FLOORING SYSTEMS

FLOORING MUST EXIBIT FOLLOWING

PROPERTIES
Strong permanent bond to the substrate.
Improved resistance to a wide spectrum of aggressive chemicals.
Impermeable to liquids.
Increased toughness, durability, resilience, and resistance to impact or
abrasion.
Non dusting.
Hygienic and easily cleaned surfaces.
Great resistance to cracking.
Lower applied thickness.
Rapid installation and curing with minimum disruption to normal
operations.
More aesthetic appearance with the opportunity to produce
decorative finishes
FACTORS INFLUENCING SELECTION OF
FLOORING SYSTEM
Type and degree of Traffic.
Temperatures to which flooring will be exposed.
Nature and duration of any chemical contact with the floor.
Texture of surface expected.
Ease of cleaning (including hygiene requirements).
Wet or dry conditions.
Slip resistance requirements.
Nature of light exposure.
Aesthetic appearance.
Crack bridging capability.
Site conditions at time of installation.
Cost.
FACTORS INFLUENCING SELECTION OF
FLOORING SYSTEM
Type and degree of Traffic.
FACTORS INFLUENCING SELECTION OF
FLOORING SYSTEM
Texture of Surface Expected
Reasonable Slip resistance
against dry & Wet Conditions.
Slip Resistance Value (SRV)
40 in wet state
Smoother and less porous a
floor surface, the easier it is to
clean
DESIGN ASPECTS
LOADINGS TO BE CONSIDERED
Wheel Loads.
Concentrated Static Loads.
Moving Loads.
Distributed Loads.

REQUIRED SLAB THICKNESS ARE BASED UPON

Strength of Subgrade Sub Base.
Strength of Concrete.
Nature & Frequency of Imposed Loads.
CODES
INDIAN STANDARDS
Code Details
Number
IS : 875 (Part Code of practice for design loads (other than earthquake ) for buildings
2) 1987 and structures.
IS : 4631 Code of practice for laying of epoxy resin floor topping
1986
IS 9162:1979 Methods of tests for epoxy resins, hardeners and epoxy resin
compositions for floor topping
IS 9197:1979 Specification for epoxy resin, hardeners and epoxy resin Jul 2011
compositions for floor topping.
CODES
BRITISH STANDARDS
Code Details
Number
BS 1881-202 Testing concrete: Recommendations for surface hardness testing by
rebound hammer
BS 8204-1: In situ floorings: Code of practice for concrete bases and screeds
BS 8204-2: In situ floorings: Code of practice for concrete wearing surfaces
INTERNATIONAL ORGANISATION FOR STADARIZATION
Code Details
Number
ISO 178 Determination of elastic modulus in flexure

INTERNATIONAL ELECTROTECHNICAL COMMISSION

Code Details
Number
IEC 61340-4-1 Electrostatic behavior of floor coverings and installed floors
CODES
EUROPEAN STANDARDS

Code Details
Number
EN 1081 Resilient floor coverings - Determination of the electrical resistance

EN 1504 Products and systems for the protection and repair of concrete structures
EN 1542 Products and systems for the protection and repair of concrete structures
Test methods- Measurement of bond strength by pull-off
EN 1766 Reference concretes for testing
EN 12086 Thermal insulating products for building applications -Determination of
water vapor transmission properties
EN 13318 Screed material and floor screeds - Definitions
EN 13529 Products and systems for the protection and repair of concrete
structures: Test methods - Determination of chemical resistance
CODES
EUROPEAN STANDARDS
Code Details
Number
EN 13687- Products and systems for the protection and repair of concrete
2 structures: Test methods - Determination of thermal compatibility;
resistance to temperature shock
EN 13892- Methods of test for screed materials; Part 4: Determination of wear
4 resistance BCA
EN 13892- Methods of test for screed materials; Part 4: Determination of wear
5 resistance to rolling wheel
EN ISO Paints and varnishes - falling weight test
6272

GERMAN INSTITUTE OF STANDARDISATION

Code Details
Number
DIN 53 754 Testing of plastics; determination of abrasion; abrasive disk method
DATA REQUIRED FOR DESIGN OF CONCRETE FLOORS
1. System information
Slab type: Construction: Design type:

Topping material Insulation under slab Separation sheet (PE):

Type: Type: Operational temperature: C
Thickness: mm Thickness: mm

Upper reinforcement
Original concrete class: Original designed reinforcement mm
area:
Lower reinforcement
Original slab thickness: mm Type: MPa mm
area:

