Factory Floor Void Filling

Factory Floor Void Filling


A GPR study indicated extensive voids under the floor of a manufacturing facility.  The building had been built in stages, and large stormwater pipes had been buried under the floor without ensuring their integrity beforehand.  Voids developed adjacent to the buried stormwater pipes and in other areas of the facility.  The GPR study indicated that voids were as small as 1/4″ and as large as 6″.  Approximately 3,000 square feet were affected by voids, with about 200 square feet showing signs of 1/4″ of differential movement (settlement).


factory floor void fillingThe work had to be completed off hours since most of the areas were in forklift aisles.  The material used for void filling had to cure quickly so that when the facility reopened in the morning equipment could operate without affecting the integrity of the void filling material.


Polyurethane grouting to raise and support the interior floor slabs. Geotechnical polyurethane injection was chosen because of its speed, cleanliness, and light weight material, which helps to reduce chances of future settlement.

Areas repaired with polyurethane grouting can be used immediate by heavy industrial traffic such as fork lifts.  However, in this facility, the spread out location of the repair areas, and the limited access locations made it easier to complete work outside of normal operations hours.


CJGeo concrete floor repair crew completed the project in one night.  Approximately 20 cubic yards of high density polyurethane were placed, and successfully restored the structural integrity of the floor.  Operations resumed the next morning after the factory floor void filling.