Curled Slab Repair with Polyurethane Foam Injections in Littleton, MA
Work took place in confined areas as shown here. The polyurethane foam was successfully injected within the limited working area.
Polyurethane Injections were performed to stabilize the curled concrete slabs. The work took place during night hours and did not interrupt the busy distribution warehouse.
The Challenge
Approximately four acres of concrete warehouse slabs were affected by a condition known as slab curling, where the edges of the slabs had curled upward over time. This curling led to cracking, joint deterioration, and uneven surfaces that were being subjected to constant heavy forklift traffic. The ongoing movement threatened further damage to the concrete and posed operational risks within the facility.
Compounding the issue, the warehouse housed an active distribution business that could not tolerate downtime, restricted access, or disruptive construction activities.
Project Considerations
Traditional concrete replacement or large-scale repairs were not feasible due to the size of the affected area and the need to keep warehouse operations fully functional. The work also needed to be performed in confined interior spaces, requiring a precise and minimally invasive repair method that would not interfere with daily logistics.
Our Solution
Engineered Foundation Technologies implemented polyurethane foam injections to stabilize the curled concrete slabs. A specialty structural polyurethane foam was injected directly at the curled expansion joints. The foam expanded beneath the slabs, providing support and effectively stabilizing the concrete to prevent further movement and damage from forklift traffic.
The injections were performed successfully within the limited working areas of the active warehouse environment.
Results & Benefits
The polyurethane injection process significantly improved the condition of the warehouse floor and stabilized four acres of concrete in under four work shifts. The repair minimized disruption to ongoing operations while delivering a long-term structural solution. Compared to alternative methods, the process was faster, cleaner, and far less intrusive.