2. Ground condition
Subgrade modulus Ev2: MPa Westergaard modulus K: MPa/m California Bearing Ratio CBR:

3. Pile field information

Pile field:
L1: mm L2: mm d: mm
Le1: mm Le2: mm p: mm
H: mm t: mm h: mm
Remarks:

*EV1/EV2 min 2,5

DATA REQUIRED FOR DESIGN OF CONCRETE FLOORS
1. System information
Slab type: Construction: Design type:

Topping material Insulation under slab Separation sheet (PE):

Type: Type: Operational temperature: C
Thickness: mm Thickness: mm

Upper reinforcement
Original concrete class: Original designed reinforcement mm
area:
Lower reinforcement
Original slab thickness: mm Type: MPa mm
area:

2. Ground condition
Subgrade modulus Ev2: MPa Westergaard modulus K: MPa/m California Bearing Ratio CBR:

3. Pile field information

Pile field:
L1: mm L2: mm d: mm
Le1: mm Le2: mm p: mm
H: mm t: mm h: mm
Remarks:

*EV1/EV2 min 2,5

DATA REQUIRED FOR DESIGN OF CONCRETE FLOORS
4. Loadings

3.1. Uniform loading 3.3. Racking system load

Load q: t/m Load from shelf leg: kN

*Safety factor: Back to beck: kN

Foot plate a x b: mm
3.2. Concentrated single load Distance x-x: mm

Load q: t/m Distance y-y: mm

Dimensions a x b: mm Distance z: mm
Distance to neighboring loads: Aisle width: mm
*Safety factor: *Safety factor:

3.4. Fork lift load 3.5. Truck load

Total weight: kN Total weight: kN
Axle load: kN Axle load: kN
Wheels per axle: Wheels per axle:
Wheel spacing: mm Wheel spacing: mm
Contact pressure: MPa Contact pressure: MPa
Daily passed: Daily passed:
Vehicle speed: km/h Vehicle speed: km/h
*Safety factor: *Safety factor:
JOINTS IN CONCRETE FLOORS
Construction Joints : Necessitated due to limitations in construction
methods. Created by a form work or by 45 degree stopper or stepped
concrete
These Joints
may have
details such as:
a) Tongue &
Groove.
b) Tongue &
Groove with
dowel bars.
c) Plain Straight
Joint.
d) Plain Joint
with dowel bars.
e) b & d above,
with or without
smoothened
dowels.
JOINTS IN CONCRETE FLOORS
Contraction/Control Joints : Placed at predetermined
locations to create weakened planes where the concrete can
crack in a straight line
JOINTS IN CONCRETE FLOORS
Expansion Joints : For expansion and contraction of the
concrete floor
Consensus among many that they be avoided.
JOINTS IN CONCRETE FLOORS
Expansion Joints : For expansion and contraction of the
concrete floor
Consensus among many that they be avoided.
JOINTS IN CONCRETE FLOORS
Isolation Joints : As the name indicates, It is provided where the concrete floor
meets with permanent structural elements such as brick walls, machine
foundations, foundation blocks, columns etc i.e. which are part of the structure.
It is provided to full depth of the concrete floor and for a width of 10 to 12 mm. To
avoid ingress of moisture and other undesirable elements, these joints are filled
with a resilient material and topped with joint filling compounds.
JOINTS IN CONCRETE FLOORS
Depth of Cut
1/4th to L/5 depth of slab for early sawing. (within 24 Hrs of finishing)
1/3rd depth in case of late sawing. (Within Seven Days) is justified.

Width of Cut: Theoretically, even a hairline width of cut is sufficient.

However due the standard width of diamond blades manufactured
world wide, a minimum width of 3 mm- 4mm in achievable. Wider
width cuts are unnecessary and will lead to higher cutting and sealing
costs.

When to Cut? Timing of these cuts is very important. On large and

important jobs it may be worth while to conduct actual field trials to
make a series of sample trial cuts to arrive at the most optimum" time
- window" for cutting purposes.
FLOORING HISTORY
A. Flooring before 1970 (Chequed Board 100 mm
Method) 100M
Panel Size = 3M x 3M

100 mm
No. of Panels= 1110 Panels
Formwork for 1 Panel=4x3=12 Meters
100M
Total Form work = 12x1110/2 = 6660M
Total Linear length of joints=6660M
Reinforcement: Welded Mesh
Typical Thickness: 150mm
Construction Time assuming 10 panels
per day and 7 days before casting
adjacent panel = 111 days or say 45
months
FLOORING HISTORY 100 mm
B. Flooring Method from 1970 to 2014 (44 Years)
Long strip method with sawn joints 100M
Width of Panel 4 to 5M & Length of Panel 3050M
Total No. of Panels = 100x100/50x4= 50 Panels
Total Form work (4M wide) = 2700 Meters.

