Controlled Slab Lifting in an Active Cool Dock Environment: A 300 LF Joint Realignment Project

This weekend, Loral Concrete Slab Solutions is performing a targeted slab correction in a high-traffic cool dock environment.

Project Overview

The project involves approximately 300 linear feet of slab settlement occurring along a pour strip, where large-format slab sections (approximately 50’ x 70’) have settled 1/8″ to 5/16″ below the adjacent slab. Both sides of the joint are protected with armored joint systems, creating a rigid interface where even minor elevation differences can significantly impact performance.

In addition to the structural considerations, the repair must be completed within a 12-hour operational window, with the facility returning to full service immediately afterward.

Site Constraints

This repair presents several critical constraints that eliminate many traditional approaches:

• The facility utilizes hydrogen-powered forklifts and fueling stations
• No sparks are permitted within the work environment
• Armored joints on both sides require precise realignment without damage
• The repair must be completed in a single overnight shift

Why Traditional Repair Methods Are the Best Solution

In situations like this, commonly considered repair methods include:

Full-Depth Removal and Replacement

• Removal and replacement of a section approximately 10 feet wide by 300 feet long
• Highly disruptive to operations
• Significant cost and extended downtime

Epoxy Mortar Overlay

• Installation of a 10-foot-wide overlay, feathered to transition the elevation difference’
• Alters the original slab profile
• Results in visible color and texture variation
• Introduces long-term maintenance considerations

Grinding

Grinding is not a viable option in this scenario due to:

• The presence of armored joints
• The inability to safely or effectively reduce the elevation of the pour strip
• Operational restrictions related to spark generation

The Loral Engineered Approach

Rather than modifying the surface or replacing large sections of slab, Loral is implementing a controlled slab correction strategy focused on restoring the original elevation.

1. Controlled Mass Slab Lifting

• Polyurethane injection used to lift the settled slab
• Lift is carefully monitored and controlled to match the adjacent pour strip elevation
• Maintains the integrity of the existing armored joints

2. Elevation-Controlled Lifting

• Lift progression is controlled to prevent overcorrection
• Continuous monitoring ensures alignment across the full 300 LF

3. Precision Joint Stabilization

• Targeted stabilization is performed to improve long-term slab support
• Reduces the likelihood of future settlement

4. Joint Filler Restoration

• Existing joint material is removed and replaced
• Polyurea joint filler installed to restore joint performance and durability

Project Objective

The goal of this repair is to:

• Restore slab elevation to functional tolerance
• Realign armored joint edges
• Reduce forklift impact and vibration
• Deliver a solution that is both minimally invasive and long-lasting

A Controlled, Engineered Solution

This project reflects a key principle in concrete repair:

The objective is not simply to fix the surface—but to correct the underlying condition with precision.

By combining controlled lifting, stabilization, and joint restoration, Loral is able to deliver a solution that avoids the disruption and cost of traditional methods while improving long-term slab performance.

Follow the Project

We will be sharing updates after the repair, including field conditions, execution details, and final results.