Warehouse
Warehouse
Shallow voids beneath an existing warehouse floor slab threatened support for new mezzanine base plates within a live operational facility.
Solution
Geobear used targeted geopolymer injection to fill shallow slab voids beneath new mezzanine base plates, restoring full bearing support with minimal disruption.
Targeted void filling completed.
Five treatment holes per location
Works completed on site
A specialist fit-out contractor appointed Geobear to carry out targeted ground improvement works within an operational warehouse at Gloucester Business Park. During construction of a new mezzanine floor, shallow voids measuring approximately 5–10 mm were identified beneath the existing concrete slab at the proposed mezzanine base plate locations. If left untreated, these voids could have affected load transfer beneath the new structural supports.
The project formed part of an ongoing warehouse fit-out programme and required a solution that could be delivered quickly, safely and with minimal disruption to warehouse operations. The building remained fully operational throughout the works, with warehouse activities and customer-facing areas continuing as normal. Traditional slab breakout and reinstatement would have delayed the programme and created unnecessary disruption, making a non-invasive engineering solution the preferred approach.
Although the identified voids measured only 5–10 mm, they were located directly beneath the proposed mezzanine base plate positions where full bearing support was essential. Even small unsupported gaps beneath heavily loaded steel columns can lead to uneven load transfer and increased local stresses within the concrete slab.
The works involved treating 13 separate base plate locations distributed across an operational warehouse. Access had to be carefully managed to ensure warehouse traffic and customer operations could continue safely throughout the installation. Parking and hose routes also required coordination to avoid obstructing daily activities.
Before drilling commenced, buried services required verification using both existing site information and a secondary Geobear service scan. Floor finishes also varied across the treatment area, with carpet removed before installation where necessary while vinyl flooring remained in place and was drilled through before reinstatement.
A traditional repair involving local concrete breakout and replacement would have increased programme duration, generated significant dust and waste, and interrupted warehouse operations. A targeted, non-invasive solution capable of filling the shallow voids without disturbing the existing slab was therefore required.
Geobear designed a bespoke geopolymer injection solution to fill the shallow voids beneath each proposed mezzanine base plate, providing continuous bearing support without removing or replacing the existing concrete slab.
The treatment was carried out beneath 13 individual base plate locations. Each location was drilled using five injection holes, giving a total of 65 drilled holes across the project. A Geobear structural geopolymer was selected for the installation.
The installation methodology involved injecting geopolymer through the central injection hole while monitoring the remaining four holes for material breakthrough, confirming that the void beneath each base plate had been completely filled. Where practical, a borescope inspection was planned to provide additional visual verification of the completed void filling.
Prior to drilling, Geobear completed a secondary utility survey to verify buried services before installation commenced. Auxiliary monitoring equipment was used throughout the injection process to maintain precise control of material placement and ensure the geopolymer remained confined within the targeted treatment zone.
The works were completed by a two-person drill and injection team within a single working day. Equipment remained outside the building, with hoses routed through the warehouse entrance to minimise disruption to normal operations while maintaining safe access throughout the facility.
Geobear successfully filled the shallow voids beneath all 13 mezzanine base plate locations, providing continuous support beneath the new structural steelwork while preserving the existing concrete floor slab.
The entire programme was completed within a single day, allowing the wider warehouse fit-out works to continue without significant delay. Because the solution required only small drilled injection holes, disruption, dust and waste were kept to a minimum compared with traditional concrete breakout and reinstatement methods.
The project demonstrates how geopolymer injection can provide a precise and efficient engineering solution where localised slab voiding is identified beneath new structural elements. By targeting only the affected areas, Geobear enabled the contractor to continue the mezzanine installation programme while maintaining warehouse operations throughout the works.
Don't let unstable ground put your business at risk. Our commercial team can provide a clear assessment and a fast, effective solution tailored to your operational needs.
