Integrated Concrete Repairs Restore High-Traffic Logistics Hardstand

During rainfall, water entered the joints between the concrete slabs and accumulated within the underlying pavement structure. As heavy trucks and forklifts travelled across the hardstand, loading on the slabs forced the trapped water back through the joints, carrying fine supporting soils with it.

This repeated pumping and washout progressively created voids beneath the concrete and reduced uniform support across the slab interfaces. As the supporting ground deteriorated, the slabs began to move independently, resulting in cracking, slab deterioration, spalled edges and uneven transitions at the joints. Without intervention, continued heavy traffic would have accelerated the deterioration and increased the risk of more extensive slab failure.

Traditional removal and replacement would have caused significant disruption to the operational area. The client therefore sought a faster, targeted repair solution that could address the visible concrete damage, restore support beneath the slabs and eliminate the underlying cause of the ongoing movement.

Teretek^Æ 1000 resin was injected directly beneath the affected slab joints to fill subsurface voids, restore support and, where required, achieve controlled lifting to create smoother transitions between adjoining slabs. Approximately 574 kg of resin was injected across the 140 m≤ treatment area.

Once the slabs had been re-supported, the damaged and spalled concrete was removed and reinstated using a fast-curing, high-strength epoxy repair compound. Carbon fibre crack ties were installed across cracked sections to stitch the concrete together, restrict further lateral separation and improve the strength and longevity of the slabs.

The concrete joints were then cleaned and primed before being filled with a flexible, UV-stable and chemically resistant sealant. Sealing the joints reduced future water ingress and helped prevent further washout of the supporting soils.

Through early intervention, the client was able to preserve the existing concrete slabs and significantly extend the service life of the hardstand. Addressing both the visible damage and the underlying washout also avoided the cost, waste and disruption associated with conventional removal and replacement.

The fast-curing repair materials allowed treated areas to be returned to service on the same day, enabling the logistics facility to continue operating and fulfil customer orders without delay.

This was the third project Mainmark had successfully delivered for the existing client, further demonstrating the reliability and effectiveness of the remedial solutions provided.