Settlement in factory and warehouse floors is typically a ground-related issue rather than a surface defect. When concrete slabs begin to sink, crack or tilt, the visible damage often reflects underlying weakness in the sub-base or fill material.
For asset owners and facilities managers, the decision is strategic: repair, rebuild, or stabilise.
This guide provides an objective overview of the principal repair approaches available for industrial and logistics facilities, outlining the structural, operational and commercial implications of each.
Why Industrial Floors Sink
Industrial floor settlement most commonly occurs due to:
- Poorly compacted fill beneath the slab
- Consolidation of made ground
- Water ingress and erosion
- Vibrations from heavy plant or racking systems
- Increased loading beyond original design parameters
Understanding the root cause is essential before selecting a repair strategy. An engineering assessment should determine whether the issue is primarily structural, geotechnical, or surface-related.
Main repair approaches for sunken warehouse and factory floors
There are three primary intervention strategies used in industrial environments:
- Full floor renewal with piling
- Concrete resurfacing (levelling screed)
- Floor lifting by geopolymer injection
Each approach carries different implications for cost, downtime, structural performance and long-term stability.
Full floor renewal with piling
Method
Removal of the existing slab and reconstruction as a load-bearing structure supported by piles extending to competent soil layers.
What it involves
- Demolition of the existing floor
- Excavation works
- Installation of structural piles
- Construction of a new reinforced slab
Key considerations
- Most comprehensive structural solution
- Highest direct construction cost
- Requires shutdown of the affected area
- Often necessitates relocation of operations
- Significant indirect costs due to downtime and logistics disruption
This option is typically considered where settlement is severe, structural integrity is compromised, or the facility is undergoing major redevelopment. It provides a robust long-term outcome but involves substantial operational interruption.
Concrete re-surfacing (levelling screed)
Method
Application of a new concrete layer to level the surface of the existing slab.
What it involves
- Surface preparation
- Additional concrete pour to restore flatness
Key considerations
- Lower direct cost compared to full reconstruction
- Does not address weak or compressible ground conditions
- Adds significant additional load to the floor
- In heavily settled areas, additional load may reach approximately 2 kN/m²
- May exceed original design load capacity
- Requires operational shutdown during works
While resurfacing can restore floor flatness, it does not strengthen the underlying fill. In certain circumstances, the added weight may accelerate further settlement.
Floor lifting by geopolymer injection
Method
Injection of expanding geopolymer resin beneath the slab to densify the sub-base and re-level the floor.
What it involves
- Small diameter drill holes through the slab
- Controlled injection of geopolymer material
- Real-time monitoring of floor lift
Key considerations
- Minimal disruption to ongoing operations
- No large-scale demolition or excavation required
- Can often be undertaken without fully suspending business activities
- Improves density and bearing capacity of the underlying fill
- Does not add structural load to the slab
In addition to re-levelling the slab, geopolymer injection strengthens the supporting ground, increasing stability without increasing floor weight.
Read a technical paper to learn more.
Operational and commercial considerations
When selecting a repair strategy, direct construction cost is only part of the equation.
Both piling and resurfacing commonly require:
- Suspension of operations
- Temporary relocation of stock or production lines
- Reorganisation of logistics flows
- Potential revenue loss
For active factories and logistics centres, indirect business interruption costs can exceed the construction cost itself.
Solutions that allow operations to continue during repair may therefore offer significant commercial advantages, particularly in high-throughput or time-sensitive environments.
Environmental and sustainability considerations
Industrial redevelopment and slab reconstruction involve significant embodied carbon due to:
- Demolition activities
- Removal and disposal of concrete
- Production of new cement-based materials
- Transportation and plant usage
Ground improvement techniques that avoid slab removal can substantially reduce material consumption and carbon impact while extending asset life.
For organisations with ESG or net-zero objectives, repair strategy selection may influence broader sustainability targets.
Selecting the appropriate solution
The most suitable approach depends on:
- Extent and cause of settlement
- Ground conditions
- Structural design load of the floor
- Operational requirements
- Future development plans
An engineering-led assessment is essential to ensure that the chosen repair method addresses both the visible symptoms and the underlying cause — while aligning with operational and commercial priorities.
Need an engineering assessment?
If your warehouse or factory floor is showing signs of settlement, early intervention can prevent escalation and minimise disruption.
A professional structural and geotechnical assessment can determine:
- The root cause of movement
- The extent of affected areas
- The most proportionate repair strategy
- The likely operational implications
Understanding your options enables informed decision-making — technically, commercially and strategically.
