In June 2021, Amazon’s website was down for just 59 minutes, but that brief downtime resulted in a significant loss of $34 million. Now, imagine if one of their logistics facilities experienced a shutdown due to preventable structural damage. Here Richard Holmes, Director at ground engineering specialist Geobear, discusses how integrating periodic ground assessments into a proactive maintenance program can keep commercial properties up and running with no disruption to goods, and therefore revenue.

Natural forces and human activities can destabilise even the most secure foundations over time. In all cases where ground stability has contributed to major incidents, earlier detection could have at least mitigated the issues. In some cases, incidents may have been prevented entirely.

It is crucial for facility managers to not just consider the built assets in their portfolio, but to fully understand ongoing ground stability conditions at their site and plan for the long-term implications. Regular inspections, combined with timely interventions, are vital for maintaining commercial operations and preventing potential failures.

Ground improvement has always been a central focus in geotechnical engineering, forming the basis for safe and durable construction. Analysing local soil properties—such as shear strength, compressibility, permeability, and shrink/swell potential of soils are essential to consider before construction.

This evaluation is particularly important when structures impose heavy loads on deep soil layers. Failing to account for these factors often results in settlement, compromising the stability and safety of commercial property and risking profits.

Even the most rigorous initial surveys cannot fully account for the dynamic nature of soil. Over time, natural and human activity can alter soil properties, rendering previously stable ground susceptible to settlement. Geotechnical engineering should be considered as part of an ongoing maintenance plan, not just an activity required when performing the initial construction of a facility.

Natural forces impacting soil integrity

Natural factors, such as seismic activity, can dramatically alter soil conditions, reducing the bearing capacity of foundations. For example, the 2011 earthquake in Christchurch, New Zealand, caused widespread soil liquefaction that led to irregular ground settlement and the collapse of previously stable buildings. Soil liquefaction mitigation methods can help improve soils’ resistance to the process.

Groundwater level fluctuations also pose significant risks, with projections suggesting an increase of up to 26.7 cm by 2060. Certain soils, such as clay, are particularly susceptible to shrink-swell behavior. This occurs as the soil absorbs or loses moisture, causing drastic changes in its mass and volume over multiple cycles.

These cycles can lead to the formation of fissures and voids in the soil structure. Recent studies have focused on understanding the equilibrium stage of this behaviour to better predict long-term soil cracking and the extent of soil subsidence after repeated wetting and drying cycles.

Hydrological processes such as soil erosion further complicate ground conditions. Poor drainage systems and heavy rainfall can wash away fine particles beneath foundations, reducing soil strength.

Human activity impacting soil integrity

Human activities significantly contribute to soil destabilisation, particularly through construction practices and increased infrastructural demands. As construction loads increase, the added stress—often unaccounted for in initial surveys—compounds the soil’s natural structure.

The use of heavy machinery and the movement of goods further exacerbate this. Moreover, facility expansions, which can exceed the design assumptions of original surveys, place additional strain on the ground, leading to soil compaction and eventual settlement.

Industrial activities can introduce hazardous substances, such as strong acids or alkalis, which interact with the soil’s mineral composition, leading to chemical dissolution. This process erodes the structural integrity of the ground, accelerating the deterioration of soil-bearing capacity.

These compounded stresses highlight the necessity for continual, rigorous evaluation of soil and site conditions. Without such ongoing assessments, there is an increasing risk that unforeseen factors can compromise structural integrity.

The case for periodic assessment

The importance of periodic reassessments is demonstrated in the case of Europe’s largest wine-bottling plant. They had to implement periodic ground treatment in its facility as a solution to major slab settlement.

In 2015, the facility encountered significant settlement issues due to a ten-metre depth of unconsolidated soil beneath its foundation. Deep foundations and soft soil are particularly susceptible to settlement due to the soil’s ability to reorganise and settle over time.

Resolving this problem would have required extensive re-piling to a depth of 20 metres and the installation of new slabs—an expensive, time-consuming process that would have halted operations for six months to a year, disrupting the supply chain.

As this was not a viable option, the facility management turned to Geobear to provide an alternative remedy. Work began with a comprehensive ground evaluation of the site, analysing soil type, ground levels, and the facility’s operational requirements. This assessment provided a treatment timeline and a settlement profile to predict how frequently ground re-treatments might be needed.

The warehouse consists of a multi-racking facility with 8 levels of storage. To implement the solution, only the ground-level pallet needed to be removed, allowing technicians to successfully execute the lift with minimal disruption.

Using geopolymer injection, Geobear improved the upper two to three metres of soil, minimising the structural movement without interrupting operations. Periodic monitoring of ground conditions from then on led to follow-up treatments in 2017, 2019, and 2022 to address settlement signs early, avoiding costly downtime and ensuring operational continuity.

This approach has proven far more cost-effective and less disruptive than traditional alternatives. By integrating periodic assessments and targeted interventions, the company has successfully maintained stability without impacting production.

Given rapid urbanisation and increasing environmental unpredictability, periodic ground assessments are critical for ensuring infrastructure resilience and longevity.

Scheduling recurrent checks enables a performance-based maintenance approach. If the slab level is found to have moved significantly, geopolymer injection technicians will return to the site. However, if the level is within tolerance, no action is needed and further checks can be scheduled.

These assessments are particularly beneficial for facilities with foundations extending beyond five metres in depth or located in soft soils prone to settlement. They enable geotechnical specialists to detect changes early and implement tailored solutions, safeguarding both infrastructure and operations.

The stability of our supply chains depends on foresight and continuous care. Whether managing the flow of consumer items or storing wholesale goods, periodic ground assessments are essential to mitigate risks.

Read more about Geobear’s ground improvement and engineering services and discuss the benefits of periodic ground assessments with relevant case studies.