Warehouse Floor Stabilization

Warehouse Floor Stabilization Project in Greensboro, North Carolina

Problem:

500 linear feet of floor joints inside of a consumer goods manufacturing warehouse were flexing, causing palleted loads to shift while being moved with fork trucks.  The movement of the floor with differential loading also caused the fork truck tires to wear prematurely.  

Constraints: 

The facility operated on a 24/7 schedule; no downtime was tolerable outside of a planned single-day shut down.  The area requiring repair was within the loading dock area, so there was very high forklift traffic which couldn’t be disrupted. 

Because of the constant traffic in the facility, once an area was repaired, it had to be opened to traffic immediately in order to shut down the adjacent area.  Given that the repair stretched 500 feet across most of the width of the loading docks, speed of treatment and return to service were particularly important.

Solution:

Warehouse floor stabilization using polyurethane grouting to address slab curl and settlement.High density polyurethane grouting to stabilize the shifting joints.  The work was scheduled for during a shutdown, which reduced the amount of traffic.  However, significant work was being done by other trades, which were utilizing the loading docks for their work.

Polyurethane grouting is the  most appropriate grouting method for addressing slab curl and settlement inside of industrial facilities.  Polyurethane grouts are very low viscosity, so they travel very well into very small voids.  This is unlike cement grouts, which have to be watered down in order to flow into very tight voids, where they’re then subject to breakdown due to low strength from such high water content.

Unlike cement grouts, polyurethane grout cures very quickly, which allows for immediate load testing.  This speeds the return to service and ensures a complete repair from the beginning.

Result:

CJGeo polyurethane grouting crew stabilized all 500 linear feet of joint in the floor in 3.5 hours.  During the warehouse floor stabilization work, all joints were tested with loaded fork trucks immediately after material placement, and none of them flexed during load testing.