This technological redistribution is the most organizationally difficult stage in the device concrete coverings floors Breaks in the delivery of concrete even for 30 - 40 minutes (especially in summer time), the heterogeneous composition of concrete, different plasticity of the mixture lead to an irreversible deterioration in the quality of concrete floors - first of all, its evenness and durability.
Flooring manufacturer in in this case completely depends on the commitment and efficiency of the supplier ready-mixed concrete, therefore the choice of concrete mixing unit is the most important stage planning all floor installation work.
The concrete mixture is distributed among the grips and compacted using vibrating slats and deep vibrators. Special attention It is necessary to pay attention to the quality of concrete compaction along the tracks, walls and around columns. When constructing “ultra-flat” floors, special high-quality vibratory slats are used, and their geometry (deflection) must be checked and, if necessary, adjusted after each work shift.
The plasticity of the supplied concrete must also be checked. The manufacturer must measure the cone draft concrete mixture from each concrete mixer (“mixer”) and require the supplier to adjust the recipe. A change in cone settlement by more than 4 cm in a batch of concrete delivered in one shift can lead to difficulties during the work and reduce the quality of the finished floor.
Leveling compacted concrete using hand slats.
At traditional technology installation of concrete floors (use of guides and vibrating slats), the evenness of the floors is largely determined by the professionalism of the concrete layers. The use of high-quality guides and adjustable vibrating slats does not guarantee the installation of coatings with the desired evenness.
Unfortunately, it is not possible to obtain high-quality and even floors without a lot of manual labor. When producing “ultra-flat” floors for narrow-aisle stackers, 20 - 30% of all labor costs are spent on manual leveling of the concrete floor.
The use of concrete-laying complexes allows you to reduce the share of labor costs for distributing and compacting the concrete mixture, but also does not allow you to abandon manual labor for leveling freshly laid concrete.
Leveling is carried out using aluminum and wooden slats rectangular section, special smoothing profiles on telescopic handles with swivel joints.
Curing of freshly laid concrete.
The holding time depends on the temperature of the base, humidity and ambient temperature, and the activity of the cement used in preparing the concrete mixture. As a rule, concrete is kept for 3 to 5 hours before subsequent processing operations. The frequently used technology of vacuuming the concrete mixture reduces the holding time to 1 - 2 hours, which simplifies the technology.
In accordance with the recommendations of the American Concrete Institute (ACI) and most manufacturers of reinforcing compounds, further processing of concrete can begin only after the depth of the shoe print on the concrete is less than 4 - 5 mm. Such an informal recommendation indicates that the technology of concrete floors, and as a consequence their quality, largely depends on the accumulated experience and professionalism of the layers.
If the concrete mixture is delivered to the construction site of heterogeneous quality, the curing time of different sections of the laid concrete will be different, so at this stage it is necessary to carefully monitor the setting time of the concrete.
Applying 2/3 of the total amount of strengthening composition to freshly laid concrete
The dry strengthening mixture is applied to the hardening concrete manually or using special distribution trolleys. The latter method is the most preferable, as it allows you to achieve a controlled and uniform distribution of the strengthening mixture.
To produce strengthened concrete, dry mixtures are used that differ in the type of wear-resistant filler. The most common are fractionated quartz, corundum, silicon carbide and metal. In addition to the filler, the strengthening mixtures include Portland cement, water-retaining, plasticizing and other polymer additives.
The type of reinforcing composition depends on the intensity of wear to which the floor is exposed. IN warehouses, where loaders and stackers with monolithic polyurethane wheels are used, hardening of floors with quartz and corundum filler is used. In rooms where movement of carts on metal wheels is possible, use only metal-filled mixtures. For “ultra-flat” floors, some companies produce reinforcing compounds that are characterized by increased ductility and increased pot life and workability.
The total consumption of quartz and corundum hardener is 4 - 7 kg per sq.m., metal-filled - 8 - 12 kg. per sq.m.
Colored reinforcing compounds are produced and widely used, but the color of the finished coating is never uniform due to the heterogeneity of the composition of the concrete mixture, its thickness, and the application of the strengthening compound. The color of the floor is leveled within 1 - 3 months, depending on the thickness of the concrete and its hardening conditions. The same applies to the “spotting” of the “natural concrete” color hardener.
Strengthener grout.
