Industrial floor for a warehouse. Warehouse Concrete Floor Construction Warehouse Concrete Floor Construction

Dust-free, crack-free, smooth surface, durable - all these requirements must be met by concrete floors in a warehouse when properly installed.

The "evenness" of the floor depends on the equipment used in the warehouse. In warehouses that are equipped with narrow aisles with a lifting height of more than 9 m, the most stringent requirements for floor evenness apply. The values ​​of the indicator are determined by the manufacturers of lifting equipment. Prices for the production of "over" even surfaces on average 20% higher than floors for one or two-tier construction.

For the base of the concrete floor, compacted sand or a monolithic reinforced concrete slab is used. To provide concrete floors with high quality characteristics, the technology of hardening the surface with a dry or liquid composition is used at the stage of laying the surface.

Stages of the technological process:

• Preparation of the concrete surface. Determining the difference in surface heights; Minimum Thickness monolithic slab should not be less than 10 cm. If the coating is laid on a compacted base, then its thickness is 15-25 cm and depends on the loads and reinforcement used. Smaller concrete thickness leads to premature cracking of the floor; Dividing the surface into sections. If it is planned to install racks in the warehouse, then the edges of the grip should, if possible, pass between the racks. This will ensure the desired evenness of the surface;
• Floor laying. Installation of guides. For super flat floors, rigid molds with a flat top edge are used. Reinforcement of floors is carried out using a reinforced mesh or steel fiber. Combined reinforcement is used to prevent cracks. The leveling of the mixture is carried out with the help of "beacons" or vibrating rails along the guides. Strengthening the composition of the floor. Dry mixes are used on a freshly laid floor, they are simply rubbed into the floor, hardening its surface. Most often, Portland cement is used, which extends the service life by 20 years. The liquid composition is applied to both fresh and old floors, reducing its dustiness. Before applying the mixture, the surface is slightly polished, achieving a greater surface smoothness;
• Finishing concrete floor. A two-stage grout is carried out, before which the floor must settle for 3-7 hours, depending on the surrounding conditions. First, rough grouting is carried out with discs in two passes (the second pass is carried out perpendicular to the first). Then the final grouting is carried out with the blades of trowels.
• Cutting seams in concrete and their sealing. Most often, polyurethane and epoxy sealants with increased hardness are used.

Concrete pavements are widely used due to their high wear resistance at a relatively low price. Their manufacture is usually combined in one technological process with the installation of a supporting monolith. Depending on the purpose and characteristics of the premises, the design of the concrete floor is determined.

When constructing a concrete pavement, it is necessary to strictly take into account the features of the base, focusing on independent laboratory studies of its characteristics. To achieve high wear resistance of concrete pavement, modern technological processes surface hardening of the floor using liquid and dry mixes, cement-polymer compositions, which are laid on top of still uncured or "old" concrete with a layer of 5 to 12 mm.

The sequence of technological operations at the device concrete pavement with top layer.

1. Surface leveling.
With the help of shooting, the highest point of the base of the floor is found. Refine the thickness concrete slab: usually from 100 mm (on concrete monolith) to 150-250 mm (on compacted soil). It should be emphasized that concrete floors of lesser thickness, with undoubted savings in concrete, are not advisable, because. more prone to cracking and subsequent failure.

2. Breaking down the floor into maps.
The edges of the cards (captures) should be located between the planned storage racks, because it is at the edges of the grips that the most significant number of irregularities can form, which is especially undesirable in high-rise storage. The width of the grips is allowed no more than 4 m, and the length depends on the productivity of concrete laying work per shift.

3. Installation of guides.
With optical and laser levels install guides, which are often used metal forms, hollow profiles or channels. For so-called "super-flat" floors, it is advisable to use special forms with a high degree of rigidity and a flat top edge. Concrete paving systems used in Western countries, have a telescopic device with a vibrator and a laser emitter that performs constant automatic level control when laying the concrete mix. The high productivity of these complexes (up to 5,000 sq. m. per shift) makes it possible to abandon the use of guides.

4. Reinforcement.
Reinforcement of the concrete floor is carried out using a mesh of reinforcement A-III. To reduce the formation of cracks, combined reinforcement is used, adding steel fiber to concrete in addition to reinforcement. When installing reinforcing meshes, it is important to control their position in order to prevent cracking of the surface. When using dispersed reinforcement of concrete with metal fiber (consumption is 25-40 kg per 1 m3 of concrete), installation of a frame mesh is not required. In this case, labor costs are significantly reduced, because. it is possible to use concrete-laying complexes. However, in this variant, one should Special attention on compliance with the formulation of concrete mixtures and the quality of soil compaction.

