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Renault Samsung Motors VNA Floor Construction

June 3, 2009

In 2008 Renault Samsung Motors (RSM) started construction of its new Distribution Centre at Haman, near Busan, Korea. As 12,000m2 of the total 23,500m2 floor space would include VNA (Very Narrow Aisle) racking with a maximum lift height of more than 10.0 m, the floor construction was highlighted early by RSM as a critical part of the construction.

Renault Samsung Motors is part of the Renault Group and was formed in 2000 when Renault took over Samsung Motors. It is now the 4th largest Car Manufacturer in Korea.

Being not fully satisfied with the Epoxy floor constructed in 2002 for the existing VNA Warehouse at its Kihyueng D.C, RSM decided to specify the Haman floor as Direct Concrete finish. As aesthetics were important RSM stated a preference that no grinding work would be allowed to achieve the required floor flatness specification. It also specified the floor flatness as TR-34 ‘Category 1’ to ensure the best possible efficiency in its warehouse operations and required that the Flooring Contractor had a proven track record in achieving floors to this specification in Korea.

LGA Logis was nominated as the Flooring Contractor following a competitive bidding process and based on its proven track record in constructing Long Strip floors to Superflat tolerances in Korea. As soil conditions were actually better than expected with a minimum K75 Value of 0.08 N/ mm3 confirmed by Plate Bearing Tests, LGA Logis proposed to re-design the slab as a nominally reinforced SOG. This would not only provide a Fast-Track construction method with better control of cracking but also cost savings both in the short term from construction but also in the long term from reduced maintenance costs.

To provide the Client with peace of mind, LGA Logis offered its unique Design-Construct-Insure total solution. Face Consultants Ltd, the worlds leading Industrial Flooring Consultant, was engaged by LGA Logis to carry out the new floor design which was supported with its global Professional Indemnity Insurance policy. The Scope of work included removal of the existing lean concrete layer – which was deemed not good enough for a nominally reinforced Slab-On-Grade (SOG), and construction of a new Sub Base to the required tolerance of +0, -25 mm.

Based on a confirmed VNA & Mezzanine racking layout and confirmed loading, it was possible to design the SOG both economically and safely. The warehouse slab was designed as a 210 mm nominally reinforced SOG with a single sheet of 7x200x200 Steel Fabric in the slab bottom and C30/37 concrete. In the Factory floor area the loading only required a slab thickness of 170 mm.

The VNA floor area was constructed using the LGA Logis SF-LS (Superflat Long Strip) solution with concrete placed and finished to a 120 m long strip bay every casting day. The Free Movement area was constructed in accordance with the TR-34 specification using a combination of Laser Screed and Copperhead. From start to finish the 23,500m2 floor including the 12,000m2 of Long Strip Construction was completed on programme within 7 weeks.

During and upon completion of the floor construction, Face Consultants (Korea) Ltd carried out Compliance Testing using its digital floor surveying equipment, which is the most advanced in the world. The Digital Profileograph Survey confirmed that with a total VNA aisle length of more than 2600 m, 100% achieved the specified tolerance of TR-34 ‘Category 1’ without a single bit of remedial grinding being required.

Understanding the requirements and operation of modern Distribution Centres allows LGA Logis to provide total solutions which meet its Clients requirements at cost effective prices, something that cannot be said for some of its competitors.

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