The industry commonly refers to a Traditional Concrete floor as being one which has the following:
- Ready Mix Concrete (as designed by the engineer)
- Re-inforcing (steel or fibres)
- Saw-Cuts = these are the cuts which are made in the floor that become known as joints. They function to assist with cracking of the floor, which occurs naturally due to shrinkage of concrete.
CLF offers this type of floor to our clients, along with our approach of offering concrete flooring technology on a global quality scale by making use of specialist products and ensuring highly qualified onsite supervision.
CLF’s concrete flooring construction uses a unique system:
- Floor Design Assistance
- On site qualified supervision of floor construction
- Evaluation and acceptance of sub-base
- CLF Concrete Mix Design
- Placement of Concrete using Somero® Laser Screed Machines
- Finishing of Concrete using Razorback® Ride On Power Trowels
- Early age saw cutting of the concrete with Soff Cut® Equipment
- Joint Detailing and Joint Layout
- PermaJoint® Armoured Joint Edge System
- Patented CLF Diamond Dowel™ System for High Load Transfer Construction Joints
- Square Dowel Cages for Sawn Contraction Joints
- DUROJOINT™ Joint Protector
- CLF Aquacure Curing Compounds / Curing Blankets
- Steel Fibres
- Pentra-Sil™ Liquid Lithium Based Surface Hardener and Sealer
- MM80™ Joint Filler for High Traffic Floors
- Measurement of floor flatness (Ff) and floor levelness (Fl) to ASTM1155 or UK TR34
- Five to ten years Maintenance Program offer
- Repairs to Floors / Joints
- Superflat Thin Screeds to old or uneven floors
This system ensures the use of the highest quality technical products available by our highly qualified concrete flooring construction teams. Bringing flooring innovation to our clients to ensure world class quality flooring systems.
The quality of CLF’s concrete floors are determined by:
The productivity rates of warehouses and other logistic companies are measured up to the second for each forklift and since the performance of each forklift greatly depends on the speed with which it can travel on the concrete floor to efficiently perform operations, the flatness of the floor becomes a major concern.
It is proven that forklifts travel at a greater speed on flat floors. It is also a well-known fact that lighting efficiency is improved by flatter floors. The flatness of floors also greatly influence high racking abilities and the stability thereof.
How is Floor Flatness achieved?
The waviness or smoothness of a concrete slab is measured to determine the flatness thereof using the FF notation to describe Flatness as per ASTM 1155. The required floor flatness needs to be assessed and determined in terms of Properties I, II, III and IV as defined in the UK Concrete Society Technical Report TR 34. FM2 and FM1 classifications are suitable for most applications.
Free movement floors with wide aisle racking to 13m heights most frequently make use of the FM2 Classification which is readily achieved through the use of a laser screed machine.
CLF’s Concrete Mix Design along with suitable workmanship, attentive supervision and the latest floor placement techniques ensure that floor flatness and levelness is achieved.
For actual on site measurement of floor flatness and levelness tolerances, CLF offers the F-METER computer programme and F-METER measuring instrument that measures properties I and II along the entire length of each wheel track.
Resistance to abrasivewear from imposed loads is provided through surface hardness which allows long life to concrete slabs and ensures smooth running operations.
How is Floor Hardness achieved?
Abrasion resistance and floor hardness is primarily achieved through the use of a finishing process specified as a Burnished Finish which involves the finishing of a concrete slab by using ride on power trowels during the initial setting stage after the pouring. The next step is the spray application of the Pentra-Sil Treatment to the floor’s surface. Tested by the Chaplin Abrasion Tester and Moh’s Tester, the hardness achieved by using this method falls into the extremely hard category. The use of this method also results in significant cost reductions to the client.
3. Joint Detail
The correct detailing and co-ordination of joints reduces potential damage to the slab surface.
The most common flooring problem, Joints
CLF introduces the concept of Steel Fibre Reinforced Concrete Floors with large panel sizes which dramatically reduces the number of joints used in warehouse floors because fewer joints reduces the chance of serious joint defects.
Although it is acknowledged that larger panels will result in more movement at the joints, it should also be taken into consideration that the movement won’t be as large as believed because the concrete used is reinforced with Steel Fibres that offer a three dimensional reinforcement mechanism which redistributes shrinkage stresses within each defined panel and therefore reducing the shrinkage movement that takes place at the joints.
How is Durable Joints for hard wheel traffic achieved?
- Reduce the number of joints by using Steel Fibre Reinforced Concrete in the construction of larger panels
- Make use of the BETASTRIP Permanent Shutter system
- Reduce the number of construction joints by making use of Laser Screeds for pouring large bays of 2000m2 +
- To minimise curl and to preserve load transfer under the influence of a dynamic load, the construction joints need to be Diamond Doweled
- Square Dowel the Sawn Contraction Joints
- Joint width should be kept to a minimum – 3mm saw cut
- New joints should be protected with DUROJOINT Protector
- Concrete edges of joints should be strengthened by using Steel Fibres and Pentra-Sil Lithium Chemical Hardener
- MM80 should be used as a joint filler instead of elastomerics for hard wheel traffic areas
CLF suggests and extends various maintenance contracts for 5 – 10 years to ensure that your concrete floor remains in perfect condition in order to reduce downtime and improve productivity.
As part of the maintenance program, joints are required to be:
- Filled as late as possible in the program
- Be refilled after joint shrinkage has taken place – approximately 6 months after occupation
- Continuous monitoring and maintenance of joints