100 mm
Total length of formed Joints (25x100) = 2700M
Total sawn joints length = 5000M
Total Construction Time with 7 days before casting of
adjacent panel @ 1 panel/day : 100 days
Typical Thickness = 200 to 250MM
Vacum Dewatering is normally done

Reinforcement
2 layers of steel Reinforcement mesh
Defects of the system
1. Bidirectional shrinkage
2. Too many dowels to be placed
3. Slow Construction
4. Flatness affected by curling edges sticking up.
5. Joints are weak points
FLOORING HISTORY 100 mm
B. Flooring Method from 1970 to 2014 (44 Years)
Long strip method with sawn joints 100M
Width of Panel 4 to 5M & Length of Panel 3050M
Total No. of Panels = 100x100/50x4= 50 Panels
Total Form work (4M wide) = 2700 Meters.

100 mm
Total length of formed Joints (25x100) = 2700M
Total sawn joints length = 5000M
Total Construction Time with 7 days before casting of
adjacent panel @ 1 panel/day : 100 days
Typical Thickness = 200 to 250MM
Vacum Dewatering is normally done

Reinforcement
2 layers of steel Reinforcement mesh
Defects of the system
1. Bidirectional shrinkage
2. Too many dowels to be placed
3. Slow Construction
4. Flatness affected by curling edges sticking up.
5. Joints are weak points
DISADVANTAGES OF HAVING FLOOR JOINTS
Weak or non-existent load transfer over
the joint as the result of which the edge
of the slab can be pressed into the ground
Damaged saw-cut joints
Concrete floor slabs have a tendency for
curling
Hard tyres (e.g. of fork-lift trucks) bump
against the saw-cut joint edges

Cracks in the distance of 15 40 cm from Result: the Joint crumbles

the saw-cut joint

Wheel
Loads
DISADVANTAGES OF HAVING FLOOR JOINTS
JOINT IMPACT ON EQUIPMENTS
JOINTLESS FLOORS
Usual No of Panels = 4

Size of Panel=50Mx50M

Length of Preformed special joints=

200M

Construction Time = 7 days 3 4

Benefits of the System.

1.Faster Construction times.
2.No joints ,except day joints.
3.Floor performance guaranteed for
5 years
4. Typical Thickness: 100mm150mm
5. Reinforcement: Steel Fibers
ADVANTAGES & DISADVANTAGES OF FLOORING
SYSTEM
TRADITIONAL FLOORING SYSTEM WITH FLOORING SYSTEM WITHOUT JOINTS
JOINT
100mm -150mm Thick on compacted
150mm to 300mm Thick compacted
subgrade. subgrade

100mm-150mm PCC requirement. 100mm-150mm PCC requirement.

VDC treatment
No contraction joints or sawn joints
4M-5M wide baysX30-40 Joint less unto 5000SqM possible

Typical Sawn Joint @ spacing 4M-5M Steel Fiber Reinforcement

Construction time for typical
Typical construction time for 10,000
10,000SqM floor is 2 months.
SqM is 6- 7 days
ADVANTAGES & DISADVANTAGES OF JOINTLESS
FLOORING SYSTEM
ADVANTAGES DIS-ADVANTAGES

HIGH STRUCTURE STRENGTH HIGH COST OF MATERIAL

REDUCED CRACK WIDTH LOW WORKABILITY
IMPROVES DUCTILITY LOW COMPRESSION STRENGTH
IMPROVES DURABILITY GENERAL FIBRES DO NOT INCREASE
THE FLEXURAL STRENGTH OF
IMPROVES IMPACT AND ABRASION CONCRETE AND SO CANNOT REPLACE
RESISTANCE MOMENT RESISTING
REINFORCEMENT
STRUCTURAL BEHAVIOURS OF FRC CONCRETE
STRESS STRAIN GRAPH FAILURE OF CONCRETE

COMPRESSIVE STRENGTH
COMPRESSIVE STRENGTH
V/S FIBRE CONTENT
V/S TEMPERATURE
STRUCTURAL BEHAVIOURS OF FRC CONCRETE
MODULUS OF RUPTURE V/S
FIBRE CONTENT
FRC JOINTLESS FLOORING SYSTEM LAYING
Fibre blower

Laser machine emitter

Laser screed leveller reciever
Ploythene sheet provided
FRC JOINTLESS FLOORING SYSTEM LAYING
Cosinus slide joint Reinforcement around column to
avoid cracks

Pouring of FRC Leveled Surface

SETTING UP OF FIBRE BLOWER
POURING OF FRC
LEVELING