Concrete Floor and Extension Midsomer Norton

Introduction:

Nationwide concreting were asked to undertake a concrete floor installation for an extension at the Dickies factory in Midsomer Norton. Supplying all labour (16 operatives) and plant to pour concrete floor slabs measuring approximately 3344m2 over 4 pours.

Production process:

1. Reinforcement Design: To enhance the structural performance of the concrete floor, we implemented a double layer of A252 mesh reinforcement. This specific grade of mesh is well-suited for heavy-duty applications, providing increased tensile strength and durability. The A252 mesh was strategically placed to manage stress and reduce cracking, ensuring long-term stability in the high-load areas of the facility.

2. Membrane Installation: A robust 1200 gauge membrane was utilized beneath the mesh layers, featuring taped overlaps to prevent moisture ingress and enhance waterproofing. This membrane acts as a barrier, protecting the structural integrity of the concrete and preventing potential damage caused by water exposure. Proper installation of the membrane was critical to ensure its effectiveness and longevity.

3. Support Structure: To maintain the proper spacing and alignment of the mesh layers, we employed a 75mm steel chair positioned between the two layers of mesh. This support structure not only ensures that the reinforcement is correctly placed within the concrete but also contributes to the overall load distribution across the floor. Additionally, a 50mm plastic spacer was placed on the bottom layer to further enhance the stability and positioning of the mesh.

4. Concrete Pouring and Finishing: The pouring process was executed with precision, ensuring uniform distribution of the concrete mix. After the initial setting, we applied a full shined finish, meticulously working to achieve a high standard of surface smoothness and aesthetic appeal. The finish was crafted to comply with the FM2 specifications, which are crucial for environments that involve high stacking and racking.

5. Importance of FM2 Finish: An FM2 finish is particularly relevant for facilities that feature wide aisle racking systems with stacking heights exceeding 8 meters. This level of finish is essential for several reasons:

6. Operational Efficiency: An FM2 finish provides a smooth, level surface that facilitates the movement of forklifts and other material handling equipment. This reduces wear and tear on machinery, minimizing maintenance costs and downtime.

7. Safety Compliance: Achieving an FM2 finish enhances safety within the facility. A smooth surface reduces the risk of slips and falls, while consistent elevation minimises tripping hazards for workers navigating the space.

8. Space Utilisation: The precise finish enables optimal use of vertical space. In environments with high stacking, the ability to efficiently store goods at height maximizes storage capacity and improves inventory management.

9. Durability and Longevity: The FM2 finish is designed to withstand heavy loads and frequent traffic, ensuring that the floor remains in excellent condition over time. This durability translates to lower lifecycle costs and fewer interruptions to operations.