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:
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.
There are three primary intervention strategies used in industrial environments:
Each approach carries different implications for cost, downtime, structural performance and long-term stability.
Removal of the existing slab and reconstruction as a load-bearing structure supported by piles extending to competent soil layers.
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.
Application of a new concrete layer to level the surface of the existing slab.
While resurfacing can restore floor flatness, it does not strengthen the underlying fill. In certain circumstances, the added weight may accelerate further settlement.
Injection of expanding geopolymer resin beneath the slab to densify the sub-base and re-level the floor.
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.
When selecting a repair strategy, direct construction cost is only part of the equation.
Both piling and resurfacing commonly require:
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.
Industrial redevelopment and slab reconstruction involve significant embodied carbon due to:
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.
The most suitable approach depends on:
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.
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:
Understanding your options enables informed decision-making — technically, commercially and strategically.