Casio America Warehouse Slab
Challenge
Voids were suspected beneath areas of Casio America, Inc.'s concrete slab-on-grade warehouse floor. The voids caused rocking in slab sections and vertical displacements at joints under the weight of forklift traffic. Jarring bumps in the slab damaged both inventory and equipment. The company was also concerned about the safety of the equipment operators and surrounding personnel. Continued use of these areas of the warehouse would eventually lead to slab failure if the voids were not filled and slabs resupported. Removal and replacement of sections of concrete was not an option as it would cause disruption to the workflow of the warehouse and potential interruption of service to customers. Therefore, a quick, non-invasive solution was required.
Solution
Foundation Supportworks® of New Jersey proposed using PolyLEVEL™, a twopart urethane that expands into a rigid foam to fill voids, stabilize slabs and lift concrete (when needed). 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, rigid foam material. In its foam state, PolyLEVEL™ is very light, weighing two to six pounds per cubic foot (pcf). Other void-filling materials can weigh upwards of 120 pcf, adding significant weight to supporting soils or base materials and potentially contributing to further settlement. The voids beneath the subject areas of the warehouse floor were filled in just hours with minimal disruption to warehouse staff. Following the PolyLEVEL™ installation, the areas were proofrolled with forklifts to confirm adequate support. Casio America, Inc. was so pleased with the results, they immediately contracted with Foundation Supportworks® of New Jersey to resolve other areas of concern within the warehouse.
Project Summary
Certified PolyLEVEL™ Installer: Foundation Supportworks® of New Jersey
Products Installed: PolyLEVEL™ 400 High Density Polyurethane
Product Characteristics (PL400): 100 psi Compressive Strength, 146 psi Tensile Strength, 69 psi Shear Strength, 19:1 Expansion Rate, 6 pcf Typical In-Place Density