5. The device of sedimentary seams.
To prevent the formation of cracks in the bulk concrete floor due to shrinkage of the building elements, sedimentary seams are arranged that separate the coating from the walls of the building and the existing columns. To do this, along all walls (external and internal) and around the columns, polyethylene foam tapes are laid (tape thickness 3-5 mm).

6. Delivery of the concrete mixture and its distribution by squares.
Particular attention should be paid to the organization of technological redistribution - timely and uninterrupted delivery of the concrete mixture, its distribution on the maps, compaction with deep vibrators and vibrating screeds. Interruptions in the delivery of concrete, violations in its composition, different degrees of plasticity of the delivered mixture are unacceptable. they will adversely affect the quality of the floors. Therefore, the responsibility of the supplier of the mixture and its equipment with modern concrete mixing equipment is very important.

For the installation of "super-flat" floors, special high-quality vibrating screeds are used with strict control and adjustment of their geometry. Constant testing of the ductility of the concrete delivered to the job site will prevent degradation of the floor.

7. Alignment of the compacted concrete mix manually.
The quality of concrete floors, arranged according to traditional technology- using guides and vibrating rails. When laying floors in narrow aisles without manual labor not enough. Here aluminum and wooden slats rectangular section, special profiles with telescopic handles for smoothing the surface.

8. Exposure of the laid concrete.
The temperature and humidity of the subfloor and the surrounding air, the quality characteristics of the cement determine the curing time of the freshly laid concrete pavement. Usually this period is about 3-5 hours. When applied modern technology vacuuming the concrete mixture, the holding time can be as little as 1-2 hours.

Leading foreign firms - manufacturers offer an informal method for determining the degree of readiness of a concrete pavement for further processing. They recommend starting the next steps only when the shoes leave an imprint on fresh concrete no more than 0.4-0.5 cm deep.

9. Applying and grouting the hardening compound.
First, two thirds of the total amount of dry hardening composition of wear-resistant fillers, which are used as fractionated quartz, metal, corundum, silicon carbide, are applied manually to freshly laid hardening concrete. Portland cement, water-retaining and polymer additives are also introduced into this mixture, giving the coating plasticity and water resistance. Depending on the mechanical and other loads provided for during the operation of the floors, the type of hardening mixture is selected.

If carts with monolithic wheels made of polyurethane will be used in warehouses, then it is advisable to use quartz and corundum filler (consumption - 4-5 kg ​​/ sq.m). If it is possible to use trolleys with metal wheels, then metal-filled reinforcing mixtures should be preferred (consumption - 8-12 kg / sq.m). Colored fillers are also used, which, however, give a non-uniform color scheme. Only within one to three months (depending on the thickness of the concrete layer and the conditions in which it hardens) the color of the floor is evened out.

The applied layer of dry hardener is rubbed (smoothed) manually using special rails, which are aluminum profiles with a rectangular section 5x10 cm or 5x15 cm, equipped with a rotary handle. Trowels are also used at minimum disc speeds. Discs with a diameter of 600, 900 or 1200 mm are used. 2-3 passes are made over the entire surface of the floor. Then the remaining third of the mass of the dry hardener is applied and the final smoothing (troweling) is carried out, first with discs, then with the surfaces of the blades of the trowel. In the process of grouting, it is necessary to gradually increase the angle of inclination and the speed of rotation of the blades.

10. Applying a protective varnish.
To prevent the formation of deep cracks on the surface of the finished concrete floor, resulting from the shrinkage of the hardening concrete, it is necessary to reduce the evaporation rate of the moisture contained in it. To do this, immediately, immediately after grouting, using rollers or a pneumatic sprayer, apply special water-retaining varnishes based on acrylic copolymers to the floor surface and organic solvents. Varnish consumption is 150-200 g/sq.m. In this case, a film with a thickness of 0.07-0.12 cm is formed, which wears out as the floor is used.

11. Cutting shrinkage seams.
Shrink joints are cut to a depth of at least 2.5 cm using special machines equipped with corundum or diamond discs. The cutting step is approximately 30-40 times the thickness of the concrete layer. The seams are located depending on the location of the columns, the distances between them, the configuration of the room. The operation must be carried out no later than 6 - 8 hours after grouting, until shrinkage cracks begin to form.

12. Filling shrinkage and expansion joints.
As the concrete shrinks for a long time, shrinkage joints are formed, which must be filled with sealants. The most appropriate way to fill the joints is to fill them with polyurethane or epoxy sealant to the entire depth of the crack, because. often used polyethylene foam cords are destroyed when used in heavy traffic.

