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Nationwide concrete flooring contractor provides new steel fibre reinforced concrete floor slab for distribution centre in Measham, Leicestershire, East Midlands

The purpose of this project was to create a new concrete floor slab capable of withstanding an extremely heavily loaded racking system for the new owners of the building to operate their midlands distribution centre from. Nationwide Concrete Flooring’s scope of works entailed the following activities/services listed below;

  • The saw cutting and removal of the existing 190mm deep steel fabric reinforced warehouse concrete floor slab
  • The removal of the concrete floor slab in sections
  • To carry out off site recycling with existing concrete floor slabs
  • Replace floor with a new designed and built cast in situ steel fibre reinforced fully suspended concrete floor slab including ancillary steel fabric mesh sheet reinforcement

 

Project Details

Project name – Wolsely Midlands Distribution Centre, Measham Engineer – Clancy Consulting Manchester Area – Circa 1,500m2. Placement utilising mobile concrete pump Slab depths – ranging between 400/500mm Concrete Supplier – Hanson Pre Mix Floor loadings and pile types – Reinforcement type –  Combi Slab System Bekaert 5 D steel fibres & heavy mesh reinforcement fabric with 140mm cover Flatness tolerance – FM2 2003 edition of TR34 Dry shake topping – Rocland Permaban natural Abrasion resistance – AR1 Steel profile construction joints – Permaban Alpha joint Due to ground conditions and extreme point loading requirements an existing warehouse concrete floor slab which had previously been speculatively built was not capable of withstanding the needs of the proposed racking system. Once the existing concrete floor slab had been removed and recycled from site an new steel fibre and steel mesh reinforced fully suspended cast instu concrete floor slab had to be designed and constructed.Nationwide Concrete Flooring’s previous experience and knowledge on similar projects became forefront on the most cost effective floor slab solution both in terms of costs and timescales. The hybrid floor slab design utilising both heavy gauge mesh and Bekaert 5D structural steel fibres (see photo) was paramount to the long term performance of the floor slab. The new Combi Slab System 5D steel fibre manufactured by Bekaert allows engineers the comfort of guaranteed crack width once the floor is in situ. This is especially useful for any client requiring minimal seepage from products/liquids etc through the floor slab itself. The new Combi Slab 5D Bekaert steel fibre also negates the requirement to work within an aspect ratio and so in this instance the 9 metre wide strips of new floor did not require numerous joints to maintain aspect ratio. Once the cast instu floor slab design had been agreed between all parties the next problem to tackle became the installation. Due to awkward access restrictions the concrete floor slabs had to be cast utilising a mobile concrete pump (see photo). Careful selection of concrete mix design working in conjunction with readymix supplier Hanson Pre Mix meant that the concrete reinforced with steel fibres pumped quite easily creating minimal problems for the Nationwide Concrete Flooring laying team. Steel fibres were integrated on site using Nationwide Concrete Flooring’s conveyor system (see photo) this allows dosages of steel fibres to be controlled on site, a particular benefit when concrete is supplied from two separate batching plants. Once the reinforced concrete had be laid and compacted to the correct levels a dry shake topping was monolithically bound to the surface of the concrete. The dry shake topping helps to surprise the steel fibres beneath the surface of the slab and also creates an excellent abrasion resistance, crucial to the longevity of any floor surface. (see photo) On completion of the power floating process the floor was sealed using Nationwide Diamond Curehard the sealing and dustproofing agent. For further details on this project in Measham in the East Midlands please do not hesitate to contact us on 01405 704722 and ask for the estimating department or alternatively e mail sales@nd-group.com