Home Articles New High Quality Concrete Flooring Solution that Incurs Low Maintenance Cost

High Quality Concrete Flooring Solution that Incurs Low Maintenance Cost

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Reinforced Concrete Floors

With a decade experience nationwide in helping their clients and their fellow contractors in laying “Durafloor – Duraflex™ Steel Fiber Reinforced Concrete Floors”, Durafloor Concrete Solutions LLP is turnkey contractor vertical of Kasturi Group, with a vision to provide their clients one stop concrete flooring solution.

Their services include designing of concrete floors, laying & finishing of concrete floors, high tolerance floors with Duraflex™ High Tensile Steel Fibers, Floor Hardeners, and Concrete Densification and Polishing. Kasturi Group, also provide nationwide service having all the experience required to deliver very high quality, low maintenance, SFRC concrete flooring solution.

DURAFLOOR Concrete Solutions LLP – the industrial flooring specialists  provide clients with the complete one stop solution for the design and installation of concrete floors.

Incorporation of strong belief

The company urges to be the specialist contractor of choice by providing a quality product and therefore optimising floor performance and minimising maintenance problems for clients through innovation, Optimum Design, Quality Service, and Integrity in concrete floor design and production.

The areas of application

  • Laser / Truss Screeding of Concrete Floors for
  • Industrial Flooring
  • Warehouse Flooring
  • Logistics and Retail Stores Flooring
  • Textile Mills,
  • Chemical Plants
  • Food and Beverage Industrial Flooring
  • Malls, Showrooms and Shopping Centers
  • Shop Floor with FM2 Level Tolerance
  • Hyper Market  Flooring
  • Container Depots
  • Manufacturing Shop  Floor
  • Container Freight Station Special FM2/FM3/Super Flat Floor
  • Cold Storage
  • Railway Platform
  • Commercial Parking Lots

Advantages with Durafloor

Lower Turnaround Time, high quality, cost effective Duraflex™ Steel Fibers and mixed in concrete with aggregates, this not only gives 360 degree reinforcement to the concrete flooring, but also completely eliminates the time and labour for fixing traditional reinforcement

Flatter floors: With laser screed execution, you get laser precise flatness and level every time.

Jointless Floors: Possible to lay joint less floor upto 1000 sq mtr in a single day.

Lesser Workforce: The Laser Screed machine does the tough, strenuous work while laying concrete, so you get more work done with far less effort

The strong virtue

  • Design, Planning and Execution of High Tolerance Concrete Floorings
  • Super Flat Floors
  • Steel Fiber Reinforced Concrete Floorings
  • VNA Warehouse Concrete Floors
  • The company’s specialised services
  • Laser Screed /Truss Screed

By doing laser screed we can level a large area of concrete in less than one minute! It easily moves around obstacles on-site and eliminates regular manual framework, thus more flooring is done per man-day, reducing the project’s turnaround-time(TAT).

 

Low TAT, high quality, cost effective

Flatter floors : You get laser-precise flatness and level every time.

Jointless Floors: Possible to lay pointless floor upto 1000 sq mtr in a single day.

Lesser Workforce: The Laser Screed machine does the tough, strenuous work, so you get more work done with far less effort

Floor Flatness and Levelness via ASTM E1155

ASTM E1155 addresses a quantitative method of measuring floor surface profiles to obtain estimates of the floor’s characteristic FF Floor Flatness and FL Floor Levelness Profile Numbers (F-Numbers).

These F-Numbers use dimensionless symbols to designate both flatness and levelness and are designated as;

  • FF Floor Flatness  variation from surface plane (bumpiness)
  • FL Floor Levelness  variation from horizontal plane (pitch)

Flatness is how close to geometric planarity a slab approaches. The profile of a slab consists of concrete waves. These waves have amplitudes and wavelengths. FF is a statistical measure of the roughness of a slab’s surface caused by the presence of waves.

Levelness is the amount of slope (or pitch or tilt) in a slab. This is the degree to which the surface of the slab approaches true horizontal perfection.

Joints and Load Transfer: Key to Floor Durability

The function of an industrial floor is to serve as a work platform, supporting the movement of material handling vehicles carrying raw materials or merchandise. Floors that are smooth and interruption-free allow optimum movement and productivity. Joints serve several functions within floors: they are the ends of pours; they induce shrinkage cracks to follow straight lines; they allow for seasonal slab expansion/ contraction; and they provide the linkage between smaller slab segments. To accommodate all these functions, joint design must incorporate the four following principles:

  • Narrowness
  • Plumbness
  • Load Transfer
  • Protectability

FM2/FM3 level VNA and Warehouse Floors

Due to Optimum design techniques, Durafloor has been able to develop construction techniques that meet the highest surface regularity requirements. These would have traditionally been constructed using slow and laborious long strip methods. High Tolerance Warehouse Floors and VNA Floors for defined and Non-defined movement are executed with expertise by DURAFLOOR.

