Super Flat Flooring System Technology

Superflat floors are high-precision coatings, with a deviation of flatness deviation of not more than 2mm by 2 meters. Such high accuracy is necessary for the movement of complex technical mechanisms: stackers, mast loading machines for high-altitude storage of products. Also, superplane coatings are used in most automated lines for the production of high-precision products. Superflat floor coverings are made of self-lubricating polymer compounds. The main application of such coatings is rack storage. BGSB has decades of experience in laying super flat flooring using state of the art technology.

Modern trends in construction in large metropolitan areas show a constant and steady "growth" of all construction structures up. This is due to the increase in land prices, and with the understandable desire of developers to reconstruct on the same plot of land as much usable space as possible. Naturally, the height of not only residential and office buildings is increasing, but to no lesser extent, these tendencies are subject to warehouse facilities and modern logistics complexes.

Until recently, warehouses were stored directly on the floor, or on shelves with a maximum of 2-3 tiers, warehouses with a storage height of more than 8 meters were a rarity. In recent years, they are replaced by modern industrial complexes with storage heights of 14, 16 and more meters. For more rational use of storage areas, the passages between the shelves are made as soon as possible, the dimensions of the warehouse equipment also try to reduce. Many warehouse complexes are equipped with fully automated systems where the technology moves through laser beacons or a special induction tire drowned in the floor base, the accuracy and speed of operation of such complexes are certainly much higher, safer and more efficient.

To optimize the cost of the device floors is better to start with planning. We need a plan for the location of the shelves, based on which zones with different requirements for smoothness are described, which we described above. A very important role is played by the location of the seams. If possible, it is necessary to plan them so that they pass under the shelves. A lot of problems in the operation create transverse seams, the edges of which are the impact of the wheels, which leads to the destruction of the edge of the seam and the rapid wear of the wheels of storage equipment.

It should be noted here that BGSB is one of the few construction companies that use one of the most advanced and modern suture systems.Due to the wavy construction of the seam, the wheels of the loaders do not roll over the seam at a right angle, which provides a smooth and unstressed impact on the base in the seam zone while maximizing the protection of the edges of the concrete floor plate. This significantly reduces the load on the wheels of storage equipment and ensures its longer operating under the heaviest loads.

When designing high-rise warehouses, the requirements for permissible deviations of the evenness of the base in the inter-stack zones should be more precisely specified and agreed with the manufacturers of warehouse equipment, which will be used in this project. This technique, mainly imported, and the requirements for the floors will be based on foreign standards.

According to these standards, the base of warehouse flooring must be made of concrete of the brand not lower than M350 (B25). The location of channels, shafts or other structures should be no closer than 200 mm from the shelves and the aisles between them. The finish coat should withstand the effects of grease and oils, do not dust and do not allow moisture to pass through. It should not be pressed under the influence of loads from the wheels of loaders. A very important requirement for finishing the floor in the working area of stackers is the absence of slip. A frequent requirement of equipment manufacturers is the installation of antistatic floors. Roughness in the passage between the shelves should be no more than 1.5-2.0 mm when checking a two-meter control rod in different directions.

At the device of floors in warehouses, two basic technologies are applied: the device of concrete floors with the strengthened top layer and the device of concrete floors with the subsequent polymeric covering.

The Challenges To Superflat Floors

Make a concrete floor with a reinforced layer and at the same time meet the necessary requirements for evenness - a difficult task. Unfortunately, this is true, although this is the most inexpensive option and customers often choose it. There are too many factors that can adversely affect the final result of the work. Here, and the unstable quality of the concrete supplied by the manufacturers, and the different time of finding concrete carriers in transit due to traffic jams and much more, even a change in the weather can affect the final result. Our long experience shows that it is absolutely real to perform a concrete floor with a reinforced top layer with a tolerance of 3-3.5 mm on a two-meter control rail, and all the floors of our production correspond to it, but observe the requirements of 1.5-2 mm - this is more of a field of luck,

The correct decision when creating super flat floors is the installation of a concrete base with the subsequent installation of liquid polymer floors. Self-leveling floors are stacked during laying, which makes it possible to achieve a very high evenness. In order to optimize the costs, using this technology, first the floor-floor device is installed throughout the entire warehouse area, and then in the areas of the loaders between the racks, a second check of the base level is made and another filler layer is set up, which makes it possible to achieve an ideal evenness. To save money on the shelves, it is possible to apply a thin-layer polymer coating. Since the floor loads in these places are practically absent, thin-layer coatings under the shelves will serve for many years.

Choosing Floor Color

Depending on the requirements, bulk floors can be on epoxy or polyurethane basis, as well as in antistatic design. The color scheme of such floors is limited only by the imagination of customers and, accordingly, the warehouse with polymeric floors looks much more aesthetic. Different colors can be allocated to the areas of the passage of equipment and personnel passage, which makes such warehouses also safe, and also makes it possible to realize visual logistics inside the premises. To maintain cleanliness in warehouses with bulk polymeric floors is much easier. Do not forget that in a few years, any industrial floor will need to be repaired. 

Summarizing all of the above, it is necessary to reiterate that modern super-flat industrial floors for warehouses are a very responsible and complex element of the building. To select a technically correct and financially justified solution, it is necessary to work together and the customer works, and the design engineers of the building, and the suppliers of warehouse equipment and shelving, and of course the professional company for the installation of industrial floors. Observance of these fairly simple but important conditions will lead to the best result.

Contact Us for any query related to our Superflat Flooring Service.

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Thursday, 15 November 2018
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