Concrete Floor for distribution Center

Ching-Der Liao
Mascoris Co., Ltd. Taipei County, Taiwan
E-mail: mascoris@ms36.hinet.net

ABSTRACT: The growing distribution in volume and versatility of commodity for the convenient store, the efficiency and
maintenance cost of Distribution Center are the most concern to management, yet, the quality in floor of Distribution Center is majority in
this subject. However, seldom the people of Distribution Center involved the construction are aware its importance, which incurred a lot of
argument and complain from end-users, moreover, the hazard of commodity falling-down, slow in speed of material handling vehicle (MHV),
high cost in maintenance of MHV because of damaged floor, difficult cleaning of floor, all these problems are happened in careless
construction of concrete floor in very beginning. The article describes the construction process of concrete floor for Distribution Center
which been successfully built with satisfactory performance to end-user, yet, new concept for industrial floor been brought to adapt the usage
of Distribution Center.
Key Words: Distribution Center, material handling vehicle (MHV), liquid densifier, semi-rigid joint filler.

1. INTRODUCTION - Preconstruction meeting, quality assurance, and quality

The article is the description of floor construction for a
distribution center which serves a famous chain store. They have
eleven DC around the island, and most of them are suffering high
maintenance cost which because of improper construction of
concrete floor. After big complain from end-users, they adopted the
advice from architect, paid for site supervision specialized in
construction of concrete floor, to make sure the floor should be built
in what’s quality a DC should have, and it was successfully been
accomplished up to now.
2. REQUIREMENT OF FLOOR CONSTRUCTION
2.1 Operation Requirement of DC
The battery driven MHV and pallet trailers are main
equipment to manage the goods in DC which mostly imported with
high cost of their spare parts, wheels with polyurethane lining are
consumed most of maintenance expense. Yet, slow down speed in
moving pallets also bothering operators when their payroll
depending on piece of commodity managed. All these insufficiency
is caused by a bad floor.
2.2 Construction Requirement of DC
As voluminous and frequent mobilization in commodity
arrangement, floor of DC should be with characteristics of smooth,
durable, abrasive, no dusting and easy to maintain. Thus, well-
thought design, considered site planning and no surprised execution
is a must for successful floor construction of DC.
2.3 Design Requirement of DC
The design of slab-on-grade is well presented in ACI
committee 360, which outlines almost all respect of guides in
flooring. However, the majorities are listed as following;
- Base and subbase materials, preparation requirements, and
vapor retarder, if required;
- Concrete thickness;
- Concrete compressive strength, flexural strength, or both;
- Concrete mixture proportion requirements;
- Joint locations and details;
- Reinforcement (type, size, and location), if required;
- Surface treatment, if required;
- Surface finish;
- Tolerances (base, subbase, slab thickness, and surface);
- Concrete curing;
- Joint filling material and installation;
- Special embedment; and
control. [1]
Well thought and good detailing in listing above, is first step
to accomplish a good concrete floor.
2.4 Construction Requirement of DC
To achieve a quality floor suitable for DC use, good
preparation and well coordination is the must. Therefore, concrete
mixing property, access arrangement and interfaces coordination
among sub-contractors related to floor construction are major
subjects before flooring.
Concrete mix is most important of the job, likes what we said
in computer science “garbage in, garbage out”, never a bad mix can
create good piece of concrete product. Especially, floor is the
biggest structure piece in surface - volume ratio of concrete product,
nature of concrete likes shrinkage, cracks, settlement, curling,
warping, are most likely severe then other structure, such as beam
and column. So, good care in mixing recipe is the first aid of
successful flooring.
Like fore paragraph mentioned, floor has big surface to be
constructed, if not looking after in access arrangement, cold joints,
exceeding stamps on finished area, too much poor finishing by hand
in details will thus happen, which leads unsatisfactory result to the
owner.
Floor construction will not be the only job to floor contractor,
there has direct connection members, such as batching plant,
trucking company, pumping sub-con, and indirect members, like
forms, reinforcement, plumbing, electricity, even earth moving sub-
cons. Any one of them missing some parts may cause big trouble
eventually. Thus, a pre-pour meeting should be hold seriously to
gather those who related to the construction.
