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Lifting and Leveling a 217mm Sunken Factory Floor Using Urethane Foam Injection in Tay Ninh
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Project Summary:
Location: Japanese enterprise factory in Tay Ninh Province, Vietnam
Scale: 20,000 m² (processed across 4 factory buildings)
Initial Condition: Maximum settlement of 217 mm, causing floor tilting and operational disruption
Solution: Floor lifting and leveling technology using rigid urethane foam injection (Upcon)
Execution Time: 57 days (Executed entirely at night to maintain full daytime production schedules)
1. On-Site Challenges: Severe Risks from Sunken Factory Floors
During long-term operation, industrial plants frequently face floor settlement and subsidence due to heavy machinery loads, continuous forklift traffic, or weak subgrade conditions. At the facility in Tay Ninh, floor settlement reached a critical level:
Large Structural Gaps: The maximum settlement reached 217 mm, causing the concrete slab to detach and create dangerous gaps between columns and the building structure.
Impact on Internal Logistics: Tilting floor slabs caused goods stored on pallets to lean, creating risk of collapse, obstructing forklift movements, and increasing occupational safety hazards.
The Main Challenge: The factory could not afford to halt its production lines for demolition or traditional concrete slab reconstruction, as shutting down operations would incur immense financial losses.
2. Rigid Urethane Foam Injection Solution (Upcon) – Zero Demolition, Zero Production Halt
To address this complex challenge, the enterprise chose Upcon floor lifting technology using rigid urethane foam.
3. Standard 4-Step Construction Process
The execution process follows strict Japanese standards, ensuring cleanliness and maintaining a safe working environment:
Step 1: Preparation & Elevation Survey
Position equipment trucks and route injection hoses to the work area (hose length up to 80m). The technical team utilizes automatic level sensors to measure and continuously monitor slab elevation in real time.
Step 2: Marking & Drilling
Mark injection points and drill small holes through the concrete slab.
Ultra-small hole diameter: Only Ø16 mm (spaced approximately 1 meter apart).
Specialized industrial vacuum cleaners are used during drilling to collect dust, ensuring nearby goods and machinery remain clean.
Step 3: Urethane Injection & Elevation Control
Rigid urethane foam is injected beneath the concrete slab.
Upon injection, the resin rapidly expands and hardens with high lifting force, pushing the sunken concrete floor back to its original target level.
Effective influence radius per injection point: 1.0 to 1.5 meters. Technicians continuously monitor elevation to control lifting accuracy and prevent over-lifting.
Step 4: Grouting & Site Cleanup
Once the target elevation is reached, injection holes are sealed with non-shrink grout. The crew cleans up leftover materials, hoses, and hands over a clean workspace before morning operations begin.
4. Real-World Results
After 57 days of night-shift execution, the 20,000 m² floor settlement repair project was completed with exceptional results:
✅ Complete Settlement Repair: Areas with up to 217 mm of settlement were successfully restored. Elevation deviation across the entire work area was controlled to within 50 mm of the benchmark.
✅ Seamless Floor Transition: Higher sections were smoothed with gentle slopes, ensuring smooth and safe forklift operation.
✅ Structural Integrity Restored: Slab tilt and gaps along perimeter columns and fences were completely resolved.
✅ Zero Production Downtime: The plant maintained 100% operational capacity throughout the entire execution period.
5. Key Advantages of Upcon Technology for Factory Floors
Rapid Execution: Urethane foam expands and hardens rapidly, providing immediate floor lifting results.
No Business Disruption: Flexible night-shift execution or localized zone processing keeps factory operations running smoothly.
Clean & Non-Destructive: Small Ø16mm drill holes produce minimal noise and dust compared to traditional slab replacement.
High Precision: Real-time digital elevation control accurate to the millimeter.
Contact Us for a Free On-Site Inspection & Technical Consultation
If your facility is experiencing floor settlement, tilting slabs, or concrete cracking, contact our team today for a comprehensive site survey and customized engineering proposal!
OKASAN LIVIC VIETNAM CO., LTD.
Hotline/Zalo: 0983086993
