Problem
A distribution centre’s slab joints were destroying themselves and the forklift fleet that ran over them: spalled arrises at contraction joints, failed joint filler, and impact damage compounding at ramp transitions. The operator could not stop day-shift operations.
Diagnosis
Slab survey mapped joint condition across the facility into repair classes, correlated with traffic routes. The failure driver was undersized joint filler and eroded sub-joint support on the primary forklift routes — meaning like-for-like repair would fail the same way. 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
Zero lost operating hours across the six-week program. Joint condition data handed over as a maintenance baseline, with a two-year re-inspection scheduled.