Slab Stabilisation in a Warehouse Factory

This floor instability posed difficulties in loading and unloading warehouse racking and compromised the stability of forklift operations. Concerned about safety and the uninterrupted flow of operations, the owner contacted Mainmark to seek a solution.

Upon inspection, the Mainmark team identifiedthe presence of voiding beneath the floor slabs and deflection of up to 10 mm under load. To rectify the situation, the voids needed to be filled, to restore support, eliminate the deflection, and prevent further deterioration of the floor slabs.

Given the warehouse’s pivotal role in order fulfilment and customer service, maintaining operational continuity with minimal downtime was imperative.

As the warehouse racking was fixed in place and the solution needed to be able to be delivered while the racking remained loaded and in use. Another critical requirement of the client was that best practice be employed around the creation and management of any dust or other contaminants as Hygiene was a crucial concern.

Using a technique known as “stitching”, the Mainmark technicians used a Teretek® material specifically designed for such applications. After drilling an injection array along the slab joints, Teretek® was injected to fill the voids under the edge of the slab, confirmed by the observation of a positive uplift of the slabs of 1 to 2 mm via laser monitoring equipment.

The selected Teretek® material has characteristics and mechanical properties ideally suited to achieving a high degree of flow, the required compressive strength to support the floor loading, and to ensure a complete fill was achieved without excessive lift impacting on the floor slabs.

Throughout the work, the team adhered to best practices for dust suppression to manage any dust generation during drilling, ensuring compliance with necessary food safety requirements.

The rapid-setting properties of Teretek® also made the floor immediately trafficable. By stabilising the warehouse floor, Mainmark ensured enhanced safety for loading and unloading activities, optimised warehouse racking performance, and improved overall operational efficiency.

“We’re very happy with these guys. Their team responded quickly to our query and came down for a site inspection and advice session, which put our minds at ease. A big problem for us was an easy fix for them. Thank you.”

Steven Pike