The floor to Phase 1 of a Logistics Development in Qingpu – a district of Shanghai Municipality, owned by a global industrial property developer, had obvious damages between the warehouse and the loading dock due to differential settlement between the two. The loading dock was constructed after the warehouse and perhaps the ground condition was an oversight by the design of the loading dock.
There were 6 occupied units in the warehouse and each entrance to the warehouse was used on a daily basis. The differences in height caused by the differential settlement ranged from <3mm to 25mm. At the more severe entrances, the tenants were struggling to use their smaller fork lifts or pallet trucks.
Grinding
CoGri China was instructed to carry out temporary repairs to the entrances and to reduce damage caused by future settlement, with the minimal amount of disturbance to the operation of the tenants.
CoGri removed the step by grinding down the floor on the warehouse side and provided a smooth transition in levels between the load dock and warehouse.
Repair
After grinding was completed and the level had been checked and confirmed to be acceptable, the joint damage between the warehouse and the loading dock was cleaned and repaired using a Rapid Setting Polyurethane Repair material – similar to CoGri Rapid Mender. Larger damaged areas were also repaired with the same product.
CoGri Joint Stabiliser Installation
Subsequently CoGri Joint Stabilisers were installed at the slab interface. The CoGri Joint Stabiliser installation process is easy and dust-free. Once the repair material had cured (after 10 minutes), the locations of CoGri Joint Stabilisers were marked along the repaired crack. Core holes were then drilled using a specially imported core rig from the UK, and specific core bits for the stabilisers. The stabilisers were secured using a torque wrench. The installation of the CoGri Joint Stabilisers should reduce further differential settlement as it is designed specifically to provide positive load transfer between two slabs.
Application of Liquid Hardener
At the end of the operation, a liquid hardener was applied to the working area to seal the surface. In most area only one application was required. A second coat was only applied if required, after an on site test.
Typically, the liquid hardener was only applied in the afternoon, with prior agreement with the owner / tenants, to give the liquid hardener sufficient time to dry before 17:00 for the gates to be closed and allowed to cure properly overnight, when the warehouse was not operational.
The owner and its tenants were very pleased with the end result of this fast-track floor repair solution provided by CoGri China and have already made enquiries regarding further applications in its other developments.
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