Superflat Floor Construction Achieved Full Flatness Compliance

June 1, 2010

LGA Logis has recently completed construction of an 11,500 m2 nominally reinforced SOG (Slab on Grade) floor to a new warehouse for ‘Booksville’ Publishing at Paju, Gyunggi-Do, Korea.

The multi-use warehouse included an area of 3,500 m2 which was designated for use with ‘Wire-Guided’ VNA (Very Narrow Aisle) forklift trucks having a maximum lift height of more than 13.0 m and required a floor flatness/ levelness specification of TR-34 ‘Superflat’.

As the soil conditions at the site were quite good, LGA Logis suggested that the original fully reinforced SOG slab design be changed to a nominally reinforced SOG design (LP-SOG) for a more cost effective solution, in order to reduce floor maintenance and improve long term durability. The slab design was fixed as a 200 mm thick slab, nominally reinforced with a single layer of Steel Fabric. This also allowed the use of a full sized Laser Screed to ensure that the tolerance of FM2 was achieved throughout the Free Movement area of the warehouse.

The ‘Superflat’ floor area was constructed using the tried and tested CoGri Group Superflat Long Strip (SF-LS) solution which allows experienced and highly skilled floor technicians to achieve the TR-34 ‘Superflat’ specification without the need for remedial grinding and without the use of a Dry Shake Topping. Other claimed Superflat floor competitors in Korea commonly use Dry Shake Toppings to improve floor flatness – a very risky solution which often leads to delamination.

Although a complicated and challenging project due to the Owners programme constraints and site conditions, with careful planning, flexibility and good communication throughout the project, the floor construction was completed in accordance with the Owners programme and performance requirements. The completed VNA floor was tested by Face Consultants Korea using its Digital Profileograph and confirmed to be fully compliant with the TR-34 ‘Superflat’ specification. In fact to achieve the tolerance of ‘Superflat’ in the 716 m of VNA aisle length, not a single bit of remedial grinding was required – a remarkable achievement considering the constraints of the project and site. This is the third certified ‘Superflat’ floor constructed by LGA Logis in Korea to date.

This project proved yet again that construction of a high quality concrete floor which will improve the efficiency of the warehouse operations and minimise maintenance costs, can also be cost-effective. It also demonstrated why warehouse Owners who recognise the long term benefits of having a high quality concrete floor, turn to LGA Logis and the CoGri Group for its specialist services.

Just some of the items and expertise provided by LGA Logis in this project, which set it aside from its competitors include:

Design support and expertise is provided by qualified Engineers in house.
Supervision of Sub-Base and Sub Grade Testing is also done by LGA Logis.
LGA Logis always uses high quality specialist materials usually imported.
Detailed Construction Planning includes preparation of detailed construction drawings for the slab.
Professional Project Management is provided by a project team of 4-5 no. of LGA Logis direct employed staff including full time Engineers.
Attention to detail is critical to successful high quality concrete floor construction.
LGA Logis applies its own detailed internal QA/ QC procedures. Comprehensive Concrete Testing and Q.C checking is carried out.
Compliance Testing is carried out by an independent specialist testing company and fully in accordance with the specification requirements.

Critical to the success of this project was the understanding by the Owner that the concrete floor was the most important part of the building structure and an integral part of the Logistics system for the warehouse. Including detailed discussions together with LGA Logis – the preferred flooring contractor, forklift truck suppliers and the racking supplier, the Owner had direct involvement in the specification, design and planning of the floor construction. Subsequently the floor was correctly specified as TR-34 (2003) Table 4.3, ‘Superflat’ and the Owner demanded that the correct Compliance Testing was carried out by a specialist testing company.

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