Concrete Slab Replacement & Drainage Remediation

Slough, Berkshire, September 2026

Commercial & Industrial

Project overview

Concrete Repair Solutions were appointed to replace failed reinforced concrete slab panels within the main HGV yard of a live energy-from-waste facility in Slough.

Slab panels at the yard entrance had cracked and broken up over poorly compacted subbase, with collapsed drainage channels adding to the damage. The scope included breaking out the failed panels, reinstating the subbase, casting a new reinforced slab dowelled into the surrounding yard, and associated drainage and manhole works.

The works were planned around the site’s live operations, with road plates used to maintain vehicle access throughout.

What we did

Break Out & Excavation

Saw-cut and broke out cracked and failed slab panels
Loaded and removed all arisings off site
Excavated failed and poorly compacted subbase to formation level

Subbase & Reinforcement

Placed and compacted Type 1 MOT subbase, minimum 200mm
Fixed two layers of A393 reinforcement mesh, top and bottom
Installed 25mm smooth dowels, 600mm long at 300mm centres, one end debonded with sleeve and cap

New Concrete Slab

Cast replacement slab to a minimum 300mm depth in C32/40 concrete
Used an accelerated mix for early strength
Tamped finish with trowelled edges

Drainage & Access Works

Removed ACO channel units at the entry point, bridged with pipework and filled with concrete
Installed a new F900 manhole cover and frame (90 tonne safe test load), including chamber rebuild
Supplied and installed 20mm road plates to maintain access

Technical overview

The yard is the main HGV route into the facility’s tipping hall and carries loaded waste vehicles every day.

Slab panels had cracked and broken up where the subbase beneath had not been adequately compacted, and drainage channels at the entrance had collapsed.

The failed panels were saw-cut and broken out, and the subbase was excavated back to formation level before new Type 1 granular subbase was placed and compacted to a minimum of 200mm.

The replacement slab was cast to a minimum 300mm depth in C32/40 concrete with two layers of A393 mesh. New panels were tied into the surrounding yard with 25mm smooth dowels at 300mm centres, debonded at one end so the joint transfers load while allowing movement.

An accelerated concrete mix was used to return the yard to service quickly. Cube testing to BS EN 12390 recorded a compressive strength of 47.7 N/mm² at 24 hours, above the 40 N/mm² characteristic cube strength of C32/40 concrete.

Project challenges

Working within a live energy-from-waste facility with constant HGV movements
Maintaining vehicle access to the tipping hall during the works
Reinstating a load-bearing slab over poorly compacted ground
Achieving early concrete strength to minimise yard downtime

The outcome

The works were completed on 22 September 2026 and handed over with no defects or outstanding items.

The new reinforced, dowelled slab restores a durable, load-bearing surface to the HGV yard, with drainage and access covers reinstated to heavy-duty F900 rating.

Additional works were also completed under variation, including breaking up solidified ash within the ash store and fixing steel plates over a defective area of concrete and drainage outside the main works area.

Services demonstrated

Concrete slab replacement
Subbase excavation and reinstatement
Reinforced concrete and dowelled construction joints
Accelerated concrete for early return to service
Drainage channel and manhole remediation
Industrial yard and infrastructure repairs

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