FLOOR REPAIR OF THE FINISHED PRODUCTS WAREHOUSE OF A/T TOBACCO COMPANY «V.A.T.-PRYLUKY» PrJSC

For high-intensity warehouse logistics, the condition of the floor affects operational efficiency and safety. For such a large-scale company,PJSC “A/T Tobacco Company “V.A.T.-PRYLUKI””Failures and downtime due to floor deformations are simply unacceptable.

Reason for appeal: Floor covering defects in the warehouse complex

During the operation of the warehouse, dangerous destructive processes were recorded at the local site:

• Slab subsidencehalf: Formation of level differences, which complicates the movement of warehouse equipment.
• Cracks in the concrete slab:Evidence of excessive stress in the slab structure.
• The “cove” effect:During the passage of the equipment, vibration was felt, indicating the presence ofhidden voidson the basis of.

Diagnosis: The root of the problem is the “human factor” in construction

A detailed examination showed that the cause of the deformations wasinsufficiently compacted backfill soil. During the construction of the warehouse, the soil under the slab was not brought to the required density. Under the influence of the weight of the finished product and dynamic loads from the loaders, natural compaction of the soil occurred, which led to:

1. Formation of air lenses (voids) between the slab and the soil.
2. Loss of support for the slab, causing it to start to bend, leading to cracking.
3. Violation of the geometric evenness of the floor.

Technical solution: Comprehensive stabilization and lifting

A win-win combination of methods was chosen to restore the industrial floorGeoresin:

1. Deep Lifting Method – Deep Strengthening

The goal is to eliminate the very cause of subsidence. The geopolymer was introduced into the soil layers to a considerable depth. Expanding, the composition compacted the loose backfill, creating a reliable, stable foundation capable of withstanding multi-ton loads of warehouse racks and equipment.

2. Floor Lifting Method – Leveling the Slab

The goal is to fill the voids under the slab and restore its position. Due to the expansion of the material, the slab was smoothly raised to the design marks. The process was accompaniedreal-time laser leveling, which made it possible to achieve millimeter accuracy.

Benefits for current production

The choice of GeoResin technologies for the tobacco company was due to strict requirements for cleanliness and process continuity:

• Cleanliness (Dust-Free):Working through small diameter holes (12–16 mm) eliminates the formation of dust and dirt, which is critically important for the food and tobacco industries.
• Without stopping the train:The work was carried out locally. The warehouse continued to operate without requiring unloading of products or covering the entire premises. No additional costs or downtime.
• Speed ​​of commissioning:Geopolymer gains 90% of its design strength after15 minutesImmediately after the injections were completed, the warehouse equipment was able to return to work in the restored area.
• Water resistance:GeoResin material is moisture-proof, protecting the floor structure from the negative effects of groundwater in the future.

Final result

As a result of the work carried out on a plot of 91.56 m2:

1. The voids under the floor slab have been completely eliminated.
2. Compacted and reinforced base.
3. The floor slab is raised to the specified level, and the flatness of the covering is restored.
4. The risks of further development of cracks and destruction of concrete are eliminated.

The use of GeoResin geopolymer technologies allowed the emergency area of ​​the warehouse to be transformed into a reliable working area in just a few shifts, saving the customer money on floor dismantling and preventing operational losses from downtime.

If your warehouse is losing efficiency due to “playing” floors or cracks, contact us.Georesin technologies solve problems quickly, accurately and reliably. Remember that voids under the slab are a time bomb for warehouse equipment.