Heavy-Traffic Hardstand Restored Through Teretek® Resin Injection & Joint Sealing

The 2,531 m² concrete hardstand was exposed to frequent movements of large delivery vehicles and forklifts carrying heavy loads. Water entering the joints between the concrete panels was pressurised by this traffic and expelled from beneath the slabs, carrying fine supporting material with it.

Over time, this soil washout created voids directly beneath the concrete, reducing support and contributing to differential movement and spalling along the slab edges. Sections of the slabs had cracked and, in some areas, completely snapped due to the loss of underlying support. This reduced their structural strength and created additional pathways for water to enter, further accelerating the deterioration.

Uneven transitions had also developed between adjoining panels, affecting the performance and serviceability of the high-traffic pavement. Because the factory operates six days a week and relies on uninterrupted vehicle movements to fulfil customer orders, the repair methodology needed to minimise downtime and allow treated areas to be returned to service quickly.

Teretek® polyurethane resin was injected directly beneath the slab joints to fill subsurface voids and restore contact between the concrete and supporting ground. Where required, controlled injections were also used to lift individual slab sections and improve transitions between adjoining panels.

Once the slabs had been re-supported, carbon fibre crack locks were installed to stitch the cracked sections of concrete back together. This reconnected the separated sections of the slabs, restored tensile strength and helped extend the service life of the existing concrete.

Damaged and spalled concrete was then removed and reinstated using a fast-curing, high-strength epoxy repair compound. The rapid-curing system allowed repaired areas to be returned to operational use on the same day.

To address the underlying cause of the washout, more than 600 linear metres of concrete joints were cleaned and prepared. The joints were primed before being filled with a flexible, UV-stable and chemically resistant sealant designed to accommodate movement while preventing water from entering beneath the slabs.

Sealing the joints also addressed the pathway through which water had been entering and washing away supporting soils from beneath the pavement, reducing the risk of continued void development and further slab deterioration.

The works were completed within four days with minimal disruption to the facility. Rapid-curing repair materials and targeted resin injection allowed operational areas to be progressively returned to service, enabling truck and forklift movements, customer orders and deliveries to continue without interruption.

By repairing the existing hardstand rather than removing and reconstructing the slabs, the client received a faster and less disruptive solution that reduced downtime and avoided the cost and operational impact of conventional replacement.