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World-class Warehouse
Floors
Neil Williamson
BSc CEng MICE
Managing Director
Monofloor Technology Limited, UK
to
Godfrej & Boyce Manufacturing Co Ltd,
Mumbai, May 2012
Why is the floor so important?
• IT SUPPORTS ALL THE OPERATIONS
CARRIED OUT IN THE WAREHOUSE
• If a floor slab goes wrong then these operations
are disrupted (at best), or stopped (at worst).
• Repairs are expensive and cause disruption.
• If the floor is not flat enough the MHE runs
slower – or there are accidents & safety issues
• A poor floor lowers value and increases the
maintenance and dilapidation costs
Monofloor Technology Ltd
• Founded 1994 to provide consulting & site
supervision services to UK investors in new markets
• Principal is Neil Williamson now with over 28 years
experience in Concrete Industrial Floors
• All site supervisors have a minimum of 10 years
practical floor contracting experience
• Our Asia headquarters is in Singapore
• > 70% of turnover is outside of UK
The clients' concerns
• Joints – the number,
type and location
• Floor tolerances – is
the floor flat enough?
• Abrasion resistance-
is the floor able to
withstand the traffic?
• Does the floor look
good & is easy to
maintain & clean?
Client Expectations
Best Practice in Design
1. Locate the construction
joints under racking for strip
construction of VNA facilities
2. Limit the number of joints
in marshalling areas, e.g. in
this case it was achieved by
designing the floor in 900m2
panels without sawn joints.
3. Armour the 'daily' joints
World-class Solutions to
Construction Joint Problems
These profiles prevent edges of
the joints from spalling. This is
particularly important in case of
placing large areas & joint-less
floors where joints open wider.
These Steel armoured profiles
produced by Permaban Limited
in Europe protect the edges of
concrete at construction joints.
Choosing the Right Specification
• Is truck movement Defined
(by rack position) or Free
(the trucks can turn in aisle
or move in multi-directions)
• Is racking position certain?
• Future changes of use?
• Racking (or potential
racking) height
• Important: In general the
flatter the floor is the more
joints there are likely to be
Floor Flatness Specifications
� DIN 18-202 & 15-185
� F Numbers, Fmin (US)
� CSTR 34 (UK)
Free Movement Categories
� FM1, FM2, FM2 Special,
FM3
Defined Movement
� 3 Categories depend on
racking height
�EN 15620: Racking Code
TR34 Defined Movement:
Which Specification?
• Racking height < 8m
(defined movement)
• Racking height < 13m
(defined movement)
• Racking height > 13m
(defined movement)
• Potential Racking 8-
13m Layout not known
• Wide aisle, Racks >8m
• Construct to Category 2
(TR34:2003 Table 4.3)
• Construct to Category 1
(TR34:2003 Table 4.3)
• Construct to ‘Superflat’
(TR34:2003 Table 4.3)
• Construct to FM2 Special
• Construct to FM2
Definitions of TR34 Properties
All allowable limits shown in millimetres Column A = “95% property limit” Column B = “100% property limit” The pour will be considered satisfactory when: a) not more than 5% of the measurements exceed the particular property limit in column A b) none of the measurements exceed the particular property limit in column B
Diagrams showing measurements taken for Table 7.1 Properties
Property I Property II Property III
300mm
300mm 300mm
II
Wheel Track
III
Difference in elevation over 300 mm.
Difference in slope over 600 mm. Difference in elevation across
wheel track
Defined Movement - How Flat? Extract from Concrete Society Technical Report (2nd Edition, 1994)
Table 7.1 ‘Allowable Values of the properties of flatness for defined movement areas’
Category Allowable Limits
Property I Property II Property III
Wheel trackup to 1.5 m.
Wheel track over1.5 m.
A B A B A B A B
Superflat 0.75 1 1 1.5 1.5 2.5 2 3
Category 1 1.5 2.5 2.5 3.5 2.5 3.5 3 4.5
Category 2 2.5 4 3.25 5 3.5 5 4 6
NOTE: Retained in Concrete Society Technical Report (3rd Edition, 2003) asTable 4.3 ‘Allowable Values of the properties of flatness for defined
movement areas’
Other Defined Movement
Specifications• DIN15-185 Below & above
6m lift height – 4 categories
depending on track width.
E.g. transverse allowance =
2mm for track width 1-1.5m
• DM1/DM2/DM3 as per EN
15620. Includes rate of
change of Tr34 Property III
and measures front to back
• Fmin (normally 80+) –
similar principle to DM1/
DM2 etc., expressed as no.
New: FEM Standard – as DIN
Plus short wavelength measure
Free Movement Areas
� FM1 – Only used for floors requiring very
high levels of flatness – some GV’s
� FM2 Special – Where building height is
over 11m or so, and there is the possibility
of future VNA use
• FM2 – Normal standard for wide-aisle
warehouses where lift height is over 8m
• FM3 – Basic specification for retail / cash &
carry, non-critical floors
• FF25/FL20 and above depending on use
(FM1 = FL46). Normally FF>FL
• DIN 18202 Table 3, Line 4
• FM specification of EN15620 –based TR34
World-class Super-flat Floors
• Monofloor are specialists in
training teams for this critical
work. These floors are needed
for VNA warehouses
• Normally little or NO grinding
is required after training of the
team. Grinding can affect long-
term flexibility of the facility
and be unsightly, or dusty.
• Floors should be constructed to
recognised international
specifications, such as CSTR34
This floor to a pharmaceutical
warehouse was constructed by an
inexperienced team to TR34 Super-
flat tolerance under MTL guidance
Superflat Floor Construction
� True Superflat floors
can only be constructed
using long-strip method
� Not possible with large
area pouring without a
lot of expensive grinding
� Flatness to be checked
daily, and/or supervised
by specialist consultant These tools are essential for S-F
Essential Floor Flatness
Control
Monofloor FloorPro
The flatness should be checked daily
after the first two or three pours
If the floor does not meet the
specification, the methods, equipment
or the concrete mix should be changed
and the next pours checked daily until
OK.- DO NOT WAIT UNTIL END -
Thereafter surveys should be every
few days
IF FLOOR IS NOT CHECKED IT MAY ONLY BE AFTER RACKS ARE UP AND TRUCKS TESTED THAT THE PROBLEM SHOWS
Floor Survey Reports
Confirming Abrasion
Resistance:
• Testing against
required classification
of BS8204-2 & TR34
• In UK tested using
accelerated abrasion
testing apparatus
• There are other test
methods in EN 13813
e.g. Bohme
Key points to Avoid Grinding or
Slowly Operating VNA Trucks
• Concrete quality & consistency
• Preciseness with datums and setting up
• Well trained, skilled operatives
• Experienced supervision
• Checking, re-checking and checking again
• Early survey to monitor performance
• Review surveys and make improvements
Meeting Expectations
• MTL ensure specification is
appropriate to use
• Monofloor technicians know
how to tune and control concrete
mixes
• Monofloor can train
inexperienced teams and help
others to improve
• Monofloor are on site to help to
ensure the work is done ‘right
first time’
Monofloor Service
• Agree the specification with client's
representative
• Provide tender scheme including outline design
• Review or advise on flooring contractor
proposals
• Assess the concrete & other suppliers
• Design or specify formwork and joint details
• Train & Supervise the team
• Survey & certification of the floor
Other Services
• Defects diagnosis
• Floor flatness surveys & Rectification advice
• Specifications, Quality Plan and supervision – e.g.
Renaissance Bhiwandi
• Expert Witness work
• Internal and External Concrete
• Joint-less and Super-flat floor specialists