Warehouse floors. Concrete floor for a warehouse What is the name of the floor covering in warehouses?

Warehouse floors are constantly exposed to mechanical loads, impacts, and sudden changes in humidity during operation. Unscrupulously executed concrete floors in a warehouse can cause additional financial costs associated with repairs, as well as warehouse downtime. Therefore, you should only trust to carry out industrial concrete floors in a warehouse experienced craftsmen who will be able to implement the assigned tasks taking into account the requirements and technologies.

Requirements for concrete floors

The bearing layer is a reinforced concrete slab on a sand, crushed stone or soil base. Layer thickness, concrete class, diameter of reinforcing bars, size reinforcing mesh are determined individually for each case at the design stage based on the magnitude of the expected loads, the purpose of the room and other factors.

Based on the purpose of the warehouse (storage of consumer goods, pharmaceutical products), its type (transit, customs, production) concrete floor There will be certain requirements.

Pouring technology

So, let's immediately note that technological process The construction of concrete floors may vary slightly. We have already found out why and what this depends on. In most cases, the technology involves the following three stages:

1. Preparatory;
2. Pouring floors;
3. Hardening.

Each of these stages involves performing certain work, so let’s look at the process in more detail.

Preparatory activities include the following activities:

1. Contaminants of any origin are removed from the working base, as well as easily peelable and crumbling material;
2. The zero level is determined and marks are placed on the wall. Note that the thickness of the layer should be at least 10 cm, but if concrete is poured onto a sand bed, then it should be at least 15 cm.
3. On the base that is planned to be concreted, a reinforcing mesh is laid or a welded frame is made; the reinforcement is performed at a height of 1-1.5 cm from the base of the floor and 0.5-1 cm from the zero point.
4. Installation of beacons. Recommended to use metal profiles, it is convenient to fix them on plaster. Please note that the installation process must be carried out strictly according to the level.
5. At the very end of preparing the surface for pouring, damper tape is glued to the surface of the wall, namely to the areas where the concrete will come into contact with the wall.

Pouring freshly prepared concrete mixture on the prepared working base:

1. The prepared concrete is evenly distributed over a pre-prepared base, starting from the far wall of the room, and then leveled according to the rule;
2. When performing leveling, the concrete layer must be compacted; for this, a deep vibrator is used;
3. The final (finishing) leveling is carried out as a rule; it is not superfluous to use a level at this stage, which will guarantee a perfectly level base;
4. After the surface has been poured and carefully leveled, it is given time to dry, as a rule, this takes 6-9 hours, after which you can walk on the concrete floor.

ADVICE! At the design stage of pouring a concrete floor, it is necessary to provide holes for laying the communication system (if, of course, it is necessary).

• After all the measures aimed at creating a concrete floor have been completed, topping (a special dry mixture) begins to be rubbed into the surface. This part of the work is performed manually or with a special machine, it all depends on the volume of work.

IMPORTANT! To ensure uniform drying of the concrete layer, it is recommended to moisten it with water for 7-10 days using a paint roller.

After grouting, if the area of ​​the concrete base is large, it is recommended to make expansion joints with a depth of 2.5 cm in increments of 40-70 cm, depending on the thickness of the concrete layer. The seams are cut using a special machine equipped with diamond or corundum discs.

At this point, the process of installing an industrial concrete floor in a warehouse is considered completed and the base can begin to be used. Provided that all stages and technologies have been followed, such a floor is guaranteed to last long time qualitatively and reliably, regardless of the loads that will be placed on it.

IN modern conditions Warehouse floors must meet a number of requirements. The point here is, first of all, the enormous loads that warehouse floors experience, since today warehouses are mostly high-rack, and for unloading works technique is often used.

