1. Commercial
Problem:
Ball Packaging is a food / drink container manufacturing facility that operates
24 x 7 and produces over 2.5 billion aluminum cans per year. Heavy loading
and varying slab thickness caused the slabs in the 200,000 square foot facility
to experience differential slab settlement. These areas posed safety concerns
to both foot traffic as well as forklift operations. The containers produced at
Ball are food grade and any proposed solution could not generate any
significant amount of dust.
Solution:
Slab replacement was briefly considered but was eliminated due to the long
term disruption and mess that it would create. Mudjacking was an option but
the potential for extremely messy blow outs coupled with long cure times
eliminated that as an option as well. Ultimately, Ball Packaging chose to work
with Foundation Supportworks of Ontario to install the PolyLEVEL® System to
raise the uneven concrete slabs in their facility. PolyLEVEL® is a two-part
urethane that expands into a rigid foam used to fill voids, stabilize slabs and lift
concrete. Once injected through small 5/8-inch drilled “ports” in a slab, a
chemical reaction converts the liquid urethane components in to a strong,
rapidly-setting foam. In its foam state, PolyLEVEL® is extremely light,
weighing 2.5 to 6 pounds per cubic-foot (pcf). Other void-filling or lifting
materials can weigh upwards of 120 pcf, adding significant stress to
supporting soils which will contribute to further settlement issues. With a
typical installed compressive strength of 75 to 100 pounds per square inch,
PolyLEVEL® provides the necessary strength to support even very heavy
loads.
Results:
Foundation SupportWorks of Ontario injected PolyLEVEL® beneath the
settled slabs and returned them to a safe, and stable position. Using a HEPA
vacuum, the minimal amount of dust generated using the PolyLEVEL®
process was easily contained and the slabs were ready for heavy forklift traffic
within 30 minutes after installation. The entire process was completed in less
than a day with no impact to daily operations.
Installing Contractor: Foundation SupportWorks of Ontario
Foundation SupportWorks Certified Inspector: Mike Cordell
Products Installed: PolyLEVEL
PolyLEVEL™
Project: Ball Packaging
Location: Whitby, Ontario
Date: October, 2014
© 2009 Foundation Supportworks, Inc. All Rights Reserved.
Project Summary
BEFORE: Differential slab settlement
CASE STUDY
Ball Container Facility in Whitby, Ontario
AFTER: Slabs returned to a level position
Excellent compressive strength supports
even extreme loads