The dry hardener applied to the concrete is smoothed using manual slats, which are aluminum profile with a cross section of 50 x 100 or 50 x 150 mm, to which a handle is attached on a rotary hinge. Using a manual lath allows you to more evenly distribute the strengthening mixture over the surface of the concrete and control its saturation with moisture coming from the concrete.
For mechanized grouting, self-propelled and manual trowels are used. Grouting begins with discs fitted to the machines (diameter 60, 90 or 120 cm) at minimum speed. Grouting is stopped after one or two passes over the surface.
Applying the remaining 1/3 of the hardener and final grouting.
After applying the remaining part of the strengthening composition to the concrete surface, grouting is continued using disks, and as the concrete hardens, the disks are removed from the troweling machines and the surface continues to be treated with blades. At the same time, the angle of inclination of the blades and the rotation speed of the rotors are gradually increased.
Floors in warehouses constantly experience enormous mechanical loads from the movement of warehouse equipment, enormous pressure from shelving, severe abrasive and impact effects, and temperature changes. Their poor performance can cause significant financial losses associated with repairs and downtime.
Requirements for floors in warehouses
The load-bearing layer of the floor in warehouses in most cases is a reinforced concrete slab made over crushed stone, soil or sandy base. Concrete class for the structure, slab thickness, reinforcement zones, diameter of reinforcing bars, cell sizes reinforcing mesh determined at the floor design stage depending on the intensity and magnitude of the expected loads, type of base, etc.
Depending on the type of warehouse (industrial, customs, transit) and its purpose (storage of pharmaceutical products, explosive materials, consumer goods, etc.), corresponding requirements are imposed on the floor.
Floors in warehouses should be:
- resistant to abrasive wear - one of the most important factors in the destruction of concrete floors in warehouses. Abrasive wear occurs due to the movement of people and vehicles around the warehouse;
- resistant to mechanical loads. Various vehicles travel on warehouse floors, so they must have improved characteristics to withstand the shear stresses that arise;
- resistant to impact. Quite often in warehouses, various heavy objects fall onto the floors, so the coating must be so strong that it can withstand impacts from falling objects and at the same time maintain its solidity;
- resistant to various aggressive chemicals. Due to the use of various mechanisms and machines, floors in warehouses become contaminated with fuels and lubricants and engine products. Floors in chemical industry warehouses may experience negative impact from various liquids, salts, alkalis, etc.;
- insensitive to temperature changes. This is especially true for warehouses with access to the street, refrigerators and freezers;
- impermeable to liquids. The floor must be moisture-resistant so that it is not adversely affected by frequent wet cleaning;
- non-slip in both dry and wet conditions to ensure safety for pedestrians and vehicles;
- fireproof.
Features of flooring in warehouses
The key to the quality of concrete floors is compliance with all rules of laying technology and the experience of the contractors. When arranging a warehouse floor, it is necessary to plan in advance the location of shelving, driveways, and decide on the equipment that will be used for loading and transporting stored goods.
When designing the floor, care should be taken to ensure that shrink joints do not end up at joints in areas of high loads or on passage lines. All drain holes and service grooves should not be installed near rack supports or in the routes of loading equipment.
Until recently, storage in warehouses was carried out directly on the floors or on racks in 2-3 tiers. Warehouses with a storage height of more than 8 m were rare. In modern warehouses, the storage height of cargo reaches 14, 16 and even more meters. At the same time, the passages between the racks have become smaller, as have the dimensions of warehouse equipment. With the use of modern technology and the “growth” of warehouses, the requirements for floor levelness have also changed.
There should be no slopes on warehouse floors. This is primarily due to the stability of warehouse racks. There should also be no local unevenness on the floor, since lifting equipment often has low ground clearance and can simply “sit” on a protruding hump.
In addition, even slight unevenness in the floor leads to quite strong deflections of the forklift mast and rocking of the lifted load. The most stringent requirements are imposed on the floors of those warehouses where three-sided stackers are used, and the width of the aisles between them is 1.6-1.9 m.
Floors in warehouses with three-way stackers must comply with the following conditions:
- with a warehouse height of up to 3 m, the difference over a segment of 2 m should be no more than 5 mm;
- with a warehouse height of up to 6 m – no more than 3 mm;
- with a warehouse height of more than 6 m - no more than 1.5 mm.
