Beckton Industrial Estate – Warehouse Slab Lifitng
Background
The client, sought to bring a warehouse unit at Beckton Industrial Estate back into use after a prolonged period of vacancy. The unit, earmarked for lease to a distribution tenant, suffered significant slab settlement due to compressible peat bands beneath the structure. It is part of a wider estate-wide issue, with previous subsidence problems addressed by Geobear on neighbouring units (Units 5&6 in 2015 and 39&40 in 2018). The affected area in this instance (Unit 8) was measured at 1,292m², with the worst affected area needing up to 179mm of lift.
Alternative Methods
The primary alternative to Geobear’s geopolymer injection was to break out and reconstruct the concrete slab, including ground compaction and reinstatement. This method would have taken several months to complete, keeping the unit non-operational and incurring significant further rental losses during that period. The extended timeline and disruption made this option commercially unattractive.
Why Geobear
Geobear was the preferred partner due to its proven track record on the same industrial estate and extensive experience delivering slab lift projects for logistics and warehouse customers. The client cited Geobear’s previous successful interventions and technical understanding of the site’s ground conditions as key decision drivers. Case studies from previous warehouse jobs were also instrumental in building confidence.
In addition to this proven expertise, Geobear’s solution offered substantial operational advantages over traditional methods. The geopolymer injection process is fast, with works completed in weeks rather than months, and is non-disruptive—allowing surrounding units or operations to remain unaffected. There is no need for demolition, heavy plant movement, or removal of structural elements, meaning lower health and safety risks, significantly reduced noise, and minimal dust generation. The low-impact methodology also eliminates the risk of damaging below-ground services, which would otherwise require diversion or protection during excavation. This fast, clean approach enables clients to bring commercial assets back to revenue-generating use far more quickly than traditional rebuilding.
Geobear Solution
Geobear’s methodology involves precision drilling into the existing concrete slab at approximately one-metre centres, followed by the injection of a two-part expansive geopolymer resin. Once injected, the geopolymer expands beneath the slab, filling any voids and compacting the underlying soils. The expanding foam generates controlled upward pressure, lifting the slab back towards its original level.
At Beckton, 555 injection points were installed across the 1,292m² treatment area. The worst-affected section required up to 179mm of lift. A pre-treatment laser level survey established a benchmark for required adjustments, and a follow-up post-treatment survey validated the outcome. Over 90% of injection points met the agreed tolerance of ±10mm, aligned with TR34 guidelines stated tolerances.
Operational Continuity & Risk Avoidance
The geopolymer method allowed the client to avoid months of uncertainty, disruption, and logistical complication. For landlords and asset managers, this approach minimises void periods, removes the need to coordinate large-scale construction, and allows marketing or lease negotiations to resume immediately. In risk-sensitive commercial environments, this agility and certainty are often more valuable than upfront cost differences.
Carbon Savings Results – 78% Lower Emissions than Traditional Methods
Using emissions benchmarks from road slab construction (excluding asphalt), Geobear’s solution generated a carbon saving of approximately 144,000 kg CO₂e—representing a 78% reduction—compared to traditional slab reconstruction. These savings were achieved by avoiding the embodied carbon of new concrete, extensive transport movements, fuel-heavy excavation, and the disposal of hundreds of tonnes of waste. The geopolymer injection process delivered similar structural outcomes with a fraction of the environmental impact, helping the client align with ESG objectives without compromising commercial timelines.
