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Case Study: Commercial Machine Shop Concrete Floor Lifting

Concrete shop floor with several wet patches, a small propane tank on the left, and a coiled yellow extension cord near the right; a red hose reel is mounted on a blue wall in the background.
image of damaged sunken concrete floor before concrete floor lifting from Stabil Solutions

Problem:

A commercial machine shop noticed several warning signs that suggested the concrete floor was no longer being fully supported by the underlying soils. Existing floor patches produced hollow sounds when walked on, indicating potential subsurface voids. Additionally, the edge of the original concrete slab had settled approximately 1 inch across a 6-foot span, and a separate 5- to 6-foot-wide section of the floor had developed noticeable settlement and sloping. With new machinery scheduled for installation, the facility needed to restore a stable, level floor without the downtime and expense associated with removing and replacing large sections of concrete.

Solution:

After evaluating the affected areas, Stabil Solutions recommended polyurethane injection concrete floor lifting as a minimally invasive alternative to slab replacement.
Small injection holes were drilled through the concrete in the targeted locations, allowing plural-component polyurethane to be injected beneath the slab. As the material expanded, it filled existing voids, restored contact between the slab and the supporting soils, and stabilized the settled concrete. Injection efforts focused on the hollow-sounding floor patches, the settled slab edge, and the 5- to 6-foot-wide section where the floor had developed an improper slope.
image of Stabil Solutions employees during concrete floor lifting for commercial machine shop
Concrete shop floor with several wet patches, a small propane tank on the left, and a coiled yellow extension cord near the right; a red hose reel is mounted on a blue wall in the background.

Results:

The polyurethane injection successfully filled the underlying voids and achieved a slight lift in the areas that concerned the customer most, improving the overall stability of the machine shop floor ahead of equipment installation. The customer was pleased with the results and was able to move forward with installing new machinery without the delays, excessive costs, and operational disruption that concrete replacement would have required, since the project was completed in a single day.

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