The pre-pour meeting should confirm and document the
responsibilities and anticipated interaction of key participants
involved in floor slab construction. The list items following are
agenda during the discussion in the meeting, and should be clearly
described as supplementary document of contract.
2.4.1. Preparation
A. Concrete
a. Concrete mixing design to be tested as required; such as
compressive and flexural strength, shrinkage, warping and
curling, slump control (workability), bleeding character,
finishability confirmed, setting time control, material limited
from sole supply if color of product is important, chemical and
mineral additives restriction of its percentage.
b. Supplying and transportation; calculate the demand of concrete to
arrange hour supply in concrete volume, never let extra trucks
line up before pump and waiting.
c. Pumping; day before pour, pumping line should be surveyed and
prepared, container for lubricant and pipes cleaning should be
ready before day.
B. Site
a. Access in site; Pump position, mixing truck route and its traffic
control, the way fore and back to working area for all the
facilities of flooring, storage place for the material and back-up
equipment….etc should be designated and confirmed.
b. Job preparation; decided the lead time of concreting of
notification to related parties, notification includes job detail, like
size and thickness of floor, double check the bench mark to be
used in flooring, water and electricity supply and lighting for
night time finishing.
c. Coordination of sub-con; requirement of form work, steel
reinforcement, electricity, plumbing, make sure everybody with
consensus of quality assurance.
d. Safety and sanitation; restrict all the workers are training with
qualification of Safety and Sanitation regulation, all openings
been fenced, designated area for rest, food and smoking.
2.4.2. Concreting
A. Batching plant; close watch the slump, and adjust it according to
weather, traffic and site condition. Control delivery volume never
let the trucks line on the road, waiting for pumping.
B. Concrete pump; be sure to chair delivery pipe line, avoid the
pumping vibration transit to setting concrete via reinforcing steel.
Follow to the procedure of concreting which left the least cold
joint.
C. Vibration; poker vibrator is normal practice for floor construction,
but rare follow to standard operation, this may cause serious
problem in finishing stage. Never move the concrete by vibrator,
all the vibration spots should be same distance and time interval.
D. Strike –off; the method of strike-off should be clearly defined.
No person should be allowed to step in the area after strike off
unless a permit from authority.
E. Finishing; Timing for first step on is most important of finishing
operation, a footprint indented 6 mm can be referred to the right
timing of floating. Straightening before and after dry shake is
great related of smoothness of concrete surface.
2.4.3. Care after poured
A. Curing; Acrylic curing component is used in this project because
of compatible to liquid densifier which to be used later on.
B. Protection; a 3 mm polyester sheet is used to protect floor from
contamination from works later of flooring, like plumbing, fire
proofing, water supply, and electricity.
C. Joint filling; as small wheels and heavy loading are common
practice in Distribution Center, and consider the most significant
shrinkage takes place within the first year to protect the edge of
joint [2], polyurethane sealant is used for joints, after 9 months
operation, those elastic material should be digged out and filled
with semi-rigid joint filler to protect the edge of joints from
spalling.
D. Liquid densifier; to increase abrasive resistance and prevent
dusting, liquid densifier is used on this floor, a lead time over 28
days is request by material supplier. Daily cleaning by auto-walk
cleaning machine is advisable to promote more shine by
triggering chemical reaction of densifier to free lime inside of
concrete.
3. CONSTRUCTION
Actually, concreting of a floor likes production line in the
factory, it is linked by material chosen, proper mixing, on-time
delivery, smooth pumping, even strike off, organized finishing, well
curing, in-time sawing, and perfect coordination laterally with many
related parties. All the problem incurred are influenced greatly by
weather, environment of construction site, miscellaneous geared-up
with sub-contractors, those factors are non-predictable,
uncontrollable, and complicated, therefore experience is most
important asset in the practice, in other word, there should be at least
one engineer with substantial field experience in this respect to
handle and check all the critical points afore-mentioned, and
stationed in situ for supervision of all the procedure of flooring.
3.1 Site Preparation
3.1.1. Set the reference points and mark down with precise positions
on the ground as layout of forms erection according to
designed bench marks.
3.1.2. Strip and infill pattern of concreting is right choice to get a
flat and smooth floor, especially in Distribution Center, we
hided the construction joints, weakness of floor, beneath the
racks.
3.1.3. All the works about flooring, like steel reinforcement,
plumbing, electrical ducting should be fixed in its place
before-day. Concreting in next day shall be notified to related
parties before three PM for easy coordination.
