PolyLevel Case Study


Ball Container Facility in Whitby, Ontario

Ball Container Facility in Whitby, Ontario

Differential slab settlement

BEFORE: Differential slab settlement

Slabs returned to a level position

AFTER:Slabs returned to a level position

Excellent compressive strength supports even extreme loads

Excellent compressive strength supports even extreme loads


Project: Ball Packaging
Location: Whitby, Ontario
Date: October, 2014


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 foor 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.


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 Supportworks of Ontarioto 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 into 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.


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.

Project Summary

Installing Contractor: Supportworks of Ontario
Supportworks Certified Inspector: Mike Cordell
Products Installed: PolyLevel®







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