Floor hardness for fork lift truck traffic
Floor hardness for fork lift truck traffic
(OP)
I am currently involved in a buildability study for the design and build of a new cargo terminal. I am looking for ideas on how to enhance the floor hardness for heavy fork lift traffic. The gross floor space of 400,000 sq.M. 1,400sq. M.
The ground floor is to be cast as a traditional reinforced concrete slab whiles the remaining areas on the upper two floors shall be post tensioned precast beams and slab with an in suite topping.
Given the large floor expanse the method or product used to enhance the hardness of the floor surface will have a significant cost impact. I am trying to avoid epoxy finishes due to costs and maintenance. Can any one give me some inspiration regarding glass fiber reinforcing, concrete finishing methods and concrete mix etc. any ideas will be greatly appreciated.
I am also looking at protection of columns from mechanical damage and have adopted a surface mounted cast in steel plate with a circular column to protect against and deflect impacts. Any innovative ideas here would also be appreciated.
Cheers Mick
The ground floor is to be cast as a traditional reinforced concrete slab whiles the remaining areas on the upper two floors shall be post tensioned precast beams and slab with an in suite topping.
Given the large floor expanse the method or product used to enhance the hardness of the floor surface will have a significant cost impact. I am trying to avoid epoxy finishes due to costs and maintenance. Can any one give me some inspiration regarding glass fiber reinforcing, concrete finishing methods and concrete mix etc. any ideas will be greatly appreciated.
I am also looking at protection of columns from mechanical damage and have adopted a surface mounted cast in steel plate with a circular column to protect against and deflect impacts. Any innovative ideas here would also be appreciated.
Cheers Mick





RE: Floor hardness for fork lift truck traffic
I would not bother with either polypropylene or glass fibers as these do little to enhance surface durability, though they help in crack mitigation.
I've had success with steel fibers that are 25mm long or less (but not less than 20mm), ductile (not springy), and have a rectangular cross section, not round.
I know of one US supplier that still provides such fibers....Mitchell Fibercon. I believe they are in one of the small towns around Pittsburgh, Pennsylvania.
RE: Floor hardness for fork lift truck traffic
RE: Floor hardness for fork lift truck traffic
Ron: Thanks for the info on the steel fibre supplier... good stuff to file away...
Dik
RE: Floor hardness for fork lift truck traffic
Hg
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RE: Floor hardness for fork lift truck traffic
RE: Floor hardness for fork lift truck traffic
1. Get a copy of ACI 302.1R-04: Guide for Concrete Floor and Slab Construction from the American Concrete Institute.
2. There is a very detailed book on industrial floor design written by Ringo and published by The Aberdeen Press, search the archives of Eng-Tips it is in a number of threads.
3. There is a distinct difference between floor strength and floor hardness and the costs associated with different levels of each. Be specific about the levels of each your project requires. Fibermesh type products are really more for micro-crack control and strength than for surface hardness.
4. There are lots of special coatings and toppings for concrete floors ranging from liquid surface hardeners like Lapidolith; dry shake-on hardeners like Masterplate; and coatings like urethanes and epoxies. Prices vary all over the map. I would contact representaives from Sika and Master Builders to name two and discuss your specific requirements and they can recommend a product and some typical costs.
5. Some of the things to watch for: forklift tires can leave marks on some toppings/coatings; don't over spec a product that doesn't apply to your needs; be watchful of subgrade preparation, joint spacing/desing,and reinforcement requirements. Some poly fibers can cause a "fuzz" on the concrete surface, this generally doesn't happen with steel fibers because the finishing blades knock them down.
5. There is a special order cement additive, Chem-Comp, that gives an expansive cement property to the concrete mix that can reduce the number of joints in floor slab. It does require more reinforcing - so a cost analysis is needed to see if it is worth it to your project.
Just some additional things to think about!
RE: Floor hardness for fork lift truck traffic
"Designing Floor Slabs on Grade, Step-by-Step Proceedures, Sample Solutions and Commentary", 2nd Edition, by Boyd C. Ringo and Rober B. Anderson, published by The Aberdeen Group, 426 South Westgate, Addison, IL 60101, ISBN 0-924659-75-0