The global logistics industry was valued at $9.41 trillion in 2023 and is projected to exceed $14.08 trillion by 2028. In such an essential sector delays are not an option, and facility managers must maintain seamless operations to keep the global supply chain running smoothly.
Alongside key insights from geotechnical contractor Geobear, we’re exploring the financial impacts of subsidence in logistics centres, the potential cost of disruptions and strategies for effective management while maintaining operational targets.
Subsidence, which causes uneven floors and cracks in concrete slabs, presents a significant risk to logistics centres. These issues disrupt operations, damage equipment or inventory, and compromise workplace safety.
Failing to identify early warning signs of subsidence and settling for invasive remediation solutions can result in costly downtime and disrupt these critical facilities’ efficiency and profitability.
The threat of subsidence in logistic centres
Subsidence occurs when the ground beneath a built asset sinks, shifts or forms voids which causes the asset’s foundation to settle. In logistics centres, this often results in uneven floor slabs – disrupting automated systems, threatening safety protocols and leading to significant operational inefficiencies.
Automated systems like conveyor belts and automated storage and retrieval systems depend on stable, level surfaces to function efficiently. Misalignments caused by subsidence can result in unplanned downtime, equipment failures and unbudgeted repairs.
Uneven or shifting floor slabs can cause warehouse inventory storage shelving to lean, reducing their safe use or collapsing in the worst cases. Similarly, forklifts operating on uneven floors may make those areas unusable for forklift traffic, forcing an unoptimised re-route.
Financial impact: a real-world example
Subsidence can have severe financial and operational consequences – evident at one of Europe’s largest bottling facilities in southwest England, where differential settlement of up to 36 mm disrupted operations.
The settlement only became apparent after the 80,000m² facility was fully loaded, exceeding tolerance limits and compromising the structural performance of its floor slabs.
Traditional underpinning – often used to stabilise foundations – was unsuitable due to the months of downtime it would require, risking substantial revenue losses.
To combat this issue, Geobear implemented a tailored solution using small, mobile pumping units designed to fit the facility’s narrow aisles. By injecting geopolymer material, the company restored the floor slabs to within a 4mm tolerance without impeding operations.
This approach allowed business operations to continue uninterrupted while meeting all health and safety criteria. As the process required only electricity to power the pumps, it posed no environmental or hazardous risks and no potential for water contamination.
Non-invasive solutions for modern facilities
While slab replacement is a traditional approach, it’s often impractical for active logistics centres that cannot afford extended shutdowns.
Slab replacement requires access for heavy equipment, the movement of any automation processes or equipment installed in the vicinity, and measures to control the noise, dust, and construction during this process. Repair time is typically measured in weeks.
The geopolymer technology developed by Geobear offers a non-invasive alternative. This method improves the ground in hours rather than weeks, without the need for major excavations and operational halts.
This adds value for facilities where any unplanned downtime adversely affects the daily or weekly KPIs. Improved efficiency allows facilities to address subsidence without compromising revenue, safety, or service delivery.
To protect their asset flow and secure their KPIs, facilities managers should add subsidence monitoring to their operations maintenance planning. If they notice issues of subsidence, immediate action is recommended. Understanding your options is critical.
By choosing non-invasive alternatives, asset operators can ensure the long-term integrity of their logistics centres while maintaining operations and meeting performance targets.
Learn more about GeoBear here.
