Warehouse Rocking Slab Stabilization at Grainger Canada Distribution Center

The Challenge

Deteriorating floor slabs posed risks to forklifts.

At a warehouse owned by a distribution center for electrical supplies, concrete floor slabs had begun to sink and deteriorate over time. This type of settlement is common in large distribution facilities, where constant traffic from forklifts, heavy shelving, and daily operations place stress on the flooring. Unfortunately, deterioration had progressed to a point where it posed several serious risks: misaligned joints interfered with forklift operations and unchecked slab movement carried the potential for total structural failure in portions of the floor. These risks threatened both worker safety and the company’s ability to maintain efficient operations. Before long term surface repairs could be made, it was essential to first restore the slabs back to grade, ensuring a safe and stable working environment.

Key Facts

The Solution

Polyurethane injection to stabilize floor slabs.

This is where Groundworks Commercial comes in: the team was contacted to perform polyurethane injection to stabilize the slabs and fill the voids in the soil below. While working under a general contractor, work began. Penny sized holes were carefully drilled in a one meter grid pattern across the affected treatment areas, stretching between 1100 and 1200 square feet. Through these injection points, polyurethane was introduced beneath the slabs in its liquid form. Once in place, the material expanded to fill voids, re-establish soil contact, and provide a stable base beneath the concrete. As the injections progressed, the slabs were gradually re-supported and stabilized, creating a uniform surface that could safely receive the necessary surface repairs.

The Impact

Movement was eliminated from the floor slabs in 1 day.

This project was completed in a single day! Groundworks Commercial successfully stabilized the floor slabs, eliminating the movement that had threatened forklifts and daily warehouse operations. By addressing the underlying soil voids and restoring the slabs to a stable condition, the team not only improved safety but also extended the service life of the warehouse floor. The quick turnaround minimized downtime for Grainger Canada, allowing them to resume operations without costly delays. With the polyurethane injections complete, the company could immediately move forward with surface repairs, confident that the slabs were fully supported for the long term.