Super Flat Flooring
 
Concrete floors are critical elements in any industrial & warehouse facility. This is particularly the case in high-bay warehousing, where high tolerance, very flat floors are essential for the efficient operation of the materials handling equipment used. Monofloor understand the importance of correctly designing and installing these floors, often referred to as Super-flat floors.

We are experienced in the construction of flat floors in accordance with Concrete Society Technical Report 34, DIN 18202, DIN 15-185, all ASTM standards (including the Fmin specification), and many other leading international standards.

We have precise plate optical level with micrometre to do survey of Super Flat floors.

 
 
 
Recently we completed ‘Nerolac Paints Limited’ as flat floor & started ‘Arshiya International limited’ with FM1 floor specification.
 
 
 
In Warehouses, materials handling equipment is used in two different distinct areas: areas of free-movement traffic and areas of defined-movement traffic:
 
In free-movement areas, MHE can travel randomly in any direction. Free-movement areas typically occur in factories, retail outlets, low-level storage and food distribution. They are also found alongside defined-movement areas in warehousing.
   
In defined-movement areas, vehicles use fixed paths in very narrow aisles: they are usually associated with high-level storage racking. The layout is designed specifically to accommodate the racking and MHE only.
 
 
 
Definition of surface regularity terms.
 
Elevational difference
 
The distance in height between two points. The points can be fixed at prescribed distances or they can be moving pairs of points at prescribed distances apart.
 
Change in elevational difference
 
The change in the elevational difference of two moving points, at a prescribed distance apart, in response to a movement of the two points over a prescribed distance.
 
Datum
 
The level of the floor is controlled to datum (any level taken as a reference point for levelling).
 
Flatness
 
Surface regularity characteristics over a short distance, typically 300 mm.
 
Evenness
 
Surface regularity characteristics over a longer distance, typically 3 m, and to datum.
 
Property
 
Elevational differences or measurements derived from elevational differences that are
limited for each class of floor.
 
Property I - The elevational difference in mm between two points 300 mm apart.
 
 
Property II - To control flatness, the change in elevational difference between two consecutive measurements of elevational difference (Property I) each measured over 300 mm.
 
 
Property III - The elevational difference in mm between the centres of the front load wheels of materials handling equipment.
 
 
Property IV - To control levelness, the elevational difference in mm between fixed points 3m apart.
 
 
 
 
Permissible limits on Properties II and IV in free-movement areas.

 

Floor Classification

Typical Floor Use

Property II Limit (mm)

Property IV Limit (mm)

95%

100%

95%

100%

FM 1

Where very high standards of flatness and levelness are required. Floors to FM 1 classification may need to be constructed using long strip methods.

2.5

4.0

4.5

7.0

FM2

Buildings containing wide aisle racking with stacking or racking over 8 m high, free-movement areas and transfer areas.

3.5

5.5

4.5

12.0

FM3

Buildings containing wide aisle racking with stacking or racking up to 8 m high Retail and manufacturing facilities.

5.0

7.5

10.0

15.0

 
 
 
Permissible limits on Properties I, II and III in defined-movement areas.
 

Floor Classification

MHE Lift Height

Property I

Property II

Property III

Wheel Track up to 1.5 m

Wheel Track over 1.5 m

95%

100%

95%

100%

95%

100%

95%

100%

Superflat (SF) Over 13 m

0.75

1.0

1.0

1.5

1.5

2.5

2.0

3.0

Category 1 8-13 m

1.5

2.5

2.5

3.5

2.5

3.5

3.0

4.5

Category 2 Up to 8 m

2.5

4.0

3.25

5.0

3.5

5.0

4.0

6.0

 
 
 
 
Benefits of Superflat Floor
 
Superflat Floor has a number of Benefits, listed below are some them...
 
High material handling efficiency.
   
Safer working conditions for Lifting Equipment.
   
Lower maintenance cost on Lifting Equipment.
   
More durable floor, longer working life-span.
 
 
 
 
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