Alchatek Blog

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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Management at a luxury hotel in Atlanta contacted geotech specialists Panhandle Seawall and Infrastructure after discovering significant voids beneath their swimming pool during routine maintenance. What began as a standard pool inspection quickly escalated into a serious structural emergency that threatened the integrity of part of the building. PSI was able to mobilize within days, providing temporary support until the foundation contractor could underpin the column footing and provide a permanent solution.

Initial Assessment

The investigation began when hotel maintenance staff noticed several concerning issues:

• Visible cracks developing in the pool structure.
• Accelerated water loss beyond normal evaporation.
• Significant increase in monthly water bills.
• Further investigation revealed an approximately 800 cubic foot void beneath the pool.
• A critical structural issue where a column footing was precariously supported only by the edge of a rock formation.

The severity of the situation led to a partial condemnation of the hotel structure, requiring immediate intervention to prevent potential catastrophic failure.

Proposed Solution

After careful evaluation by the project engineers, AP Lift 475 was selected as the optimal solution due to its superior characteristics:

• Higher density formulation for enhanced structural support.
• Superior bearing capacity to meet engineering requirements.
• Rapid deployment capabilities for emergency situations.

The project required approximately 300 gallons of material, deployed in three separate sets, to provide the necessary structural reinforcement.

Procedures

1. Safety Implementation

• Installation of proper ventilation systems.
• Deployment of temporary support beams.
• Setup of adequate lighting for the work area.

2. Grout Implementation

• Initial deployment of the Deep Lock® method to solidify underlying soil.
• Systematic void filling through carefully timed injection intervals.
• Continuous monitoring of material flow and structural response.
• Progressive filling to ensure complete void elimination and stabilization of footing.

Results and Conclusion

• The emergency shoring proved successful on multiple fronts:
• Complete stabilization of the compromised column footing.
• Establishment of solid connectivity between the underlying soil and structural elements.
• Prevention of further structural degradation.
• Removal of condemnation threat to the building.
• Restoration of structural integrity to engineering standards.

The project demonstrated the effectiveness of polyurethane void fill as a rapid response solution for critical structural emergencies, successfully averting potential building failure while providing a long-term stabilization solution.

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