The labor and cost of producing these “ultra-flat” floors is approximately 15-25% higher than flooring for single- or double-bay warehouses. That's why necessary requirements to the evenness of the floor must be determined by the customer at the stage of drawing up the technical specifications.
Protecting Concrete Warehouse Floors
Concrete floors are often criticized due to their poor resistance to moisture and chemicals. Today, there are two methods for solving this problem: the initial choice of concrete High Quality and subsequent strengthening of its top layer.
The following compounds can be used to protect concrete floors in warehouses:
- dust-removing, strengthening impregnations;
- dry strengthening mixtures (topping);
- polymer paint coatings;
- polymer highly filled self-leveling floors.
Polymer coatings for warehouse floors
The choice of polymer coating depends on the operating conditions of the floor in a particular warehouse. Most often, polyurethane compounds are used to protect floors in warehouses, which have excellent wear resistance. Polyurethane impregnation penetrates concrete to a depth of 2-6 mm, forming a concrete polymer in the top layer of the base. This increases the density of the floor and also seals it. Polyurethane self-leveling flooring has high tensile and compressive strength. It has high impact resistance and can withstand very high mechanical loads. In modern warehouses, self-leveling floors made using the two-component polyurethane material Polymerstone-2 have proven themselves to be excellent.
Self-leveling polymer floors are recommended for use in warehouses Food Industry , as they provide additional safety and hygiene for food storage. Such floors are also indispensable in warehouses for chemical products, as they are characterized by increased safety.
Instead of a self-leveling floor, epoxy or polyurethane based impregnation can be used. If more is preferred a budget option, then the floor can be painted polyurethane enamel, for example, Polymerstone-1. It will give the flooring elasticity, as well as abrasion resistance and various deformations. An undeniable advantage paints for concrete floors - low cost.
Concrete paints primarily perform protective functions. They prevent the penetration of water into the pores of concrete, reduce abrasion, and reduce the crumbling of the floor under the influence of physical activity. Floors in warehouses do not need spectacular decoration. For them, the main thing is not beauty, but protection. Although sometimes they are painted bright colors to allocate work areas or areas for finished products.
Concrete paints in some cases can be applied directly to floors, but they must be dry and free of dust and dirt. However, paints will adhere much better and retain their properties if applied to prepared surfaces (cleaned and primed). For these purposes, special polymer primers and impregnations are used.
The maintenance-free operation time of any polymer coating depends to a large extent on the preparation of the surface of the concrete base. The adhesion of the polymer and concrete depends on the degree of roughness of this surface. Reliable adhesion of the polymer coating to the concrete base can be ensured by shot blasting the concrete or grinding with an abrasive tool.
Shot blasting or grinding concrete allows you to achieve a uniform surface roughness. With the help of these operations, the adhesion area of concrete and polymer is greatly increased, the layer of cement laitance is removed and the filler grains are exposed.
The technology for applying highly filled coatings consists of the following operations:
- processing of the concrete base by grinding or shot blasting (providing the necessary roughness, removing laitance);
- filling cracks and filling them with sealant;
- applying a low-viscosity primer in order to create the required degree of adhesion of the polymer coating to the concrete base;
- applying the main high-fill coating layer over an uncured primer;
- processing the hardened coating layer using a mosaic grinder;
- cleaning the floor surface from dust using construction vacuum cleaner;
- application of colored protective and decorative coating;
- cutting expansion joints and filling them with polyurethane sealant.
This coating can be used 2-3 days after installation is completed. Pedestrian traffic is allowed every other day.
More details about the technology of installing concrete floors in a warehouse are described in the article Technology of installing warehouse concrete floors
How much does a warehouse floor cost?
The cost of a warehouse floor includes two components: installation cost and operating cost. If the floor is not designed correctly, various defects will occur, the elimination of which will require additional costs. Therefore, it is more profitable to create high-quality floors, especially in modern warehouses, where the quality of structures is of paramount importance.
Cost of flooring for a warehouse:
There are several ways to install floors in a warehouse. Each time the choice is made taking into account many factors, comparing the features of one or another option and the requirements for gender in a particular case. Today's material will tell you about the types of warehouse floors.
On the degree and variety of possible external influences Warehouse floors are affected by the following factors:
- Purpose of the warehouse (universal or specialized, production or industrial).
- The structure of the building is open or closed.
- Intensity of use.
