Every year, the Spray Polyurethane Foam Alliance recognizes some of the top polyurethane projects in the country during the annual SPFA Convention & Expo. The event brings together contractors, manufacturers, and industry professionals from across the nation to showcase advancements in polyurethane technology and celebrate projects that push the industry forward.
RPC Industries, Inc. and JACKCRETE of Virginia are proud to announce that we were awarded the 2026 SPFA National Industry Excellence Award in the Concrete Lifting category for our work on the Harrell’s Mill Pond Spillway restoration project in Jarratt, Virginia.
The project represented a unique combination of historical preservation, soil stabilization, void filling, and structural support. More importantly, it demonstrated how polyurethane technology can solve complex infrastructure problems while preserving structures that traditional repair methods often cannot.
A Historic Structure Facing Serious Failure
Harrell’s Mill Pond dates back to 1864, when the original pond and mill were constructed to power a local grain mill serving the surrounding community. After the mill was destroyed during the Civil War, it was rebuilt in 1915 and continued operating for decades before eventually becoming a private fishing property.
Over time, the pond’s concrete-reinforced earthen spillway began developing significant leakage issues. Water flowing through the structure created erosion beneath the spillway, washing away supporting soils and creating large underground voids beneath the concrete structure. Previous attempts to stop the leak using excavation, tarps, and membrane systems had proven unsuccessful.
Due to the age and historical importance of the structure, complete replacement was never considered a desirable option. The owners needed a solution capable of stabilizing the spillway while preserving the integrity and history of the site itself.
Why Polyurethane Was the Right Solution
After evaluating the project conditions, polyurethane injection was determined to be the most effective and least invasive repair method available.
Traditional mudjacking methods would have introduced excessive weight into the already unstable and swampy environment surrounding the spillway. Full replacement would have required major reconstruction and dramatically altered a historic structure that has existed for more than 160 years.
Using hydrophobic polyurethane foam, the JACKCRETE team was able to inject material beneath and around the spillway structure, displacing flowing water, filling void spaces, stabilizing soils, and restoring structural support. Once complete, the water channel beneath the spillway was eliminated and the ongoing erosion stopped completely.
The lightweight nature of polyurethane made it the ideal solution for the conditions present on the project while allowing the repair to be completed with minimal disruption to the surrounding site.
Challenging Conditions Require Experienced Crews
Projects recognized by SPFA are rarely simple, and the Harrell’s Mill Pond restoration was no exception.
The project involved active flowing water conditions, extensive void space beneath the structure, and concrete sections measuring over five feet thick. The remote rural location also created additional logistical and equipment challenges for the crew.
Despite the difficult conditions, the project was completed over two long days, with the project led by Chris Frazier, SPFA-PCP Master Installer, and and Bryan Heldreth, SPFA-PCP Project Manager. During the SPFA award ceremony that our team was awarded at, Chris expanded his expertise with further SPFA-PCP certifications.
The team utilized a self-contained rig equipped with a PMC PH-2 Proportioner, PX-7 spray foam guns, and IPM transfer pumps to precisely install the polyurethane beneath the spillway structure.
As with every JACKCRETE project, safety remained a top priority throughout the process. All personnel involved held SPFA-PCP certifications in addition to OSHA and CPI safety training credentials, while the project itself followed RPC Industries’ comprehensive safety and hazard analysis procedures.
Continuing a Tradition of Award-Winning Work
JACKCRETE evolved from the experienced polyurethane specialists at RPC Industries, Inc., a company that has been working within the polyurethane industry since the 1970s. Over the years, JACKCRETE has continued to grow into one of the leading concrete lifting, leveling, and soil stabilization contractors in the region.
The 2026 SPFA National Industry Excellence Award adds to previous national honors earned in 2015, 2016, 2018, 2020, and 2025, and reflects the continued commitment of the JACKCRETE team to innovation, professionalism, safety, and quality workmanship.
We are honored to once again be recognized by the SPFA and proud of the opportunity to preserve an important piece of Virginia history.
