Challenge
A 1,292m² warehouse slab at Beckton Industrial Estate had severe differential settlement, with the worst sections 179mm below datum, making the unit un-leasable.
Solution
Geobear was commissioned to lift the slab, installing 555 injection points to inject geopolymer resin, compact the ground, and precisely lift the slab back to tolerance.
Maximum lift achieved
In carbon reduction vs. slab reconstruction
Estimated total carbon saved
The project involved a large, 1,292m² industrial unit at the Beckton Industrial Estate. The concrete floor slab had suffered from extensive and severe differential settlement, making the entire unit unusable and un-leasable for the asset manager, which resulted in significant, ongoing rental losses.
A pre-treatment laser level survey established the full extent of the problem: the worst-affected sections of the slab were 179mm below the required datum. The challenge was to re-level this entire area to a strict tolerance without the extreme cost, timeline, and environmental impact of breaking out and reconstructing the entire slab. The client needed a fast, technical solution to bring the asset back to revenue-generating use.
The primary alternative to Geobear’s slab re-leveling soltuion was to break out and reconstruct the concrete slab, including ground compaction and reinstatement. This method would have taken several months to complete, keeping the unit non-operational and incurring significant further rental losses during that period. The extended timeline and disruption made this option commercially unattractive.
Geobear's design involved installing 555 injection points across the 1,292m² treatment area. A two-part expansive geopolymer resin was injected in a controlled, phased approach. The resin expanded beneath the slab, first filling any voids and compacting the underlying soils, then generating a powerful, controlled upward pressure to lift the slab back towards its original level.
The entire process was monitored by a post-treatment laser level survey to validate the outcome against the pre-treatment benchmark.
The Geobear solution was a complete technical success. The slab was lifted by up to 179mm in the worst areas. Over 90% of the injection points met the agreed tolerance of ±10mm, a specification aligned with TR34 guidelines for floor flatness.
The solution avoided months of disruption and, by preserving the existing slab, generated a carbon saving of approximately 144,000 kg CO₂e—a 78% reduction compared to traditional slab reconstruction. The asset was quickly returned to a leasable condition, ending the client's void period.
Don't let slab settlement make your industrial property un-leasable. Get a fast, technical, low-carbon solution.
