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UPCON Solution – Instant and Efficient Floor Lifting for Differential Settlement Correction
UPCON is a method using polyurethane to repair, lift and reinforce concrete floors that are sagging, skewed or have voids underneath. This method was developed in Japan and is widely used in factories, warehouses, industrial floors, plants, etc.
1. Introduction
UPCON is an advanced Japanese method that uses expanding polyurethane resin to repair, lift, and stabilize sunken or uneven concrete floors.
It has been widely adopted across Japan for industrial floors, warehouses, factories, and infrastructure where downtime and precision are critical.
The concept is simple yet highly effective:
Small holes (about Ø 16 mm) are drilled through the concrete floor into the void or weak soil below.
Polyurethane (PU) resin is injected through these holes. The resin expands rapidly, filling voids and exerting upward pressure to lift the floor back to its original level.
During injection, laser leveling instruments continuously monitor floor elevation, ensuring millimeter-level precision.
2. Mechanism and Technical Advantages
2.1 Expansion & Filling Mechanism
The polyurethane reacts with ambient moisture, expands, and fills voids or gaps under the slab.
The expansion pressure can reach up to 10 tons/m², providing effective soil compaction and floor lifting capability.
Due to its low density, PU adds minimal additional load to the ground, preventing further settlement compared to cement grout.
2.2 Real-time Leveling Control
Floor elevation is monitored continuously with laser measurement systems to ensure even lifting and prevent cracking.
Injection holes are spaced approximately 1 meter apart to ensure complete coverage of the voided area.
2.3 Key Advantages
| Fast installation | No demolition, no curing time; floor restored within hours |
| Minimal disruption | Operations can continue during repair – no relocation of machinery or stock |
| High precision | Level correction accuracy up to ±1 mm |
| Reduced recurrence of settlement | Lightweight resin and long-term durability prevent re-settlement |
| Eco-friendly | Uses CFC-free materials, non-reactive with groundwater |
3. Construction Process
Survey & Elevation Mapping
Measure floor deflection and identify voided areas.
Drilling Injection Holes
Drill Ø 16 mm holes to the target depth.
Polyurethane Injection & Lifting
Inject controlled amounts of PU while monitoring elevation in real time.
Finishing & Sealing
Seal injection holes and clean the repaired surface.
4. Typical Applications and Effectiveness
Repair of sunken industrial or warehouse floors
Factory and cleanroom floors requiring continuous operation
Floor leveling and stabilization over weak subgrades
Rehabilitation of pavements, slabs, or foundations without reconstruction
In Japan, UPCON has successfully lifted concrete floors up to 50–60 mm over areas exceeding 100 m² per day, proving its efficiency and reliability.
5. Illustrative Diagram
(Example schematic comparing traditional grout vs. UPCON polyurethane foam injection)
The polyurethane foam expands uniformly, fills voids completely, and lifts the slab evenly — achieving durable stabilization with minimal environmental impact.
6. Conclusion
UPCON represents a breakthrough in non-destructive concrete slab repair and ground improvement technology.
Its combination of speed, precision, and sustainability makes it the preferred solution for industrial facilities, logistics centers, and infrastructure projects requiring high flatness and minimal downtime.
UPCON – Japanese Polyurethane Injection Technology for Fast, Accurate, and Sustainable Concrete Floor Repair.