3.1.4. A trash collector at pumping area, to prevent concrete trash
contaminating the ground.
3.1.5. Enough lighting is necessary for good finishing operation,
checking it before day.
3.2. Form Erection
3.2.1. After stripped off the forms from previous pour, workers
should clean the form and oil every time before forms
erection.
3.2.2. The subbase should be surveyed and tested before handed
over to concreting contractor, as all the deviation out off
specified allowance, sub-con of earth moving should rectify
the deficiency and meet to allowance before handed over to
concreting sub-con.
3.2.3. The forms erection should be firm enough to withstand
workers’ abuse during concreting.
3.2.4. All forms for flooring should be double checked in size and
deviation, in longitude direction should be within 6 mm out
of line, vertical direction should be within 3mm in tolerance.
3.3. Pumping
3.3.1. The most important thing of pumping arrangement is to
reduce the number and length of cold joints, any joints delay
fused over 50 minutes called, this is the prior subject should
be taken care before concreting.
3.3.2. Prepared worker for the cleaning of splashed wall.
3.3.3. Never let the mortar lubricant disposed into floor to be
constructed, trash pit or bulk bags should be used in disposal
of pipe lubricant.
3.3.4. Arrange the border lines for cold joint will make finisher easy
to operate and smoothen of the joints.
3.3.5. Any sudden change in concrete mix, operator of concrete
pump should report to superintendent and take necessary
process according to the instruction from site engineering.
3.4. Placing and Consolidation
3.4.1. Pumping outlet will never leave the strike-off area exceeding
3 meters, or rectify the leveling of concrete become difficult
and hard work to the labor.
3.4.2. Never move the concrete by poker vibrator, it can incur
segregation easily. Normally the range of vibrating force can
reach around 20 times of its diameter of vibrator head, then
influencing cycle should be overlapped at least 1/3 ~ 1/2 for
proper consolidation, that means a 50 mm head of poker
vibrator, the distance of each stinging in for consolidation has
distance between 66 ~ 50 cm. Of cause, stiffness of concrete
is major factor of gap in consolidation.
3.4.3. Never place a driven vibrator too long in the concrete, serious
segregation may happen, especially the concrete with high
rank water reducer (ASTM C494, F type).
3.4.4. Always have extra vibrators in job site one or two, in case a
broken down happened.
3.5. Strike Off the Concrete and leveling
3.5.1. Each come-along can take care roughly 2 meters wide per
person, floor contractor can take it as reference in labor
arrangement.
3.5.2. Vibrating screed and roller screed are used in this project.
The key to create a flat floor is even distribution and no gap
placing. Thus, close watch the concrete roll in front of screed
is important task to be monitored, the experienced worker
and/or engineer should be assigned for the job.
3.5.3. Although guide rail system been adopted in slab-on-ground
perfectly, however, deflection and settlement of metal deck
make it unreality to true plain in suspension slab. The laser
screed is therefore selected for mezzanine slab which create a
satisfactory result to end-user.
3.5.4. There should always be two finishers in both side for edging
during screeding, who should also be responsible in
monitoring any bump in the surface after vibrating beam
crossing over, and call back the beam to eliminate bump
happened. They should keep the rail and/or form top free
from concrete debris that may cause bump when vibrating
screed or roller screed cross over it.
3.5.5. A cross pass by bull float or channel float to eliminate the
ridges of concrete which created by screeding, is needed,
even second and third passed will be done if ridges are
stubborn there.
3.5.6. Unless necessary, never step into concrete floor been
implemented of leveling before power troweling begun.
3.6. Finishing and Texturing
3.6.1. Wait after water shimmer gone, and check by footprint with
indent 5~10 mm, that is right time for finishing,
superintendent and site engineer should watch carefully in
this step.
3.6.2. The finishers in both side taking care the edges, should also
keep the rail and/or form top free from concrete debris。
3.6.3. Normally, edge and detail will dry faster, and difficult access
by machine, so, labor tending should be arranged prior
machining. This is also the corner for superintendent to look
after.
3.6.4. Depending on consistency of concrete, when surface is firm
enough to carry the weight of 10’ straightedge, will follow
the bull float to adjust high-low spots, this action will
improve flatness greatly.
