Zacklim Flat Floor Specialist Sdn Bhd

MR. LIM ENG HOCK (ZACK)

Managing Director

HOW TO CONSTRUCT WORLD CLASS

SUPERFLAT CONCRETE FLOORS
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 CONSEQUENCES OF BAD FLOOR

 Excessive cracks & defects.

 Undulating–slow down operation.

 Costly repairs on forklifts .

 Dusty floor.

 Unsightly–Co. image affected.

 Cost more to maintain.

 Litigation.

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 DO IT RIGHT THE FIRST TIME

 Initial cost - slightly higher.

 Higher productivity.
 Less wear & tear on forklifts.
 Safe to operate.
 Easy to clean.
 Dust-free.
 Reduce floor maintenance.

HUGE LONG TERM SAVING

& HASSLE FREE

A FLOOR TO BE PROUD OF ! 3
DO IT RIGHT WITH THE FLOOR TEAM
CULTIVATED WITH
“THE BEST PRACTICES”.

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 THE FLOOR TEAM
FLOOR BEYOND STRUCTURAL
DESIGN, NEED FIELD
DESIGNER/ENGINEER EXPERIENCE

FLOORING EXPERIENCED, COMPETENT

WITH STATE OF ART
SPECIALIST MACHINERY

SUPPLY GOOD QUALITY &

CONCRETE SUPPLIER CONSISTENT CONCRETE.

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 FLOOR
DESIGNER/ENGINEER

Standard structural floor design:

a) What is the floor usage?
b) What is the floor loading?
c) What is the best floor system?
- sog, sop, post-tension, steel fibers
Beyond structural floor design:
d) What is the relevant floor specification? Racking height, type of vehicle
e) Type of floor measuring instrument?
f) Type of floor finishes.
g) Class of abrasion resistance? (AR1, AR2, AR3)
h) Mitigate cracks - type of joints and details, 6
 FLOOR
DESIGNER/ENGINEER
TYPE OF GROUND FLOOR DESIGN?

• Slab-on-grade?
a) Mesh
b) Steel fibers, polypropylene(pp) fibers.

• Slab-on-piles?
a) Mesh & rebars
b) Rebars only
c) Steel fibers

• Post-tension slab?

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• Precast or Hollow-core slab?
 FLOOR
DESIGNER/ENGINEER
WHAT IS THE FLOOR SPECIFICATION?
1) What is the racking height?
2) To specify floor tolerance:
Random Traffic - F-numbers - FF,FL (USA) FM1, FM2, FM3 (UK)
Defined Traffic - F-min (USA) Category Superflat, 1,2 (UK)

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 FLOOR
DESIGNER/ENGINEER
INSTRUMENT FOR FLOOR MEASUREMENT

“Random traffic” - Dipstick .

“Defined traffic” - Profileograph or Dipstick.

F-METER

PROFILEOGRAPH DIPSTICK
 FLOOR
DESIGNER/ENGINEER
TYPES OF FLOOR FINISHES?
• Natural/coloured hardener, coatings?
• Abrasion resistance - AR1, AR2, AR3

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 FLOOR
DESIGNER/ENGINEER
CRACKS MITIGATION
Make known to client
• All concrete floor will have cracks
• How to control, minimise and prevent cracks
• Expansion joints, isolations joints, contraction joints, etc

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 FLOORING SPECIALIST

Experience & competent flooring specialist

a) State of art machinery

b) Understand concrete properties.
c) Technically strong.
d) Capable to build edge formwork straight.
e) Plan the pour size.
f) Quality workforce – besides well-trained.
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 FLOORING SPECIALIST

PRE-CONSTRUCTION MEETING
• Prepare a checklist to be discussed
• Invite all party involved.
• Ready with construction schedule

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 FLOORING SPECIALIST

CONTROLLED ENVIRONMENT

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 FLOORING SPECIALIST
“STATE OF ART” - MACHINERY &
EQUIPMENT
Tip-top condition & well-maintained

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 FLOORING SPECIALIST

WELL TRAINED WORK TEAM

• Finishes esp. column & wall edges
• Edge formwork – straight & no spalling

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 FLOORING SPECIALIST

CURING AT RIGHT TIMING IS IMPORTANT

• Retain moisture for hydration-gain strength
• Prevent crazing, dusting, curling, etc

Methods
• Curing compound
• Floor painting? – do not spray
• Curing Blankets
• Water/Polythene sheet

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 CONCRETE SUPPLIER

Premier quality concrete with consistent supply

a) Understand what is “superflat” flooring.

b) Floor specialist need 4-5 hrs to finish a slab unlike beams or columns.
c) Ensure concrete mix to be consistent to avoid random setting.
d) Supply to be continuous to avoid cold joints.
e) Characteristics of concrete:-
i) Good workability
ii) Window for initial set to final set to be about 5 hours.
iii) No excessive bleeding.
iv) Achieve good finishes.

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 CONCRETE SUPPLIER

INCONSISTENT CONCRETE SUPPLY

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 CONCRETE SUPPLIER
CONCRETE MIX DESIGN

• Grade of concrete (min C30)

• Cement content
• Weight of fine & coarse aggregate
• Type & quantity of admixtures use
• Water/cement ratio
• Slump: Normal mix, slump: 75-100 mm
Pump mix, slump: 100-130 mm
• Maximum allowed shrinkage 0.03%
• Carry out trial pour of 3m X 3m X thickness specified, to
check:-
a) Workability
b) Bleeding (<2%)
c) Setting time
d) Finishing characteristics
 BEST PRACTICES
IN FLOOR CONSTRUCTION

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BEST PRACTICES IN FLOOR CONSTRUCTION

Ensure sub-base is well compacted

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BEST PRACTICES IN FLOOR CONSTRUCTION

Provide and lay polythene sheet

To act as a moisture barrier
To provide slip membrane

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BEST PRACTICES IN FLOOR CONSTRUCTION

Insufficient/excessive concrete cover

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BEST PRACTICES IN FLOOR CONSTRUCTION

Place concrete at the coolest time

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BEST PRACTICES IN FLOOR CONSTRUCTION

Try not to restrain the floor slab

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BEST PRACTICES IN FLOOR CONSTRUCTION

Avoid pre-mature loading

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 BEST PRACTICES IN FLOOR CONSTRUCTION
Do not add water into concrete truck

Result:
• 1. Loss of strength.
• 2. Promote cracks.
• 3. Surface efflorescent

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BEST PRACTICES IN FLOOR CONSTRUCTION

Do not splash too much water during

troweling – discoloration, dusting
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Photos of Good Concrete Floors

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IKEA Car Park, MALAYSIA
Pavilion - Tour Bus Parking Area, KL
 Polished Finish

Tesco Car Park – Seremban, Malaysia 33

Tesco Car Park – Scott Garden, KL 34
AirAsia Hanger, LCCT 35
AirAsia Apron, LCCT 36
DHL, Kuala Lumpur 37
Freight Mark Warehouse, Malaysia 38
Cold Storage Warehouse, Doha 39
Giant Distribution Centre, Sepang, Malaysia 40
Mydin Warehouse, USJ, Malaysia 41
BIG supermarket, Mont Kiara, Malaysia 42
Rolls-Royce Assembly Plant, Singapore 43
Restaurant- Petaling Jaya
-THANK YOU-
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