Technologies

Construction of jointless industrial floors of dispersive reinforced concrete.

Main stages in the production process of high quality jointless industrial floors of „Chemobau” are as follows:

- design stage
- technological stage
- main stage

Design stage

The industrial floor Design stage starts with introduction of the technologists with the needs of the construction project, as well as the most important information about:


- pavement type – concrete, reinforced with fibres; concrete, with air pores, etc.
- terms of use – aggressive environment, temperature changes, etc.
- design constraints in the pavement thickness and surface geometry
- design loads – static and dynamic
- type and actual compressive strength of the foundation, on which the concrete coating will be applied

Based on this information, and based on the long experience of our German partners, our team of highly qualified technicians calculates the quantity and type of the steel fibres, to be incorporated in the relevant pavement, as well as the recipe for concrete mixture, which is prepared individually for each project. After the static analysis, the most cost-effective solution for concrete pavement is achieved, and in many cases the pavement thickness is reduced, reinforcement with welded mesh is avoided, costs for cutting joints are reduced, etc.

Technological stage

The Technological stage starts with solving the sequence and means for concreting, preparing Tact-Plan for implementation of concreting of individual sections. The Tact-Plan is consistent with the construction site characteristics, as well as with the technological sequence of the operations, carried out in the site. In general, the Contracting authority also participates in the organizational process in order to achieve maximum consistency between the individual construction and installation works.

Main stage

 

Preparation of the working site

The main stage of the process for construction of jointless industrial floors starts with preparation of the working site, which includes: 

- application of polyethylene 200 microns - 2 layers on the foundation.
Its purpose is to separate the concrete pavement from the existing one, in order to implement smooth bearing between both surfaces, which is one of the prerequisites to prevent cracking of the concrete surface.
- application of special micro porous tape around steel concrete and other elements, in order to separate them from the concrete pavement.
In this way the free horizontal deformations on the pavement are not impeded and there are no preconditions for crack formations.
- installation of steel profiles in dilatation and working joints.
Provide an extremely smooth transition between two working sections, which is an excellent technological solution for floors, on which cars and forklifts will be moving.

 

Concreting the working area

After preparation follows concreting of the working area. In general, concrete mix with added inside steel fibres is delivered to the site with concrete mixers, transportation to the working area within the site is carried out by automatic concrete pump, dumper trucks or directly from concrete mixers, depending on the access restrictions and approach to the working sites. Application and processing of the fresh concrete mix is carried out in rapid succession. Processing is smoothing of the mixture, so it adopts its design position in the relevant area. It is done mechanically (by Laser Screed – machine with laser transmitter) or by hand with lute, and the design level is monitored by a laser leveling device and transmitter. Concrete mixture vibrates only around the formworks and the steel profiles. After smoothing of the concrete mixture you should wait for the concrete to gain strength (around 1.5 MPa), so you can step on it and then the grinding process can begin. It is performed mechanically by smoothing the small bumps on the concrete surface. Together with that starts also the application of surface wear-resistant layer of topping material, which reacts with the moisture of the freshly laid concrete and creates the smooth surface of the finished product. It is processed by machine, and the areas, which are inaccessible for machines are processed manually by trowel. Thus, the applied steel concrete pavement is treated with impregnator, which is activated only upon the occurrence of moisture on the pavement, thus providing better efficiency and durability of the final product. Joints are cut one or two days after concreting. They are filled with bitumen based highly resistant material, which does not age under the influence of UV-radiation.