Requirements for warehouse floors:

• Resistance to abrasive abrasion. When grains of sand get inside the premises on the wheels of forklifts and on the soles of employees, they negatively affect the surface of the floors.
• Impact resistance. Loading or unloading goods often involves falling heavy objects, which can cause serious damage to the flooring over time. That is why floors for warehouse shelving must be impact-resistant.
Special requirements for the floors of warehouse premises are imposed on work areas, passages and places for turning around, since in these areas the wear of the coating will be maximum (great damage to the floor in a warehouse is caused by “rokla” trolleys - loaded and with a small diameter of wheels, since they cause excessive shear polymer layer stress).
• Resistance to chemicals and aggressive environments. For warehouses with acids, solvents and various paints and varnishes, such liquids tend to periodically spill and the self-leveling floor must be prepared for this.
• The influence of high temperatures. A high-quality self-leveling floor for warehouses must adequately withstand temperature changes, because their impact reduces the service life of an unprepared floor covering.
• Waterproof. Wet cleaning and exposure to various detergents will not be a problem if this parameter is met.
• Anti-slip effect. Another requirement for floors in warehouses is the absence of slipping, because working on a slippery surface is not only inconvenient, but also dangerous to health.
• Fire safety. High-quality warehouse floors, the price of which is very reasonable from the Polix Group company, should prevent the spread of flames both in the work sectors and in evacuation zones.
• Noise absorption. A huge role in the construction of floors in warehouses is noise insulation from the rumble and noise produced by various mechanisms.
• UV resistance. This requirement relevant for areas under glass or open air.
• Antistatic effect. If there are explosive substances, pharmaceuticals or electrical equipment in the warehouse, antistatic floors will help avoid excessive accumulation of static electricity in the floor covering.
• Easy to clean. Dust-resistant floor coverings in warehouses can significantly reduce cleaning time and costs.
• Hygiene. This requirement is relevant for warehouses where food products, as well as products of the pharmaceutical, cosmetic, chemical and electronic groups, since there are special requirements in the absence of dust and dirt.
• Durability. A requirement that is relevant for all types of self-leveling floors and allows for repairs of warehouse floors as rarely as possible.

Types of floor coverings in warehouses:

The most reliable coverage for floors in warehouses - these are polymer compounds that are used in the manufacture of:
• Self-leveling floors;
• Highly filled thick-layer coatings with quartz addition;
• Enamel paint coatings;
• Reinforced concrete floors top layer(topping);
• Polymer strengthening impregnations for concrete floors.

Polymer floors from Polix Group - the cost of installing a floor for a warehouse will please even the most economical

High-quality polymer flooring for warehouse floors from Polix-Group specialists meets all the above requirements. Our thick-layer coatings are practically not subject to abrasive and mechanical influences; moreover, they are able to withstand heavy loads and prevent excessive dust formation. And most importantly, the price for the work is one of the most attractive in the region.

Price for industrial flooring for warehouses

Warehouse floor repair

The Polix-group company conducts high-quality repairs warehouse floors with a guarantee for all work performed. Do you want your flooring to last as long as possible? Then don’t hesitate - call us or leave a request on the website and soon our specialist will come out to evaluate the work.

Concrete flooring was invented before other types self-leveling coatings for certain reasons. At the time of its appearance, it was a leader in solving several problems at once: resistance to mechanical and chemical influences, ease of installation and further maintenance.

But time passes, requirements change, and after them, device technologies in premises also progress.

Despite the emergence of completely new technologies for creating self-leveling polymer coatings, concrete remains in demand as a base - a subfloor. And often Newest technologies protection of concrete allows it to be used as the main floor even in premises such as warehouses.

Chemical exposure

In warehouses with chemically aggressive substances, spills of alkalis, acids and solvents occur. The concrete coating must be resistant to this type of impact.

Fire requirements

There are high requirements for the arrangement of warehouse premises in terms of fire safety. The walls, roof, shelving and floor of the building must meet fire resistance standards. So the surface concrete flooring must not contain substances that can ignite or smoke.