Floors in a warehouse must meet not only general, but also special requirements:
- During operation, as little dust as possible should form on the surface of such a floor. This will protect products and materials from contamination, and also ensure safe conditions labor for workers.
- The increased strength of the floor ensures the organization of storage of large quantities of products on high racks and the safe, unhindered operation of lifting and loading equipment. The strength indicator is measured in the ability to withstand load in kilograms per 1 centimeter of floor.
- The wear resistance of the coating is important, since the floor will be exposed to mechanical loads from the movement of forklifts and people on it, and will be subject to the possible fall of heavy loads.
- The floor should be as level as possible, only minor differences in height are allowed. This ensures the correct operation of modern forklifts associated with the shipment of products, as well as the stability of storage systems - racks, pallets, pallets.
- Special requirements include increased moisture resistance of the floor. Its level depends on the purpose of the warehouse and the specific storage conditions of a particular product category.
- Another special requirement is the frost resistance of the floor. This applies to unheated warehouses.
- To ensure the safety of movement around the warehouse for maintenance personnel, the floor surface must be non-slippery, including when liquid gets on it.
- Where warehouse lighting is provided by natural light penetrating through translucent structures mounted on the hangar ceiling, it is important that the floor does not lose its performance properties when exposed to direct sunlight.
- In warehouses with complex household appliances, food, medicine, explosive substances, the floor must have an antistatic and dielectric surface.
- The noise-absorbing properties of the floor in a warehouse are of no small importance; the higher this indicator, the more comfortable it is to work in such a room.
- The floor in the warehouse must be durable, resistant to cracks and other defects on its surface;
- The specifics of warehouses in which medicines, food, and cosmetics are stored place special demands on floor hygiene.
- The flooring material must be non-flammable and will not support or contribute to the spread of fire.
Types of loads
Warehouse floors are subject to various types of loads and impacts. The main two categories are static and dynamic loads.
The types of static load include linear, uniform and point (concentrated).
At distributed load Single loads are stacked in blocks. Taking into account safety measures, the height of the stack should not exceed 4 m, otherwise the load may resist crushing (crumbling). Used to store products wooden pallets and metal shelving. In order for the stacks to be stable and the storage process to be organized as efficiently as possible, the weight and size of the products to be stored are taken into account.
Heavy equipment is often installed on additional basis. When installed directly on the floor, it should provide a uniform or concentrated load.
A linear load on the floor is exerted by a storage system or equipment with a rail base that is in contact with the floor and is loaded along its entire length.
When moving products around a warehouse using rails, we are talking about point loads. For example, stacker cranes mounted on diskette base plates exert a point load on the floor.
When equipment or structures are placed on base plates or racks, point loads are placed on the floor. For example, warehouse racks or any lifting mechanisms.
A storage system organized using racks provides storage of products and provides quick access to required type cargo
As a result of impact on the floor structure mobile mechanisms, which is used in the warehouse for moving pallets, containers and bulk products - wood, roll materials, a dynamic load occurs.
Table 1. Floor requirements depending on load
| Type of equipment | Purpose | Control | Load capacity | Floor requirements |
|---|---|---|---|---|
| Forklifts, trailers | Transportation of one or several pallets with cargo, selection of goods to order | Driver or operator | No more than 3 tons | Flat and level. Particular attention should be paid to seams that collapse under the weight of small wheels. The width of the seams should be 20 mm, and their spacing should be 50 m. As an option, you can arrange a seamless reinforced concrete floor. |
| Forklift with telescopic lift | Used inside and outside the warehouse (laying in blocks, on racks up to 7 m high, moving goods inside the warehouse) | Driver | More than 10 tons | The floor surface should be free of moisture and dust to prevent damage to the floor by tires. The floor may have uneven surfaces and seams. |
| Retractable Forklift Truck | Selection of goods to order and transportation of products throughout the warehouse | Driver | 2 tons | Thanks to the presence of vulcanized neoprene tires, there is no spillage on the floor. Negative influence. However, special requirements are placed on the evenness of the floor and its location in the horizontal plane. The seams are made smooth and narrow. |
| Front and side stacker | Applicable in hard to reach places and narrow passages. They can move on rails. | Operator | - | Do not have a serious effect on the floor. |
| Stacker cranes | Rail guides are used to move them. | Operator | - | There are no special requirements for the floor plane, but it must be located in a horizontal plane relative to the original zero level. |
Concrete floors for a warehouse as a base
Most often, when designing a warehouse, the base of the floor is concrete. This material makes it possible to satisfy all the necessary requirements to a greater extent - concrete is reliable, has long term service and high strength. in a warehouse is the most reasonable choice, since this method is the most affordable and easy to implement.
