Uneven slabs are a common warehouse problem; and if left untreated, they can affect forklift stability, cause joint damage, prevent proper racking installation, and reduce safety. Whether it's from poor initial placement, settlement, or repeated wear, slab leveling is critical in both active and retrofit warehouse environments.
This guide explains the most effective methods to fix uneven warehouse concrete floors — whether you need a full resurfacing or just targeted correction. Each method is suited to different degrees of damage, so it's essential to match the repair to the actual floor condition.
For minor height differences and isolated high spots, diamond grinding is the fastest and cleanest option. A planetary grinder removes thin layers of concrete with precision; ideal for trip hazards, door thresholds, or forklift runways. This method produces a smooth finish and works well for shallow corrections (1–5 mm). Always follow up with a densifier or sealer to restore durability.
If slab areas have settled or dropped, slab jacking can raise them back into place. Technicians drill small holes and inject foam or cement-based grout beneath the slab to lift and stabilise it. This method is perfect for ground-bearing slabs with voids or sunken corners. Foam systems cure quickly and are often traffic-ready within hours. Structural engineers should verify feasibility before use.
For widespread surface variation (5–30 mm), a pump-applied self-leveling compound can create a smooth, flat finish across the floor. SLCs are ideal for preparing surfaces before applying resin or polished finishes. Choose a heavy-duty, fibre-reinforced compound designed for warehouse traffic. Substrate prep is critical; the slab must be primed, cleaned, and free of movement or moisture before application.
If the slab is severely worn or uneven over large areas, consider resurfacing it with a bonded screed. Traditional sand/cement screeds (50–75 mm) or liquid anhydrite screeds (35–50 mm) can bring the floor back to tolerance. Screeds require cure time and often need sealing or coating after installation. Joint layout, load specs, and moisture testing are critical before installing over an active slab.
For extreme cases — such as slabs out of level by 50+ mm or those beyond repair — a new topping slab can be poured over the existing surface. This approach creates a fresh, durable surface while correcting the slope. Toppings are typically 75–100 mm thick and must be bonded with a primer or grout slurry. Expansion joints, surface prep, and edge transitions all need to be designed correctly for long-term success.
If the slab is mostly level but has small dips, breakouts, or joint damage, use resin-based repair mortars or fast-set cement patch to rebuild only the affected areas. These materials bond strongly, cure fast, and resist forklift traffic. They’re ideal for limited downtime environments. Use a grinder or saw to key edges before applying for maximum adhesion and lifespan.
If you'd rather skip the stress and get a flawless concrete floor polished by professionals, we’ve got you covered. From precision prep to polished perfection, we handle it all.
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