3.6.5. As dry shake hardener been specified, a dry shake spreader is
used in this project, this machine was invented by writer in
order to eliminate uneven spreading the dry shake hardener
with traditional way - shoveling. It is encouraging facility for
floor chasing the super flatness.
3.6.6. Following the concept of floating – troweling – finishing, we
develop new machine to fill up the gap of industry, a six-
blade walk behind power trowel after pan type and four blade
machine, this is an excellent tool in finishing stage due to less
pressure on the blades, particularly for colored dry shake
hardener. Then the plastic blade coming up, the new finding
reduces burnish mark dramatically, makes even color more
feasible.
3.7. Joint arrangement and Saw Cutting
3.7.1. Material handling consideration derives joint arrangement,
typical raking of DC is back to back sitting on construction
joint to mitigate the impact by wheels of MHV.
3.7.2. Contraction joint is cut the day after finishing been done to
avoid unexpected crack happened.
3.7.3. During operation in saw cutting, cleaning up is been following
immediately to eliminate cutting grout sticking on the floor.
3.7.4. Consider the small hard wheel of MHV, cutting width leaves
3 mm only with temporary seal by polyurethane to keep dirt
and debris away, and avoid the contamination.
3.7.5. To support the edge of joint and ease spalling in joint banks,
the semi-rigid joint filler is used after 9 months from floor
cast. The time, shrinkage of floor is reaching up the limit,
volume change of concrete is much steady for the filler to
take by its elasticity.
3.8. Cleaning and Densifying
3.8.1. Cleaning the floor prior application of liquid densifier is
absolutely demanded, all the debris, dirt, stains, grease will
impede the application, yet, some stains will be fastened by
densifier if it is ignored.
3.8.2. As densifying and hardening process of liquid densifier is the
reaction of SiO2 carried by Lithium or Sodium ions in the
solution to free lime (CaO), the by-product of hydration,
during forming the gel of Calcium-Silicate-Hydrate (C-S-H),
refill the voids in surface of concrete floor.
This process brings the benefits of concrete floor with;
- eliminate dusting
- increase compression strength
- strengthen abrasive resistance
- reduce permeability
- ease carbonization.
3.8.3 All floor needs maintenance, densifier treated floor may be the
easiest one to maintain, mopping or clean by auto-scraper
with water, and/or mild detergent will do most of job to keep
shine of surface.
3.9 Rectification and Measuring
3.9.1. Plump edges is the key to the successful construction joint,
any damaged and/or spalled edge is requested to be repaired
by resin mortar before next pour.
3.9.2. Contamination by grout generated in finishing stage is serious
and can not be avoid in the stripe and infill pattern of flooring,
the only way to get rid off it, is scraping by labor. Thus,
caution to be taken when finisher doing his work along the
edge.
3.9.2. The flatness and levelness are most concerned by end-users, it
relates greatly operation cost in future, the F-number
measuring was adopted as reference in this project.
According to ASTM E1155(M)-96 “Standard Test method
for determining FF Floor Flatness and FL Floor Levelness
Numbers” we got the numbers of FF 42 / FL 24[3] , better
than most floors of warehouse application.
3. CONCLUSION
In this project, owner paid for extra in many respects in order
to prevent those problems happened in their floors of other DC.
Most creative idea is, hiring construction consultant for flooring to
review concrete recipe, set up checking point for main contractor
and floor sub-con, monitoring each step in concreting. Adopted the
concept of delay filling the joints with semi-rigid filler, it helps to
keep neat joint during operation. Yet, F number measuring provides
reference to their future floors to be constructed. All these efforts
pursue a major purpose – a cost effective, little maintenance, high
efficiency floor for DC operation.
4. REFERENCES
[1] ACI 302.1R-04, “Guide for Concrete Floor and Slab
Construction” 3.2, pp 6-7.
[2] ACI 302.1R-04, “Guide for Concrete Floor and Slab
Construction” 9.10.1, pp 61.
[3] ASTM E1155(M)-96, “Standard Test method for
determining FF Floor Flatness and FL Floor Levelness
Numbers” [metric], 9.10, pp 5.
[4] ASTM E1155(M)-96, “Standard Test method for
determining FF Floor Flatness and FL Floor Levelness
Numbers” [metric], 9.12, pp 6.