In the 4 years since construction, the factory floors had settled up to 65 mm, making some areas difficult and costly to operate. The settlement did not stop, with a settlement of 10 mm over the last 12 months. Uretek successfully stabilised and levelled these settled areas to design tolerances without stopping production processes or closing the factory for major repairs.

Tasks
The factory, measuring 155 x 105 metres, was built in a new industrial district of Mytishchi, which was created on land once used as a landfill. The land for the site was reclaimed by placing 2 to 5 metres of fill over the old waste. The factory structure was standard, divided into 5 sections, 21 metres wide and 155 metres long. Strip foundations ran along the partition lines and around the perimeter of the factory. The floors, cast as a slab on ground, extended 20 metres between the foundations.
Geotechnical tests showed:

1. The fill that was placed had not been compacted in layers and was described as “loose” and subject to “self‑compaction”.
2. Highly compressible black organic clays at a depth of 3–7 metres below the fill.
3. Soft silty clays in other zones at a depth of 5–10 metres below the fill.
4. Cavities and voids in the layers of former waste dumps.

The main tasks were to stabilise and restore:

• Settled factory floors
• 2 settled columns
• The mezzanine‑type logistics office
• A factory toilet block that had become unusable
• Food processing block: floors and drains
• Misaligned threshold levels at the entrance to the site.

A combination of Uretek methods was used. Resin injections into the upper layers of the foundation at depths of 6–8 metres to compact soft soils and provide local lifting of structures. Floor slabs were lifted using resin injected directly under the structure to fill voids and lift settled floors.

1. Low‑pressure flowable resins were used to fill cavities and voids.
2. Dynamic probing tests were carried out comprehensively across all factory areas, mapping the quality of the foundation soil layers.
3. Soil stabilisation and compaction were carried out using Deep Injection technology with high‑expansion reactive resins in weak zones.
4. Floor slabs were lifted and voids under the slabs were filled using heavy polymer resins using the Slab Lifting method. All operations were controlled by laser levels and geodetic surveys.

Outcomes
URETEK completed the restoration and stabilisation of the floors and foundations in stages over 2 weeks at times convenient for the client. The factory maintained 100% productivity throughout the entire process.

Results

1. Floors were stabilised and levelled to design tolerances.
2. Remediation was carried out without closing the factory.
3. Factory production was not stopped or seriously affected by the restoration work.
4. No inconvenience was caused to the staff.
5. The client was delighted, as the alternative was to move production elsewhere.