In order to create a more effective cured floor, the substrate can also be optimized with the use of Superflat technology. This creates a cured floor that is more aesthetically pleasing and at the same time enhances the practical value of the floor.
So, what exactly is super flat floor? Why is it so popular with so many factory owners?
What is super flat floor?
Ordinary concrete flooring has a flatness of only 5mm/2m, while super flat floor refers to flooring with a flatness of 3~4mm/2m or higher, which is widely used in VNA (super narrow aisle) warehouses, airports, highways, etc. super flat floor is also commonly used in TV show studios, cinematography studios, skating rinks, production workshops using precision equipment. It is widely used in VNA (super narrow aisle) warehouses, airports, highways, etc. Superflat floors are also commonly used in TV program studios, movie studios, skating rinks, and production halls where precision equipment is used.
For the ground, the general requirement is that 80% of the ground should not be greater than 4mm/2m, 20% of the ground should not be greater than 6mm/2m, and the super flat floor requirement is that 90% of the ground should not be greater than 2mm/3m, 10% of the ground should not exceed 3mm/3m.
Commonly used machines for super flat floor
super flat floor has very high requirements on the ground, and generally requires the use of laser screed for leveling to obtain a good flatness. The power trowel is divided into two types, one is walk behind power trowel and the other is ride on power trowel.
Specifications and Measurement Standards for Superflat Floors
(1) The Importance of Levelness of the Ground As an important part of the warehouse, the ground provides the basic operating surface for overhead forklift operation. Therefore, the flatness of the ground surface will affect the working efficiency and safety of the forklift at the same time. The design of a logistics warehouse will give an hourly value for the flow of goods, and forklifts must run at full speed to reach this design value. As a logistics manager, the only thing you can do when faced with a collision between a forklift and a rack is to slow the forklift down, which will result in reduced productivity. Uneven ground will lead to increased pressure on the forklift mast and body, and will easily cause fatigue to the forklift driver, and most importantly, if the forklift moves from side to side beyond the controllable range due to uneven ground, it will cause damage to the electronic sensors, which is very costly to repair.
(2) Classification of super-flat area Generally speaking, the application of super-flat surface can be divided into two categories according to the operating environment of forklift trucks: limited traffic area and free traffic area. The restricted traffic area is the area where forklift trucks can run in a restricted direction, typical examples are the VNA channel and the distribution center floor where high level goods are applied; the free traffic area is the area where forklift trucks can move in different directions, typical examples are production, retail supermarkets, logistics centers, etc.
(3) Super flat floor standard
Codes and standards for free-flowing traffic areas with super-flat floors are: ASTM Fnumber system, DIN18202, TR34 FM specifications for restricted traffic areas. ACI F min number tem (American Concrete Institute F min system standard), DIN15185 (DIN18202 supplement for VNA), TR34 standard chapter 4. The F value system divides the flatness of the ground into two values: FF (flatness) and FL (levelness), and the F value is measured by professional instruments (such as DIPSTICK Floor Profiler) after continuous dynamic measurement of the ground and statistical analysis by computer. The results shall be obtained. The measurement line should be measured longitudinally along the roadway at the center line where the left and right wheels of VNA forklift walk; the measurement line should not be less than 3.35m long; the measurement position should be not less than 600mm away from the edge of the floor, construction joints, pillars, etc. The measurement line should not cross the construction joints; the parallel distance of the measurement line should not be less than 1.22m. Therefore, the F value cannot be directly compared with the specification of ruler inspection.
How to construct super flat floor?
Nowadays, laser screed, infrared detection and ultrasonic levelling are the main techniques used in the world for the construction of super flat floor. In addition, the construction of super flat floor needs to be completed in close cooperation with the civil construction side of the foundation concrete construction.
(1) Formwork calibration
When the civil contractor installs the formwork for the foundation concrete construction, it should be completed in close cooperation with the concrete construction civil contractor, using a given elevation as the base point on the whole site, and using a laser leveler to correct the elevation (zero-point elevation) and make the formwork so that the upper edge of the formwork is level.
(2) Pouring Concrete
After the concrete is pumped into the field, it is quickly and evenly pulled apart, laid to the basic level (elevation ± 0), and pounded with a vibrator to make the concrete compact. The concrete is basically leveled.
(3) Precision leveling
Take 0.5m or so as the sampling point, use laser screed instrument to check whether the concrete is flat or not, and reduce or increase the concrete in places where the elevation is not reached, and then level again.
(4) Vibratory leveling and retesting
After precision leveling, power screed and smoothen the surface, and wait for initial setting. After initial setting, use long scraper to level, and then repeat and adjust with laser screed instrument.
(5) Aggregate construction
Spread the hardened aggregate on the surface after initial setting, and work according to the hardened aggregate construction process. Use laser screed to double check and adjust when lifting the slurry.