An F-Number measurement is required in evaluating an existing floor’s ability to support a new operation, especially when a change of concrete profiles used is planned. One may be required to obtain a truck lift warranty or a new AGV system may require a floor flatness of a higher degree.
In older applications, the concrete for flooring was often poured with no flatness and levelness specifications. This was probably done by striking off each slab by hand, or by bull floating. The results of such old-fashioned approach were FF20/FL15 floors. But even in the hands of a skilled craftsman, with the use of wet screed, highway straightedge, as well as machine troweling, one can only get as much as an FF25/FL20 floor.
Existing floor levelness and flatness may be improved by the following methods:
Applying a self-leveling, synthetic material as in the case of low-wear applications undergoing mostly some traffic, as in the case of light vehicles.
For high-wear applications, one can top the floor with concrete.
In cases of minor or localized problems, corrective spot grinding may be used.
In the case of Super Flat tolerances, a floor flatness machine such as the wheel-track or aisle grinding can be used to correct imperfections. This is a requirement for most AGV applications, as well as VNA Turret Truck operations.
Loose and shifting joints can slow down truck operations, however there is no standard solution for this kind of problem. Loose and shifting joints are common in older buildings, thought this problem can also occur in new ones. Typical signs include bumps or knocking sounds as they cross the joints. This will force them to reduce speed to avoid damaging the vehicle. Eventually, joint edges will begin to chip, requiring patching-up, which does not last for long.
Other ways of correcting chips involve sub-slab grouting and doweling, which reply on hour long chemical reactions to cure the flooring. These come with a high price and severe drawbacks which disrupt the efficiency of operations.
The foundation of a well-run operation is a good, sturdy, high-quality, reliable floor. They must bear the toll of traffic in a variety of ways: via steel-tipped boots, pallet-laden metal racks, lift trucks, conveyors, as well as other assortments of heavy industrial vehicles and equipment.
It’s no wonder why floors crack, crumble, or shrink over time. Within the course of our research, we have come up with these basic do-it-yourself tips which you can use to repair the most common floor problems:
Don’t make the Condition Worse – if it’s only a hairline crack, it is best to just leave it alone. Applying epoxy over the crack gives it extra protection against deterioration.
Cut Only when Necessary – if the crack is snapped cleanly with no islands, and if the edges have not spalled, filling them with a proper semi-rigid epoxy will do the trick of fixing them.
Cut Out as Narrow a Section as Possible – Don’t attempt to fix a 1/8-inch wide crack with a tool that will make a larger repair furrow.
Cut Deeply Enough – Go at least 1/2-inch deep when cutting out cracks to provide enough area for the epoxy to adhere along the joint walls. The strength and bond of the epoxy to the concrete is stronger than the concrete itself, although it does not generally provide a ‘filler’. What it does is it simply provides a strong surface for heavy traffic. Remember to always rout out narrow cracks with a grinder first before filling it with epoxy.
Don’t Weld – welding the slab together along the seam of the crack may result in another stress crack following the first.
Don’t do Feather-Edge Repairs – Feather-edge repairs involve tapering to zero thickness. Instead of doing this, creating a trough or vertical edge at least 1/2 inch deep on all cracks will allow the epoxy to firmly attach itself to the concrete.
Determining the exact FF and FL specifications, the type of grinding necessary, as well as the time and the cost involved to fix a bumpy, faulty, or deteriorating floor can be a very taxing and challenging effort. Operating with inferior floors bring with it a myriad of consequences which interfere with the smoothness of performance. Therefore, whether considering new floor construction or simply upgrading the floor in your existing facility, the foremost step that one should undertake is to consult a qualified expert which can offer advice on how to obtain a floor – one which has the best and suitable concrete flatness and the likes, that can best serve you long term needs and which fit your specified requirements.
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