However, in pure form concrete floor is not used - through certain time the top layer will begin to collapse, the surface will become uneven, and a large amount of dust and dirt will begin to form. An additional front coating applied to the concrete screed will allow you to maintain resistance to aggressive influences for many years.
If the technology for constructing such a floor is not followed or the front layer of the covering is incorrectly selected, over time, an irreversible process of destruction of the floor structure will begin; microcracks and other defects may form on its surface, leading to the complication of the storage organization process, deterioration of the stability of stationary systems and the emergence of difficulties in the operation of mobile equipment. To prevent this from happening, even at the design stage it is necessary to perform calculations, take into account the upcoming loads and operating conditions of the base and the front covering that protects the concrete screed.
The main obstacle to using a clean concrete floor is its instability to moisture and chemicals. In this case, it is recommended to either use concrete of the highest quality or use substances that can strengthen and protect the top layer of the concrete screed.
Installation of heavy-duty concrete floors
The main advantage of such floors is their low cost and durability, subject to the installation technology. The process is quite labor-intensive, and its result depends on several factors:
- The competence and experience of concrete workers, their availability of a full range of professional tools.
- Uniform and timely delivery of the working solution.
- Uniform quality for each batch of workers.
- At the design stage, it is recommended to provide for the presence of reinforcing steel fiber, which will prevent the appearance of cracks during concrete shrinkage. It is also desirable to have shrinkage and expansion joints, which have a positive effect on the service life of the coating.
- Having a plan for the placement of racks and equipment on the warehouse territory will allow you to rationally organize the process of filling the floor with grips (sections) so that their edges are located under the storage systems.
- In the room where floor installation work is taking place, ensure there is no draft, sufficient illumination and a temperature of at least 10 C° - this will allow you to obtain a smooth coating without cracks.
- After laying each section, it is necessary to check its levelness the next day and perform timely leveling using epoxy or cement-polymer compounds, but not earlier than after 3 weeks.
- It is important to keep under control the amount of consumable reinforcing composition - if it is insufficient, the thickness of the wear-resistant layer will decrease and the durability of the coating will be reduced.
Important! If the concrete mixer truck is delayed in delivering concrete to the site for more than half an hour, it can be argued that the levelness of the floor at the junction of the previously laid and fresh concrete will suffer significantly.
Base for concrete floor
To arrange the foundation, use natural or bulk soil. The soil base ensures uniform distribution load bearing from the building. If at the construction site in some areas there is soil of a different consistency from the larger massif, it is replaced with a more compacted one so that it is the same throughout the entire construction area.
Filled soil will help replace unsuitable soil or raise the height of the foundation above its natural level. Its composition and a certain amount of moisture allows it to achieve the required level of compaction.
As an important structural element of a concrete floor, the underlayment performs three main functions:
- Creates a durable working platform for construction work that is not subject to deformation under the weight of transport.
- Provides required height bases for installing the foundation slab.
- Transfers the load from the foundation slab to the ground.
The underlying layer is formed using a resistant material with a special granulometric composition. Sometimes it is further strengthened cement mortar. Under operating conditions that do not imply impact on the underlying layer low temperatures, its frost resistance becomes optional, as is the case for floors in refrigerated warehouses, where thermal insulation of foundation slabs is used.
If during the examination of the soil its sufficient strength is revealed, then the underlying layer can be abandoned, but it is necessary to take into account the quality of the soil and weather in the construction region.
Important! When choosing a material for the underlying layer, it is recommended to make sure that it does not release chemicals that can cause destruction of the floor from the inside, as well as that the material does not expand and contract when it is moistened.
Table 2. Types of gender
| Floor type | Description |
|---|---|
| Floor with seams over a large area | Construction of a large floor area is carried out non-stop. The spacing of formwork structures fixed at the edges is 50 m. |
| Seamless floors of a large area | A seamless floor is created using special method laying taking into account the large area of the room. Included concrete mortar contains steel fiber, which controls the size of cracks that appear during the shrinkage process. |
| Strip laying | The width of each laid concrete strip is from 4 to 6 meters. The strips are laid in any order; later, the remaining space formed by the formwork is filled. |
| Sectional floor | Multilayer concrete slabs containing special materials and components are laid on the soil base. |
Video - Concreting floors in a warehouse
Defects when laying concrete floors
After laying a concrete floor, some defects may appear on its surface.