Waterproof and anti-slip properties
Methods of processing a concrete floor can be anything: from polishing to installation, workshops and warehouses. With all this, the floor in the warehouse must retain its high performance characteristics. A slippery floor leads to injuries; in addition, these are critically unacceptable conditions for the operation of warehouse equipment.

Protecting concrete floors in warehouses

So, the basic requirements for concrete floors in warehouses were considered. Now let's talk about ways to solve these problems.

Concrete floors are often criticized due to their reduced resistance to chemicals and moisture. On this moment There are two ways to solve the problem: the initial choice of high-quality concrete or subsequent strengthening of the top layer with topping.

Topping is a hardener, which is a mixture of special cements, fractionally distributed high-strength fillers (corundum, quartz, metal shavings) and chemical additives. Pigments are added to the mixture to add color.

The method of creating an initially strong concrete foundation is good to a certain extent. The fact is that this method may lead to delamination of the floor during its operation.

To avoid this problem, primers with a reduced material viscosity are used.

The process of strengthening the surface layer of concrete with pre-diluted dry mixtures is called topping. A durable layer prepared on the basis of cement, quartz and other special additives is laid on a pre-prepared base. In this case, adhesion will be higher.

Thanks to the topping, the durability and impact resistance of the floor are significantly increased. Bottom line: industrial concrete floors protected with topping will last several times longer.

Another way to protect the surface layer of concrete is to use paint. In addition to all the above mentioned influences, one should not forget about the influence of open sun rays and such important indicators as aesthetically attractive appearance concrete base.

They help solve these problems concrete paints. They prevent the floor from becoming saturated with moisture, reduce crumbling and abrasion of the material, and make it possible to obtain decorative coatings.

In warehouses, the aesthetic side of the issue is not relevant. However, even here one cannot do without highlighting certain color zones: working, finished products and others.

In addition, concrete paints to some extent replicate the design of polymer floors. This is due to the fact that many floorings are made on the basis of the same material – polymer. Polyurethane and acrylic concrete paints have gained great popularity. These types of impregnations are capable of creating a durable layer on the surface of concrete.

Another undeniable advantage of concrete paints is savings. If there is no need to create a super-durable coating, paints will be the most advantageous option in terms of price. Concrete paint and varnish compositions can be applied manually, since they have self-leveling properties, and using technology.

The best protection and higher quality application is achieved using special machines.

Despite a decent length of service, concrete bases have not yet lost their relevance. There are several ways to improve the performance of concrete floors in warehouses, but topping remains the most reliable.

The floors of hangars, garages, workshops, warehouses and other industrial buildings will be subject to serious loads throughout their entire service life. They will be subject to weight loads and temperature loads, which in industrial structures can deform any material.

Therefore, flooring for such structures must be selected wisely and meet all requirements and standards.

For industrial premises the most the best option is a concrete floor covering. Floors must have special wear resistance and withstand the entire load so that cracks do not form under load.
Requirements for floors, high loads. The requirements for flooring in an industrial building, either a workshop or a warehouse, are very serious, because in these structures it bears the most direct load from everything that is located in this building. In such a structure, the flooring is most often subject to mechanical damage and excessive loads.

The main requirements for a concrete floor are listed below:

1. Have sufficient bending resistance, tension and compression; Since there will be different temperature differences in hangars, workshops, warehouses and other structures, concrete covering must work in tension and compression 2. Be wear-resistant, resistant to impacts and aggressive chemicals;
2. In such premises, vehicles often travel for loading and unloading cargo, constant traffic floor covering can ruin it, so wear resistance must be at its best. A heavy object may fall on the coating in such rooms, and it must cope with this task without being damaged. Various liquids, including aggressive chemicals, can also be spilled.
3. The surface should easy to clean and repair;
4. if the floor surface is difficult to clean, this may lead to the release of toxic substances that will be absorbed even when high temperature start, evaporate.
5. Withstand temperature changes, exposure to moisture;
6. Moisture, another enemy that concrete must cope with, but for this it must be treated with waterproofing.
7. Be safe for vehicles traveling on it;
8. Vehicles that will travel through the hangar or workshop should not damage the concrete in the room. The floor must withstand all the loads from this transport.
9. The external flooring should be smooth and slippery.

