A large warehouse and office facility in the U.S. Mid-Atlantic, spanning over 1,000,000 square feet, was experiencing significant structural issues including cracking and vertical displacement of the concrete slab-on-grade. These issues were especially prominent at the transition point between the warehouse and adjoining office space. On-site staff reported that the cracks had widened over time and were accompanied by vertical shifts—up to half an inch in some areas—causing doors and windows to jam, wall joints to split, and interior thresholds to become unusable.
VERTEX was hired to investigate the root cause of these problems. Upon inspection, VERTEX uncovered a concerning pattern of subsurface instability. The facility is situated on karst terrain, a geological formation known for its susceptibility to sinkholes. Sound testing conducted by VERTEX revealed excessive voids beneath the slab in several locations, indicating the potential development of a sinkhole. The presence of storm drains directly beneath the areas with voids raised additional concerns about leaking water accelerating subsurface erosion.
Further compounding the issue were deviations from the original construction plans. While the design specified a continuous thickened slab between the warehouse and office, a construction joint had been installed instead. This seemingly minor deviation likely introduced weak points that contributed to the structural displacement and cracking observed. In addition, cracks along the southern elevation of the building and visible sloping in the slab suggested thermal stress—likely caused by restrained movement that prevented the slab from expanding or contracting properly.
To help the client address these issues and prevent further damage, VERTEX recommended several immediate actions. These included detailed subsurface mapping using ground-penetrating radar, inspection of underground drainage systems to identify potential leaks, and physical sampling of soil conditions beneath the building. While initially believed to be a routine maintenance matter, VERTEX’s investigation uncovered a deeper set of challenges linked to geological conditions, construction practices, and environmental factors—all of which require careful management to maintain the facility’s structural integrity.
VERTEX’s team of experts is uniquely equipped to investigate, assess, and mitigate complex structural and geotechnical issues like these to protect your assets—contact us today using the form on our website to learn more.