Table 3. Causes of defects
| Type of defect | Description |
|---|---|
| Formation of cracks | During the process of shrinkage, a certain number of cracks are formed on the facing concrete layer, arranged in a free order. In the process of grinding the floor using metal attachments, it is possible to reduce the depth of such cracks to 3 mm. |
| Warping process | This is a type of deformation of a concrete slab when its edges bend and the middle becomes curved. The reason is the difference in moisture content in different layers of the product. |
| Smoothing traces | Swirls or changes in shade often accompany the drying process of the concrete mixture and appear as a result of unnecessary actions during grouting. |
Types of warehouse floors
The type of floor structure for a warehouse is selected in accordance with the requirements for storage conditions of products, with the intensity and nature of the use of the coating.
Dye
Where loads are insignificant and lifting equipment is not used very intensively, a concrete floor with a painted front surface can be used. Such floors are quite suitable for warehouses with medical supplies and food products - the most demanding product category. A 0.5 mm thick paint layer can protect the base from moisture and reagents. Compared with self-leveling floors, painted ones will cost much less.
Quartz (high-flow) floor
This type of floor is recommended for installation in rooms with high traffic volumes of heavy equipment and personnel. The strength of the coating is ensured by the presence in its composition epoxy resins and quartz sand, which allows us to call the composition of such a coating armored. By introducing dyes, it becomes possible to produce coatings of different colors. The main advantage of the armored coating is its high degree of readiness - a few hours after its application to the concrete screed.
Polyurethane floor
This is one of the types of polymer coatings that can be used in warehouses due to their elasticity and wear resistance. The polyurethane composition forms a concrete polymer, penetrating into the screed to a depth of 6 mm. As a result, the top layer is sealed and eliminates the process of dust formation on the concrete surface in the future. Thin layer polyurethane can also serve as a concrete impregnation and a base for highly filled coatings. Using polyurethane, you can quickly and efficiently install flooring in a warehouse.
Dry mixtures for strengthening floors
The floor surface can be strengthened using special dry mixtures that increase the wear resistance of the coating, for example, Portland cement. Additives are added to the solution at the pouring stage. You can also add dyes of natural or artificial origin.
Using dry mixtures, you can increase the decorativeness of the coating and its performance characteristics, and reduce the likelihood of cracks and other defects. Upper layer concrete becomes more durable and resistant to moisture. Depending on the percentage of additives and dyes, the texture of the concrete floor is grainy, smooth or mirror-like.
Industrial polymer floors
Polymer floors performance qualities meet all requirements. Their advantages:
- fire safety;
- waterproof;
- impact resistance;
- resistance to mechanical stress and abrasives;
- antistatic;
- elasticity is maintained in conditions of negative temperatures;
- non-slip surface.
I use polyurethane impregnation, which penetrates into the concrete structure to a depth of 6 mm; I can obtain a durable coating inexpensively and quickly.
Single-layer polyurethane coatings are used in warehouses where there is no special load on the coatings; in other cases, the polymer coating is reinforced with reinforcement. Due to their hygiene, such coatings have become popular in food warehouses, and high level safety has made them indispensable in chemical storage areas.
TO budget method Strengthening a concrete floor involves impregnating it with epoxy, polyurethane or enamel (Polymerstone-1). The result will be the formation of an elastic surface that is resistant to deformation and abrasion.
The advantages of polymer paints for concrete are as follows:
- Protecting concrete pores from moisture penetration.
- Increased abrasion resistance.
- Allows you to create bright markings that simplify logistics within the facility.
- Increasing strength and resistance to physical stress.
The base for paint should be clean, sanded and primed - this way the composition will last longer. For this purpose, special compounds are used.
The quality of the polymer coating largely depends on the preparation, during which the base is sanded to increase its roughness to improve adhesion.
The polymer coating manufacturing process is as follows:
- Grinding the concrete base.
- Treatment of small cracks using sealant with preliminary jointing.
