Concrete Floor Installation
Warehouse Floor Construction – Time-Lapse Video
In the run-up to Christmas, we checked off a significant milestone at our Stourport project, which is the construction of a 10,000-square-foot warehouse. Installing a state-of-the-art concrete floor has set new construction quality and efficiency standards. A time-lapse video of this installation, which is now featured on our website below, showcases this remarkable process from start to finish.
Land Preparation For Concrete Floor
For warehouse floor construction, preparation is undoubtedly the key to success. The journey began with meticulous preparation of the land, with the site undergoing extensive engineering and compression tests by a specialist contractor. This critical step ensured the land’s stability, laying a solid foundation for both the building and the concrete slab that would form the base for the storage racks it was designed to hold.
Key to this project’s success was the use of hardcore, forming a robust and workable base. This material, renowned for its stability, was laid once the ground met the required compression standards, setting the stage for further construction.
Advanced Moisture and Gas Protection
Understanding the importance of protecting both the warehouse contents and its users, we installed a dual-layer membrane system. Sandwiched between these layers were insulation sheets, mitigating the effects of the cold ground underneath. This installation, executed by certified contractors, ensured a seamless barrier against moisture and gas ingress, integrating flawlessly with the floor and extending into the brickwork.
Reinforcement and Precision
Per the engineer’s specifications, the strength of the floor was further enhanced by incorporating two layers of A393 steel mesh. Packers were positioned under this to enable total emersion by the concrete. This reinforcement ensures durability and longevity.
Warehouse Floor Construction: A Blend of Art and Science
With 29 lorries delivering 476 tonnes of concrete throughout the day, our team expertly poured concrete to a depth of 200mm over the entire area, achieving the required flatness and level. Both warehouse and industrial floors typically adhere to three accepted level standards:
- Flatness (F.F.): This measures how bumpy or wavy a floor is.
- Levelness (F.L.): This assesses the tilt or slope of the floor.
- Overall Floor Flatness (F-number system): This comprehensive measurement combines flatness and levelness.
To achive the accuracy required, technology played a vital role, with the team utilising the benefits of the Ekin Conscreed E1800, a cutting-edge tool for achieving unparalleled consistency in level and flatness tailored for warehouse requirements.
The Art of Power Floating and Precision Joint Cutting
As the concrete began to cure, our specialist contractors’ power floated the entire area. This technique involves smoothing and finishing the concrete to achieve the desired surface texture and hardness.
Power Float Operator: Using the machine is easy; anyone could do that. Knowing when to use the machine is where the skill is.
Power floating is critical for creating a durable, smooth surface that can withstand heavy warehouse use.
As part of the process, specialist contractors cut joints into the floor using a machine called an Early-Entry Saw. This method not only speeds up the construction process but also prevents the formation of random cracks, ensuring a flawlessly segmented floor. These cuts are later filled in with a material, allowing the floor to move and breathe.
Watch the Transformation Unfold
We invite you to witness this extraordinary process through our time-lapse video below. This visual journey highlights the expertise and precision that the Gravitas team brings to every project, reaffirming our commitment to quality and innovation in construction.
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