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Hovis slab stabilisation

Challenge

Settlement beneath an industrial floor slab at a Hovis facility caused voids and loss of support, requiring stabilisation without interrupting production operations.

Solution

Geobear used precision geopolymer injection to fill voids and re‑support the slab, restoring bearing capacity quickly with minimal disruption to site activities.

Industrial facility

Operational food production site

Floor slab stabilised

Voids filled and support restored

Minimal downtime

Works completed alongside operations

Background

An operational Hovis production facility experienced localised settlement beneath a concrete floor slab. Voids had developed below the slab, reducing bearing capacity and increasing the risk of further movement.

Maintaining continuous production was critical, so any remedial works needed to be completed quickly and safely within a live industrial environment.

Challenge

Traditional repair methods would have required breaking out and reconstructing sections of slab, leading to significant downtime and disruption to operations.

The client required a non‑intrusive method capable of restoring support and stabilising the slab while allowing the facility to remain operational.

Solutions

Geobear implemented a targeted geopolymer injection programme to address the underlying voids and weak ground conditions.

Small‑diameter injection points were drilled through the slab, allowing a two‑component geopolymer to be introduced beneath the affected areas. As the material expanded, it filled voids, compacted loose soils and restored uniform support.

The process was monitored in real time to ensure precise control and effective stabilisation.

Results

The floor slab was successfully stabilised without excavation or replacement.

Works were completed rapidly and with minimal disruption, enabling the Hovis facility to continue operations while delivering a durable, lower‑carbon alternative to traditional slab reconstruction.

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