Concrete Hardeners, Densification and Polishing

Concrete Floor Hardeners are finding acceptability in wide ranging applications in heavy traffic industrial floors, loading areas, warehouses, chemical and other processing plants, distribution centers, vehicle maintenance areas, etc. Mineral and metallic dry shake hardeners provide additional abrasion resistance, high light reflectivity, and also minimizes dusting by reducing porosity.

Coating the surface

Another method instead of coating the surface with organic solids, densifiers react with the concrete itself. This reaction fills in the natural pores and voids in the concrete and provides a dense, hard surface that is easy to clean. The concrete is densified internally and inorganically. There is nothing to wear off the surface, nor is there anything to replace. The same reaction also makes the surface much harder and resistant to abrasion. In addition, the floor surface is rendered free of dust.

Steel Fiber Reinforced Concrete Floors

Steel-fiber-reinforced concrete is a state-of-the-art composite material made of hydraulic cements, fine or coarse aggregate, and a dispersion of discontinuous steel fibers. The amount of fiber in concrete mixes typically ranges from 12 kg/cum to 30 kg/ cum, although smaller amounts have been used successfully in reduction of plastic- and drying-shrinkage cracking. The main effect of adding steel fibers in concrete, that is also the main advantage of SFRC is its post-crack behavior or toughness of SFRC.

Steel fibres are incorporated in concrete to improve its crack resistance, ductility, energy absorption and impact resistance characteristics. Properly designed and dosed SFRC can reduce or even eliminate cracking a common cause for concern n plain concrete.

DURAflexTM Ultra High Tensile Steel Fibre 3600 Reinforcement for Flooring

The DURAflexTM Ultra High Tensile Steel Fibre Advantage

The addition of high quality DurafIexTM Ultra High Tensile Steel Fibres to concrete turns a brittle (easily broken/damaged) material into a tough composite that is more resistant to cracking and localized damage, especially impact related damage.

The DURAflexTM Ultra High Tensile Steel Fibres are distributed rigUltra through the concrete matrix and effectively lock off developing cracks, slowing down their propagation through the concrete. This can be likened to the action of ”rip-stop“ fabrics when used in parachute canopies.

Steel Fibers in concrete start acting when the first crack appears and have the ability to absorb and redistribute the loads (or energy), so that the SFRC will still be able to bear loads even after the formation of cracks. In fact, SFRC has a ductile behavior or toughness and therefore, that surplus of flexural capacity from the plastic phase (post-crack ductility) can be used for design of structure when deformation must be controlled like slabs or for structures where deformations controlled  the design like underground linings. It is the reason why, for the same thickness, a SFRC slab on ground can support higher loads than a conventional concrete slab.

In the event of there being sufficient tension in the slab to overcome the resistance offered by the fibres a fully visible crack will develop within the concrete. The fibres, by continuing to bridge the crack, will continue to offer resistance to the crack becoming wider, effectively pulling the concrete on either side of the crack back together. This is the exact mechanism relied on with conventional mesh reinforcement to control crack widths.

Technical Advantages:

Here are the  main technical advantages  of SFRC compared to  a  normal concrete:

  • Very good crack resistance
  • High impact resistance
  • Increased shear resistance
  • Better corrosion resistance
  • Better overall performance slab
  • High energy absorption
  • High fatigue resistance
  • Increased flexural strength
  • Full reinforcement of the slab

Economical Advantages:

Building a slab with SFRC will have the following advantages:

  • Faster and cheaper construction (from 10 to 30% less usually)
  • Slab less thick so less concrete
  • No wiremesh installation and less labour needed
  • Faster concrete pouring, especially with laser screed equipment
  • It is possible to do more surface in one day
  • It is possible to reduce the numbers of saw-cuts
  • Less maintenance of the slab (less cracks, less saw-cuts, better fatigue and impact resistance, etc)

Design Excellence: Design in accordance with TR34 Standard

The company’s team members are experts in the design of Industrial Grade  heavy machinery floors, special chemical resistant Floors, VNA floors, super flat floors, high racking floors and narrow aisle floors. Warehouse floors have a very stringent requirement with respect to the operation of VNA trucks and hence require extraordinary flatness and levelness. They specialise in optimum designing of such demanding floors. The team is well-trained and well-equipped to execute such specialised projects and has successfully laid floors as per TR-34, DIN and ASTM standards for Defined Movement floors.

Industrial floors are subjected to extensive and heavy use and often onerous wide ranging loading conditions. Well designed and constructed floors impact positively and significantly toward the life cycle costs of a given structure. Such floors provide reduced downtime for operations and maintenance cost contributing toward improved profits for the client.

For Further Details
KASTURI METAL COMPOSITE (P) LTD
1005 (A) 10th Floor, Bhumiraj Costarica, Plot No 1 & 2, Sector 18, Sanpada, Navi Mumbai 400705
Ph: 022 2781 2385
Email: info@steelfiberindia.in
Web: www.steelfiberindia.in

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