Distribution Center Settled Pavement Drive Repair in Tennessee

The Challenge

Settlement issues with new FedEx distribution center’s main entrance driveway.

In October 2019, in Ooltewah, Tennessee, truck drivers at a new FedEx distribution center were struggling with settled pavement and unsafe driving conditions as they approached and exited the facility along the main entrance driveway. With construction of the new facility completed in 2017, the client knew that the problem was not age-related. Shortly upon completion of the new facility, the settlement issues had begun to appear. In fact, by the time Groundworks was contacted, the customer had already tried to have the entrance driveway issues corrected…twice.

Key Facts

The Solution

Groundworks designed a polyurethane injections grid and work schedule that would have the least impact on operations at the facility.

Groundworks crews consulted with the FedEx and reviewed an existing geotechnical analysis that indicated surface water drainage issues were concentrating and negatively impacting poor soils below the surface. Groundworks crews determined that polyurethane injections would provide an ideal solution for the ongoing weak soil issues, and that all work could be completed without interrupting the owner’s normal business.

Groundworks consulted with the civil engineers to provide budgets, injection plans, specifications, and schedule input. A design package was put out to bid by FedEx based on Groundworks’ specifications. Groundworks won the polyurethane grout scope of the project in a competitive bidding situation.

Because of the nature of the customer’s business, Groundworks designed an injection grid and work schedule that would have the least impact on operations at the facility. As work began, crews performed polyurethane injections into soils supporting the problematic areas to stiffen, compact, and reduce the permeability of the soil mass. Dynamic Cone Penetrometer (DCP) testing was performed by Groundworks’ crew to confirm and adjust the design. In some areas, additional depths of injection were required to properly treat the soils. Concurrent with Groundworks work, other contractors addressed the surface water drainage issues present at the site and completed asphalt mill and overlay work.

The Impact

Over three weeks, Groundworks successfully stabilize the soils at the FedEx distribution center.

Over three weeks, Groundworks crews worked with other contractors to successfully stabilize the soils in the problem areas at the FedEx distribution center. Work was coordinated with the customer to avoid heavy traffic times and to maintain the steady flow of trucks. With deep-soil stabilization work complete, managers at the FedEx facility in Ooltewah were at last able to consider their new facility “finished” and ready for smooth operations.