Problem
A distribution centre presented progressive slab joint failure: spalled arrises at contraction joints, failed joint filler, and accumulating impact damage at ramp transitions, with consequential wear to the forklift fleet. Day-shift operations could not be suspended.
Diagnosis
Slab survey mapped joint condition across the facility into repair classes, correlated with traffic routes. The primary failure mechanism was undersized joint filler combined with eroded sub-joint support on the main forklift routes, meaning a like-for-like repair would have failed in the same manner. Repair specification moved to semi-rigid epoxy joint rebuild with steel-armoured edges at the highest-traffic crossings.
Method
Works executed entirely on night shifts in zoned closures agreed with the operations manager, each zone returned to traffic before 5am using high-early-strength materials. Joints saw-cut and rebuilt with semi-rigid filler; spalls repaired with rapid-set repair mortar; armoured joint systems installed at ramp transitions; line marking reinstated per zone.
Outcome
No operating hours were lost across the six-week programme. Joint condition data was handed over as a maintenance baseline, with a re-inspection scheduled at two years.