- To ensure high-quality adhesion of the polymer coating to the concrete base, the latter is treated with a low-viscosity primer.
- A base polymer layer is applied to the uncured primer.
- After the coating has hardened, it is sanded using a mosaic grinder.
- After sanding, dust is removed from the floor surface using a construction vacuum cleaner.
- A protective color layer is applied.
- Sliced expansion joints and fill them with sealant.
Such floors are suitable for use after just 3 days, and you can walk on them after 24 hours.
When choosing the type of floor for a warehouse, they take into account the operating conditions, the nature of the loads and the purpose of the room, the climate of the construction region and the characteristics of the soil.
Warehouse floors are one of the most important elements warehouse complex. They experience enormous loads, harsh abrasive, mechanical, shock effects, and are constantly influenced chemical elements and temperature changes.
Warehouse floor requirements
Warehouse floors are subject to increased demands. Such coatings should be:
- Resistant to abrasive abrasive effects - one of the main factors in the destruction of warehouse floors.
- Resistant to mechanical stress. Warehouses experience frequent traffic movements, so flooring must have improved properties to withstand shear stresses. Floors in garages should have the same property.
- Impact resistant. Heavy objects may fall onto the floors. The solidity of the coating should not be disturbed.
- Possessing chemical resistance. Warehouse floors in the chemical industry are exposed to aggressive liquids: solvents, paints, acids, etc.
- insensitive to temperature changes. Industrial floors in industries where high temperatures with frequent changes are used are often damaged prematurely. Additional strengthening of the base is especially relevant for warehouses with access to the street, freezing and refrigeration chambers;
- impermeable to liquids. So that frequent wet cleaning does not have a detrimental effect on the floors in warehouses, and substances harmful to the environment do not get into the soil through them, the coating should not allow liquid to pass through.
- Non-slip, both dry and wet, to ensure the safety of vehicles and pedestrians.
Fireproof and durable to guarantee the safety of goods or raw materials stored in a warehouse. That is why, when installing industrial floors for a warehouse, it is necessary to take into account operational requirements, load distribution parameters and other factors. Don't miss any of these nuances and choose best option Specialists from the Prom-Flor company will help you install warehouse floors.
Selecting floor coverings in a warehouse
The choice of coating is carried out taking into account the above requirements.
Among the most reliable modern coatings include self-leveling floors for warehouses made of polymer materials.
Polymer floors can be applied in the form of a thin-layer strengthening impregnation, as a color coating, or as full-fledged thick-layer polymer floors filled with strengthening mixtures, such as quartz.
In a warehouse, a concrete floor reinforced with topping or impregnation can also be used. The main thing is that the floor covering meets all operational requirements.
Polymer floors for warehouses
Polymer floors are increasingly used in production and warehouse areas. Perfect option- self-leveling floors for warehouses. This is a thick-layer coating that is practically not subject to abrasive influences, withstands significant loads, and does not allow excessive dust formation.
When installing self-leveling floors for a warehouse is impractical or a budget option is preferable, you can paint the floor with polyurethane enamel. It will not replace 100% self-leveling floors, but will give the flooring additional elasticity, resistance to deformation, abrasion and abrasion.
Instead of self-leveling flooring for warehouses, you can use impregnation based on polyurethane or epoxy based. As you know, epoxy floors are one of the most resistant types of polymer coatings, so this impregnation provides compressive or tensile strength and impact resistance.
In addition, the use of polymer coatings is relevant where, according to operating conditions, only polymer floors can be used - in food production, for example, to ensure additional hygiene and storage safety food products. Self-leveling floors will become indispensable in workshops and warehouses of the chemical industry, since they have increased fire safety.
Concrete floors for warehouse
Concrete floors are most in demand for arranging warehouses, regardless of whether a self-leveling floor is installed or the concrete layer will become the finishing layer. You cannot do without concrete at the stage of preparing the base for any floor covering.
The optimal solution for a warehouse is concrete floors with a quartz topping, and for rooms with heavy loads - using a metallized topping. They are resistant to abrasion, shock, and dynamic loads. Such floors are cheaper than polymer floors. Besides, modern technologies allow you to give concrete floor coverings attractive appearance, if required by the purpose of the premises.
As an underlying base, concrete floors for a warehouse must be constructed using reinforcement and fillers made of expanded clay and crushed stone. Such a foundation will be reliable and durable.