For a concrete coating to be easy to clean, it must be smooth; if it is rough or porous, then dirt, dust, etc. will often get clogged into the pores. which leads to premature destruction. The anti-slip effect is necessary for the safety of employees working in these premises and moving vehicles.

Benefits of concrete floors

• The main advantage is its durability. It is for this reason that it is used in warehouses and industrial premises, where the load on the deck is very high, because the load huge amount of people, industrial equipment and the technology will be able to withstand it difficult. In addition to these loads in such rooms, the floor is constantly affected by the aggressive influences of the industrial environment. In such an environment, a concrete base will last much longer than one made of wood or metal. Tree with enough large quantities moisture begins to rot and the metal to corrode.
• Another advantage is the environmental friendliness of concrete, since it is created from natural materials, it doesn't highlight harmful substances, during its construction, and metal and wood need to be treated with chemicals.
• The hygiene of concrete can also be considered a plus, due to its dense structure inside of this material germs and bacteria do not penetrate and fungi and rot do not occur. It is enough just to sometimes go through industrial vacuum cleaner to remove dust.
• The heat resistance of concrete is much greater than that of the same metal, which high temperatures may become deformed, and the wood may even burn out; concrete is free from all these disadvantages.
• The concrete slab is still different for a long time operation, and when the time comes to make repairs, it does not take much time and money.

Floor laying process step by step

Concrete coatings have proven themselves with the best side due to its low cost. This cost is achieved by combining in one production cycle load-bearing structure and wear-resistant coating.
The design of the slab is influenced by many factors. When designing a future slab, the locations of shelving and equipment are taken into account in order to distribute all the loads.

• At the project stage, it is necessary to specifically study the foundation and its characteristics.
• When building a structure from scratch, compaction sand serves as the basis for the floor covering.
• Definitely need to follow the degree of its compaction in order to avoid unpleasant situations in the form of subsidence and cracks in the future.

In its original form, concrete coating is rarely used due to low performance indicators, it collects dust and has low wear resistance. To avoid these troubles, these characteristics are increased with the help of different compositions, strengthening the surface (1-3 mm). There are also cement-polymer compositions that, when applied to unhardened or unsuitable concrete (5-12 mm.)

Device and technology for pouring a concrete floor.

• The level is determined highest point at base, after that we find out the thickness of the slab. The recommended thickness of the slab, which is poured onto compacted soil, is 150-250 mm. if the basis is monolithic slab 100 mm will be enough. It is not recommended to make the slab thinner, even taking into account the savings. In the future, these savings will not be justified and will lead to destruction and cracks.
• When all the design information is ready, you need to move on to the marking and location of the grips. If the room has high shelving, then special requirements are placed on the evenness of the coating. In this case, the grips must be placed between the racks to avoid unevenness. The width of the grips is set to 4 m. The length directly depends on the daily volume of work performed. To avoid unnecessary “construction” seams.
• The next stage of making the plate is alignment of guides. The guides are channel or profile pipe. The evenness of the subsequent design depends on the quality of the guides. To set the guides, use a conventional optical level.
• Used for floor reinforcement reinforcement or steel fiber. Sometimes combined reinforcement is used.
• Taking into account all the nuances of the manufactured structure, the designer chooses the type of reinforcement. The reinforcement is tied into a mesh using binding wire or using welded seams. When installing reinforcing mesh, you need to make sure that it is installed correctly, this will increase its service life concrete slab. An incorrectly laid mesh will only harm the structure being manufactured.
• Sedimentary seams separate the slab from the load-bearing columns or walls in order to avoid cracks during foundation shrinkage. Next, the mixture brought by concrete mixers is leveled along the grips. Along the entire perimeter of the poured material, it is compacted using a deep vibrator and vibrating screed. Let stand for 3-5 hours and begin processing.
• After pouring the solution 2/3 of the strengthening composition is applied to it. This composition is made from different mixtures, which serve different purposes. For ultra-thin floors, manufacturers of strengthening mixtures produce special plastic mixtures. They are designed to protect against damage and cracks. After which grouting is done with special grinding machines. When the entire area has been rubbed, the remaining third of the strengthening mixture is applied. They rub it in the same way. Next, they are treated with a special water-retaining varnish, which retains moisture in the concrete so that it does not peel off. Now they're getting chopped expansion joints one third of the depth of the poured slab. And when the poured structure completely shrinks, this happens for the first time for 3 months, the expansion joints are treated with sealant.