Certain inconveniences arise due to the fact that the filling of the seams can be carried out only after the required time has passed, often at least 3 months. During this time, the warehouse is already put into operation, and it is necessary to repair the seams already in the existing warehouse.

In connection with the above, we can conclude that laying a high-quality and durable concrete floor depends not only on the qualifications and experience of the installers, but also on objective factors - the temperature and humidity of the air in the room without drafts, good lighting, lack of leakage of moisture and others. It is necessary to plan all work in advance so as not to create adverse conditions for concrete flooring.

For new warehouses (floors):

• When arranging on the ground, a minimum thickness of 120 mm should be designed with mandatory reinforcement;
• The reinforcing mesh is made of a 10 mm bar, with a mesh size of 150x150 mm, if the load on the floor of the warehouse is within 5 tons / sq.m.

For dust removal of existing dusty collapsing concrete coatings (floors) in a warehouse:

• It is recommended to use a polymer or paint;
• As an intermediate option, it is possible to use a thin-layer topping coating (mastertop 135 pg) with a thickness of 7 to 15 mm. This is a special topping that is laid on top of old concrete of grade at least 300.

Rokla (hydraulic trolley) rides on such a floor like clockwork. If the concrete floor with topping is treated immediately after laying with a special sodium or lithium impregnation, it will not generate dust.

An important advantage that our self-leveling floor for warehouses has is its inability to dust and stain the goods, which ensures the preservation of the proper appearance of the goods.

The cost of self-leveling floors for a warehouse

* The cost of works without material on an area of ​​2000 sq.m.
** The cost of work with the material on an area of ​​1000 sq.m.

What can be the flooring in the warehouse?

A spectrum of very serious requirements is imposed on floors in warehouses.

The cover must have:

• Abrasion resistant. We ensure long-term operation, mindful of the inadmissibility of the appearance of depressions or potholes, which can lead to the collapse of the racks;
• mechanical strength. Modern warehouses have a wide variety of forklifts, so the floors must reliably withstand the load from Vehicle and shear stresses;
• Impact strength. Warehouse polyurethane floors must be able to handle the fall of heavy loads so that the integrity of the coating is not broken;
• Chemical resistance. The coating must not be damaged by contact with paints, oils, organic and other solvents;
• Heat resistance. The floor should not be destroyed when the temperature drops from the positive to the negative range or vice versa;
• Waterproof. This is important for trouble-free harvesting with mechanized devices;
• Anti-slip, regardless of the state of humidity, which is extremely important for industrial safety;
• fire safety;
• Noise absorption, providing improved working conditions for warehouse workers.

Bulk floors for a warehouse can be made not from every mixture. It is necessary to ensure compliance with the requirements listed above, so it is important to take care of the proper selection of its device and composition.

Our experts will help you decide the right choice, the production of accurate calculations and monitor compliance with the technology during installation.

It is very important that polymer floors for a warehouse in Moscow have a perfectly flat surface. Even with a 3 mm unevenness, a deflection at a 9 meter stacker height occurs by approximately 1 meter of deflection.

The cost of one wheel of an automated loader is 12,500 euros, and due to irregularities and roughness, it wears out quickly, which is fraught with unplanned costs.

What compounds are most in demand for laying floors in warehouse complexes:

1. Impregnations having polymer base, reinforce concrete base(screed), polyurethane coating for the warehouse helps to extend its service life and improve quality characteristics;
2. Paints - there is a choice of one-component polymer enamel compositions applied to a concrete base;
3. Bulk polymers (polyurethane or epoxy floors for a warehouse) can be thick-layer or thin-layer, consist of quartz, metal, corundum fillers.

Depending on the specific conditions, it is possible to use one, several or all compositions simultaneously.

Options for pouring self-leveling floors for a warehouse

Thanks to a wide range of compositions and mixtures that are effectively used when pouring floors, we can always select the best option for specific types of premises and offer anti-dust flooring for a warehouse.

If there are stacks, shelves, racks for storing goods in the warehouse, we recommend using a paint coating or impregnation. In warehouses equipped with loading equipment, our company uses thin-layer (1-2 mm thick) cement-acrylic mixtures.

For equipping loading terminals and hangars, we are guided by similar recommendations.

If in each zone the most optimal polymer floor for the warehouse is used, it is possible to achieve significant savings in the cost of the coating, providing it with rational operational characteristics.

What is the cost of installing self-leveling floors for a warehouse?

To determine the exact price, floor markings are made in the warehouse, combined with accurate technical calculations. You can call to order a free measurement at a convenient time for you.

We will immediately deal with the calculation of the estimate, determine the optimal type of mixture and provide the exact cost per square meter.