Initial Assessment

The team at PURLevel was contacted regarding significant floor settlement issues at Outpost Harley-Davidson in Pueblo, Colorado, where a water pipe rupture had resulted in concrete movement and void spaces beneath the floor. The affected areas showed uneven surfaces with depressions ranging from 0.25 to 3 inches, creating hazards for both foot and equipment traffic.

Proposed Solution

AP Lift 430 polyurethane foam was selected for this project due to its excellent void-filling and lifting capabilities. With its 22x expansion capability and 7,200 psf compressive strength, this material is ideal for commercial floors supporting heavy equipment like that found in a motorcycle dealership.

Procedures

1. Site Preparation

   • The affected area was thoroughly inspected to determine the full extent of damage.
   • A 5'x5' grid pattern was marked across the entire interior floor area.

2. Grid Injection

   • Strategically placed injection points were established following the grid pattern.
   • Holes were drilled through the concrete slab at each injection point.
   • Polyurethane foam was systematically injected to fill voids beneath the slab.

3. Lift and Stabilization

   • After initial void filling, additional injections were performed to lift the sunken areas gradually.
   • An incremental lifting approach was used to prevent concrete cracking.
   • Areas requiring significant lift (up to 3 inches) received multiple injection passes.
   • Levels were continuously monitored to ensure even lifting across the floor surface.

Results

The project successfully stabilized the Outpost Harley-Davidson floor and restored it to its proper level. The comprehensive void-filling addressed the underlying instability caused by the water pipe rupture, providing a solid foundation for the concrete slab. Success was evident in the restored functionality of the dealership floor and the elimination of safety hazards posed by the uneven surface.

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