In a competitive retail environment, even planned operational shutdowns can have significant consequences: short-term revenue losses and reduced customer flow as well as potential long-term changes in customer behaviour.
This case examines a 3,000 m² retail area where uneven floor settlement caused shelving instability, automatic doors to malfunction, and increased safety risks. The underlying cause was weak, compressible subsoil combined with structural characteristics of the building.
The case study demonstrates how GEOLIFT technology resolved the issue at a retail centre in Estonia without interrupting operations, offering practical insights for property managers facing similar ground-related challenges.
The Problem: Settling Floors
During building reconstruction, the concrete floor slabs were installed on geotechnically weak and compressible soil and on a grid of intercolumn beams spaced at 6 × 12 m.
Over time, this resulted in differential settlements ranging from +10 mm to –135 mm. These deformation processes affected daily operations in several ways:
- Shelving instability – uneven floors caused shelving and display units to tilt, requiring constant adjustments and creating risks to both products and customer safety.
- Operational disruptions – automatic doors began to malfunction, disrupting customer movement.
- Floor unevenness – this was not only an aesthetic issue but also a safety concern for both customers and employees. Due to the resulting slopes, carts and product trolleys could begin rolling on their own.
Long-term risks
If the issue had not been addressed, continued settlement could have caused additional structural damage. This could include floor deformations, wall cracking and malfunctions in engineering systems. Over time, such issues could lead to operational restrictions or even partial or complete shutdown of the facility.
These types of problems are also common in manufacturing, warehousing and logistics facilities, where uneven floors can interfere with assembly lines, forklift movement or operational efficiency while increasing safety risks.
The Challenge: Maintaining Operations During the Works
The main objective of the project was to restore floor levelness without stopping retail operations.
In a facility operating 24 hours per day, any closure would result not only in direct revenue loss but also potential changes in customer behaviour that could have long-term consequences.
A similar situation exists in industrial environments, where manufacturing processes and logistics flows rely heavily on efficiency. Even short interruptions, equipment downtime, or reduced forklift movement speed can have significant economic impacts.
The Solution: GEOLIFT Technology for Effective Floor Lifting
GEOLIFT team of three crews, led by engineer Valdas Kordusas, applied geopolymer injection technology using GEOLIFT RESIN 035.
The project, carried out between October 20 and November 18, 2025, was implemented in several phases:
Phase I – Preparation
Work planning, equipment placement, operational planning, and preparatory activities.
Phase II – Plan validation
Test works were carried out in a selected area to analyse potential risks and evaluate the effectiveness of the execution plan and its compatibility with the retail centre’s operations.
Phase III – Project implementation
Systematic work carried out from 21:00 to 07:00, continuing for 13 consecutive nights.
Depth and scope
Injections were performed to a depth of up to 1 meter into weak soil layers across the 3,000 m² area, using expanding GEOLIFT RESIN 035 geopolymer. Approximately 20,000 kg of material was used.
- Controlled process – the geopolymer was injected while monitoring floor movement with rotational laser levels, filling voids beneath the slabs and strengthening the upper soil layer.
- Minimal disturbance – work was carried out during night hours when customer traffic was lowest.
This method fully met the client’s objective — to level the floors without stopping the operation of the retail centre.
Results and Benefits
The intervention delivered several key outcomes:
- Improved safety – leveled floors eliminated hazards and restored functional conditions.
- No operational interruptions – the retail centre continued operating 24/7 throughout the works.
- Efficient implementation – the project was completed in less than one month through phased execution.
For businesses, this approach provides additional advantages:
- a professional and competent team capable of adapting to operational constraints
- rapid implementation
- continuity of operations without downtime
- improved operational efficiency
- a sustainable solution with minimal waste and a reduced CO₂ footprint
When to Take Action
If floor settlement or slab movement is observed, it is important to act promptly.
Where floors are subjected to dynamic loads, delays can lead to irreversible damage to concrete slabs, potentially requiring full demolition and reconstruction.
GEOLIFT technology can be used to precisely stabilize the soil under structures without excavation work
For the application of this solution, contact the GEOLIFT team for a technical assessment and recommendations for your manufacturing, warehousing, logistics or retail facilities.
#FloorLifting #GeopolymerInjection #RetailOperations #ManufacturingEfficiency #WarehouseSolutions #LogisticsInnovation