Concrete Void Filling

Challenge

Located in Dover, New Jersey, Casio America, Inc.'s  warehouse floor was in need of repair.  Voids beneath the concrete floor and uneven slabs posed serious safety issues for their employees.  In addition, the uneven slabs and voids contributed to excessive wear on their warehouse equipment as well as concern regarding the overall stability of the slab.  In order to provide uninterrupted service to their customers, Casio America, Inc. was not in a position to shut down the warehouse for repairs.  Therefore, a quick, non-invasive solution was a requirement. 

Solution

Casio America, Inc. selected Quality 1st Contracting to resolve the issues with their warehouse floor.  Quality 1st proposed using PolyLEVEL™, a two-part urethane that expands into a rigid foam used to fill voids, stabilize slabs and lift concrete.  Once injected through small 5/8-inch drilled holes in a slab or surface, a chemical reaction converts the liquid urethane components into a strong, rapidly-setting, waterproof foam material.  In its foam state, PolyLEVEL™ is very light, weighing two to six pounds per cubic foot (pcf).  Other void-filling or lifting materials can weigh upwards of 120 pcf, adding significant weight to supporting soils or base materials and potentially contributing to further settlement.  With a typical in-place compressive strength of 100 pounds per square inch (psi), PolyLEVEL™ 400 (PL400) commercial foam was proposed to fill the voids, lift the concrete and support the floor slab.  In a matter of hours, the warehouse floor was lifted back to its original elevation, and all voids were filled with minimal disruption to the Casio warehouse staff.  Casio America, Inc. was so pleased with the results, they immediately contracted with Quality 1st to resolve other areas of concern within their warehouse.

Project Summary

Installing Contractor: Quality 1st Contracting, NJ

Quality 1st Certified Inspector: Ken Peare

Quality 1st Project Supervisor: Moises Alvarado

Products Installed: PL400 - PolyLEVEL™ Commercial Grade Polyurethane