Price and completion time Prices for this type of work start from I from 450 rubles per m. sq. it all depends on the region and the qualifications of the workers. And by working with a qualified team, you can achieve the pace of work 300 sq. m. per day.

For industrial construction, a concrete mix slab is the best solution. Despite all the nuances when performing work, it will serve for a very long time.

Laying a concrete floor in a production workshop:

Warehouse floors may be subject to both general and rather specific requirements: from dust-free to oil- and petrol-resistant. Let's take a closer look at them.

Dust-free

The main requirement for warehouse floors is low dust. This parameter is often called “dust-free”, but it is more correct to talk about low dustiness. Few manufacturers—regardless of their product—would want their products (like toy boxes) covered in a layer of dust. Since the main source of dust is the floor, hence the corresponding requirement for it.

Let us add that products covered with a layer of dust indicate a poor production culture. And dust-covered products in a warehouse indicate poor storage standards. All warehouse owners want there to be no dust at all (or as little as possible).

High strength

Second important general requirement to warehouse floors – high strength. Strength indicator - how much load (in kilograms) one square centimeter of floor can withstand. For example, one centimeter of ALFAPOL VK floor can withstand a load of 400 kg.

In addition to the target load on the warehouse floor, we should not forget about heavy forklifts, which in most cases are present in warehouses. This type Floors must also be able to withstand loads painlessly.

High flatness

This is the third requirement for warehouse floors. They should be really even. Small differences in height are allowed, but the surface as such must be uniform and very smooth. For what?

Mainly so that modern forklifts - which move around the warehouse complex almost along laser level– could work without errors and ship the required products safe and sound. This is why a high evenness of the warehouse floor is needed.

Other requirements

In addition to the above-mentioned requirements for warehouse floors, certain cases There may also be additional requirements. For example, requirements for water resistance of floors. With what it can be connected?

Here are three options.

First: frequent wet cleaning. For example, in pharmaceutical warehouses, wet cleaning with special solutions for water based can be done several times a day... After wet treatment, the warehouse floor should retain its properties.

Second: the warehouse is used to store water-based products (for example, alcoholic beverages) and there is a risk that some of these products will end up on the floor (bottles will break, alcohol will spill). It is clear that if there is a large amount of liquid on the floor, it will not be possible to remove it quickly. Therefore, it is important that the floor is prepared for such an unexpected event and has sufficient moisture resistance.

Third: The warehouse can be located at ground level. In this case, it is possible for water to flow from the ground, or the so-called capillary water suction. To prevent water from entering the warehouse and causing damage to the floors, moisture-resistant material is also required.

ALFAPOL materials for warehouse floors

If we talk about the assortment of the ALFAPOL company, then floors of the ALFAPOL MB, ALFAPOL VB, ALFAPOL MP-300 brands, materials of the ALFAPOL K, ALFAPOL AK family, as well as cement levelers VK and BC are often purchased for use in warehouses. The table below shows comparative characteristics floors ALFAPOL.

Table of application of materials "ALFAPOL" TM for warehouses