lead to structural instability, trip hazards, and costly full replacements.

One of the most effective concrete leveling methods available today is polyurethane concrete lifting, often referred to as polylift concrete leveling or foam concrete lifting. This technique restores existing concrete by injecting expanding polyurethane beneath the slab to raise and stabilize it. However, while foam lifting can effectively lift the slab and prevent further settlement, many wonder if it can also fill the crack and permanently repair broken concrete.

In this guide, we’ll break down how foam lifting works, when it can repair cracked concrete, and when alternative solutions are necessary. By the end, you’ll understand whether polylift concrete leveling is the best answer for your concrete needs or if another repair method is required.

Key Takeaways

• Foam lifting stabilizes concrete but doesn’t fully repair deep cracks – While polyurethane injection lifts and levels sunken slabs, severe structural cracks may require additional repairs like epoxy injection or slab replacement.
• The process is fast, precise, and minimally invasive – Foam expands beneath the slab to fill voids and restore stability, requiring only small drill holes and allowing the surface to be used within 15–30 minutes.
• Soil erosion and poor compaction cause most concrete cracks – Addressing underlying issues like drainage problems and shifting soil helps prevent future settlement and prolongs the lifespan of foam-leveled concrete.
• Foam lifting outperforms mudjacking and traditional repairs – Unlike heavy cement-based methods, polyurethane foam is lightweight, waterproof, and long-lasting, making it a superior solution for concrete leveling.
• Not all cracked concrete is repairable with foam alone – If a slab has deep fractures or is crumbling, additional repairs or full replacement may be necessary to ensure long-term structural integrity.
• Foam lifting is a cost-effective alternative to slab replacement – On average, polyurethane leveling costs 30–50% less than replacing concrete, making it an economical choice for driveways, sidewalks, and industrial floors.

How Foam Lifting Works for Concrete Repair

The foam concrete lifting process involves injecting a specialized expanding foam beneath sunken concrete slabs. As the foam expands, it raises the concrete back to its original position while filling voids beneath the surface. This method is widely used for concrete driveways, sidewalks, industrial floors, and municipal infrastructure due to its speed, efficiency, and long-term durability.

Unlike traditional stone slurry grout concrete leveling, which uses a heavy cement-based mixture, polyurethane concrete lifting relies on a lightweight poly level foam that provides superior stability without adding unnecessary weight to the soil.

What Is Foam Concrete Lifting?

Foam concrete lifting is a modern alternative to traditional slab repair methods like mudjacking or concrete replacement. Instead of removing and repouring new concrete, this process injects expanding polyurethane under the existing concrete to restore it.

This method is ideal for lifting uneven concrete while preventing further deterioration. The foam is made from a two-component liquid that expands and hardens once injected, making it highly durable.

How Polyurethane Foam Injection Levels Settled Concrete

The lifting process involves drilling small holes into the concrete surface and injecting expanding polyurethane foam beneath the slab. As the liquid foam spreads, it expands and lifts the concrete while stabilizing the foundation.

The steps of polylifting are as follows:

1. Drill Small Holes – Small, precise holes are drilled into the sunken concrete slab.
2. Inject the Foam – A liquid foam mixture is injected beneath the slab to fill voids and create lift.
3. Expand and Raise the Concrete – The expanding foam lifts and stabilizes the slab.
4. Patch and Seal – The small drill holes are sealed with a concrete patch for a seamless finish.

Why Concrete Slabs Crack and Settle Over Time

Cracks and settling in concrete slabs are often caused by soil movement, water intrusion, and improper compaction. When the ground beneath the slab shifts or erodes, voids form, causing the concrete to sink and develop cracks.

Common causes of cracked concrete and settlement include:

• Soil Erosion – Water can wash away the soil underneath the concrete, leaving holes in the slab.
• Freeze-Thaw Cycles – Water expands when frozen, leading to hairline cracks that worsen over time.
• Poor Soil Compaction – If the ground wasn’t properly compacted before the slab was poured, the concrete will eventually sink.

Can Foam Lifting Fix Cracks in Concrete?

While foam lifting is an excellent concrete leveling repair method, it is not always a complete solution for cracked concrete. The effectiveness of polylift concrete leveling depends on the severity of the crack and its underlying cause.

When Foam Leveling Is an Effective Solution

Foam injection works well when cracks are caused by settlement or sinking rather than deep structural damage. If the majority of cracks in a slab are due to soil shifting rather than internal fractures, polylifting can stabilize and prevent further deterioration.

When You Need an Alternative Concrete Repair Method

If cracks are deep, wide, or extending through the entire slab, foam lifting alone will not be enough. Instead, additional concrete patching or full slab replacement may be required. In cases where foundation repair is necessary, techniques such as epoxy injection or structural reinforcement might be the best answer.

Foam Concrete Leveling vs. Other Concrete Lifting Methods

There are three concrete leveling methods commonly used today:

• Mudjacking – Uses a cement-based slurry to lift concrete, but it is heavy and prone to further settling.
• Stone Slurry Grout Concrete Leveling – A hybrid method that is heavier than foam but lighter than traditional mudjacking.
• Polyurethane Foam Leveling – A lightweight, durable method that offers superior stability and longevity.

Polyurethane Foam vs. Mudjacking: Which Is Better?

Mudjacking is an older technique that relies on a dense slurry, while polyurethane concrete lifting is lighter and more precise.

Key differences include:

• Weight – Expanding polyurethane is much lighter than a cement-based slurry, reducing stress on the soil.
• Cure Time – Foam cures within 15 minutes, whereas mudjacking can take hours or even days.

Foam Concrete Leveling vs. Slab Replacement

Replacing the concrete is expensive and time-consuming. Concrete leveling can save up to half the cost compared to a full replacement. If the slab is severely damaged beyond repair, then replacement may be the only option.

Advantages and Disadvantages of Foam Lifting for Concrete Repair

Key Benefits of Using Concrete Lifting Foam

Foam lifting offers several advantages over traditional repair methods:

• Minimal Disruption – The process takes only a few hours, and the area can be used the same day.
• Cost-Effective – The cost of replacement is much higher than lifting concrete slabs with foam.

Limitations and When to Consider Other Repair Options

While polylift concrete leveling is a great solution, it does not repair severely broken concrete or deep structural fractures. If the slab is beyond repair, replacing the concrete might be the only option.

Final Thoughts: Is Foam Lifting the Right Solution for Your Concrete Needs?

Foam lifting is one of the most effective ways to lift your concrete, fill voids, and prevent further settlement. If your slab is sunken concrete but still structurally sound, polyurethane concrete leveling is the best answer for long-term durability. For a precise evaluation of your project, request a free onsite cost estimate today with Superior Polylift and find out how concrete leveling and concrete lifting can save you thousands compared to a full replacement!