Challenge
A distribution center off I-485 near Steele Creek reported an active sinkhole opening in its primary truck court overnight. CCTV inspection confirmed a 60-foot section of corrugated metal pipe had completely collapsed, creating a void that was undermining the concrete apron and threatening to expand toward a loading dock approach. Tenant operations could not stop — the facility ran 24-hour shifts with 80+ trucks per day.
Solution
- Mobilized assessment crew within 4 hours of the call; scope and materials confirmed same day
- Implemented traffic control and concrete barrier separation to isolate the failure zone
- Hydrovac daylighting around fiber optic and water service crossings before any excavation
- Removed 60 linear feet of failed CMP and 120 square yards of undermined concrete apron
- Installed HDPE pipe with engineered bedding, geotextile, and compacted stone envelope
- Rebuilt two catch basins with new frames, grates, and polymer concrete collars set to grade
- Poured reinforced concrete apron replacement in two phases to keep one traffic lane open throughout
- Backfilled with controlled density fill to prevent future voids; density tested at multiple lifts
Results
- Sinkhole stabilized and loading dock access restored within 5 days
- No shift cancellations or carrier diversions during the repair
- Before/after CCTV and compaction reports delivered for the property manager’s insurance claim
- Facility enrolled in annual drainage inspection program to identify pipe conditions before failures occur
Services Provided: Emergency Response, Sinkhole Repair & Remediation, Stormwater Pipe Replacement, Catch Basin Repair
Project Area
Steele Creek / I-485 Corridor — Charlotte, NC
