Industrial concrete flooring
High-quality concrete floors can withstand extremely high loads, have good performance properties and be long-lasting, which is why they are most valued in industrial buildings: logistics and shopping centres, car parks, ice arenas, warehouses, workshops and other large-area buildings.
Depending on your needs, using modern equipment and a team of experienced staff, we can install up to 2,000 square meters of concrete floor in one day.
We encourage you to contact our experts and they will offer the most effective solution and the most suitable concrete floor installation technology.
When installing industrial concrete floors, the main focus is made on the preparation of the base, quality approval tests and detailed analysis of the structure. Subsequently, reinforcement, pouring of concrete , finishing concrete surface, expansion joint installation works are performed.
Industrial concrete floors and their installation are some of the main areas of Omnistata specialisation. We have successfully implemented many large-scale projects both in business and in various strategic and public facilities – Vilnius International Airport, General Assistance Centre 112, Elektrėnai Ice Palace, Ozas Shopping Centre, Duetto, Wave, Žalgirio 94, Sail III, Uptown Park and others. The total scope of all industrial concrete flooring performed by Omnistata is more than 500 thousand square meters.
Preparation of the base for concrete floor
The durability of concrete floors depends on the quality of ground preparation, therefore, before installing industrial concrete floors, geological and soil quality tests and detailed analysis of the building are performed.
It is useful to know that the deformation modulus Ev2 of compacted layers must be at least 80 N/mm2 (Mpa) – this indicates quality preparation of the substrate.
Proper installation of all layers of foundation preparation can prevent concrete floors from settling and cracking in the future and immediately forming the correct water slopes – so that water will not accumulate on the foundation and the surface remains durable.
Sand, gravel, crushed stone or mixtures thereof of various fractions are used for the installation of foundations. First of all, the existing primer is levelled and compacted, after which the installation of individual base layers begins.
It is important to mention that a new layer can be re-installed on the existing sub-layer only if the existing sub-layer meets the required conditions, i.e. stability, load-bearing capacity, profile compliance and smoothness.
Depending on the customer’s needs, the compacted soil and the required compaction depth, we use reliable dynamic compaction devices and project-specific technologies. Where it is necessary to compact a thicker layer of soil, each layer is compacted individually.
The following devices are used to dynamically compact the soil: compactors and vibration rollers, and small areas, trenches, hard-to-reach areas – vibration plates. Most often, slopes in the moulds are formed during the installation of the base, therefore, this process comprises a very important part of the installation of industrial concrete floors.
The following methods and materials are most often used for reinforcing concrete floors:
- rebar or rebar nets,
- steel fibre,
- polypropylene (plastic) fibre.
It is useful to know that Omnistata experts can perform the most optimal calculations of the fibrous content (kg/m3) of your facility, after assessing the floor loads specified in the project. This saves our customers money and reduces the amount of fibre provided per cubic meter of concrete.
Call us and we offer you the most suitable reinforcement method and modern materials.
Pouring and finishing concrete floor
Pouring and finishing is the most critical part of installing an industrial concrete floor. At this stage, a commercial concrete is used, the composition, compaction and laying method whereof provides the best conditions for the installation of a strong, abrasion, shock, vibration and mechanical resistant quality coating.
Depending on the environmental impact (loads, water, salt, etc.), a concrete mixture of appropriate strength with special additives for solids and liquids is produced in the concrete unit.
Concrete produced by concrete trucks is delivered to the facility and the layer of concrete floor provided in the work project is poured using a concrete pump. It is levelled and compacted using vibrating screed. When the concrete begins to cure, its surface is trowel-finished, the moisture content and its evaporation rate are actively monitored.
It is useful to know that the maintenance of concrete during placement (protection against rapid evaporation and drying of moisture) is one of the main requirements to ensure minimal cracking and convexity of concrete slabs.
Proper care of the curing concrete ensures that moisture is retained and the concrete reaches its most optimal properties: required strength, volume stability, fluid absorption, resistance to cold and heat, mechanical abrasion, surface peeling and hole formation.
Temperature hardening and the start of maintenance are directly affected by temperature, wind and humidity. At higher temperatures, strong winds or low humidity, the concrete loses moisture faster, therefore, the maintenance of curing concrete must be carried out very carefully.
Different types of concrete hardeners (mineral or liquid) can be used to reinforce the concrete surface. Polishing work is carried out depending on the purpose of your concrete floor (production building, parking lot, access ramp) and the chosen concrete surface option (smooth, polished, combed or roughened).
During active exploitation, a well-equipped floor surface maintains integrity, resistance to environmental influences and is easy to clean.
Concrete floor polishing
Concrete floor polishing is a technology allowing to renovate old or to further strengthen new concrete floors. This method can be applied not only when installing new floors, but also when renovating existing old concrete floors or even removing construction defects.
Using this technology, it is possible to eliminate small defects of old concrete floors: fill in small bumps, fix the pores. During renovation, the floor is polished until a structurally intact surface is achieved, improving its aesthetic appearance and functionality.
HTC diamond polishing machines remove the top, less resistant layer of concrete – cement paste. The deeper, stronger layer of concrete is polished in several stages using diamond tools of different parameters. The result is a functional, perfectly looking, perfectly smooth and flat surface.
Polishing of concrete floors is especially suitable for various grocery and gastronomic warehouses and logistics centres, where the tyre marks are almost invisible on these floors.
It is good to know that this is an exclusively environmentally friendly technology and no chemicals are used for concrete processing.