A warehouse complex in the Moscow region, built in 2010, had not caused concern for the owners for a long time. There were minor local settlements, but they were not noticeable. However, in 2024 the situation changed: noticeable deformations of the slabs began. The floor was not just settling, but going in waves. The stability of the racking was disrupted, equipment began to tilt, and personnel started complaining about discomfort and safety. And most importantly, no one understood what was happening under the slab.

What the diagnostics showed
The team of engineers conducted a visual inspection and technical audit, after which they decided on a comprehensive check of the foundation:

• Dynamic probing was carried out at 11 key points;
• A check for voids under the slab was performed at 21 locations;
• Areas most subject to load were selected: near the gates, loading/unloading zones, and racking rows.

The result left no doubt: the soil under the slabs is partially loosened, and in some places there are voids. The foundation cannot withstand operational loads, and the deformation process is progressing.

The classic solution? Long. Noisy. Expensive.
Usually, in such cases, the following is proposed:

• opening the floor;
• excavating the soil;
• backfilling and compaction;
• re‑pouring concrete.

The problem is that this means weeks of downtime, complete shutdown of warehouse operations, and losses. Such a scenario was unacceptable here, and one must not forget that the loosened perimeter would still remain along the edges.

Deep injection method
The engineers proposed a modern and uninterrupted solution – stabilising the foundation by injecting Uretek geopolymer material.

How it works:

• A resin is injected into the soil under the slab through small holes under pressure;
• The material expands, filling voids and strengthening weak areas;
• If necessary, the slab is lifted to the design level;
• All processes are controlled in real time.

How the work proceeded

• The project was promptly agreed with the customer;
• The work was carried out during the day without stopping warehouse operations;
• No heavy equipment was used, and the shipping schedule was not disrupted;
• Noise and vibration levels were minimal, safe for personnel.

The warehouse continued to operate. The racking remained in place. The personnel did not even realise that a surgical operation was taking place “under the hood”.

Result
After completion of the work:

• A geodetic survey was carried out confirming the stabilisation of the foundation;
• Geomonitoring was scheduled to monitor the condition of the foundation over time;
• The owner received a full report and recommendations to prevent repeat deformations.

The slab is levelled. Settlement has been eliminated. The foundation is strengthened. And most importantly, the entire process took place without stopping the business.

Conclusion
When there is a void under the floor and the business needs a stable foundation, the solution must be fast, precise and technological. The deep injection method from URETEK is not just an alternative to excavation. It is a new standard in industrial foundation repair. It works. And it does not stop others from working.