The Italian Job

June 1, 2011

Concrete Grinding Ltd has successfully completed their LARGEST EVER FLOOR GRINDING CONTRACT in linear meters for a global glassware company in Italy.

The client’s new DC floor was originally built by a flooring contractor using Laser Screed construction to meet with DIN 18202 floor flatness specification. Whilst the racking was being installed, Trimmer S.r.l Profilegraph surveyed sample aisles and found they all failed to meet DIN 15185, the required floor flatness standard for VNA operation. TRIMMER S.r.l. contacted CONCRETE GRINDING LTD, whom they represent in Italy, and Concrete Grinding Ltd were then commissioned to grind the aisles to tolerance.

Testing Floor Flatness and Grinding

See below:
1. Trimmer S.r.l testing floor flatness using the FACE DIN Profileograph.
2. The Laser Grinder ® in an aisle

Testing Floor Flatness With Face DIN Profileograph

FACE DIN Profileograph
1. Trimmer S.r.l testing floor flatness

The very busy and operational warehouse facility consisted of 64 aisles, which were split in to 7 different compartments, totaling just over 5700 meters. Before corrective work commenced Trimmer S.r.l. surveyed the remaining aisles, Concrete Grinding Ltd analysed the data and identified that only 80% of the total aisle length required remedial grinding. As Concrete Grinding Ltd are the only superflat floor grinding specialist in the industry that could laser ground exact areas out of specification rather than the whole aisle, the client commissioned Concrete Grinding Ltd to grind the aisles to specification. This also benefited the client as precise corrective grinding provided a cost-saving solution.

Grinding An Aisle

The Laser Grinder ®
2. The Laser Grinder ® in an aisle

To meet with the client’s deadlines, Concrete Grinding Ltd operated two Laser Grinders and carried out 2 wheel track grinding x 400mm cut paths on 4570 metres of aisles. The facility operates B.T. (Toyota) 4 wheel fork Lift trucks where the wheels fitted perfectly within the 400mm cut path. The grinding program was executed on a 5 aisles rolling program so that the client’s warehouse operation could function as normal.

Floor Joint Repairs

See below:
3. Joint Arris Repair within ground path.
4. Ground path and fully operational aisle.

Joint Arris Repair

Joint Arris Repair
3. Joint Arris Repair within ground path.

Concrete Grinding were also asked to carry out floor joint repairs in the facility. With assistance from CG Flooring Systems Ltd, the team carried out 110 metres of joint arris repairs and 1200 metres of joint reseal repairs within the 400mm ground path to cater for the wheels of the trucks.

Cost Savings

Ground path
4. Ground path and fully operational aisle.

This resulted in an additional cost saving as the whole aisle width did not have to be repaired. The saw cut joints were resealed every 4 metres along each aisle. 50 metres of joint repairs were also completed within door openings between the 7 separate compartments. A large portion of the joint repairs were completed immediately after Christmas, during the client’s shutdown, ahead of grinding work.

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