Brand of concrete for floors in the production room. Technology of production and pouring of concrete industrial floors. Requirements for floors in production halls

Industrial concrete floors are usually used for commercial purposes - in warehouses, parking lots and other industrial premises. Their main difference from conventional concrete floors is high strength, fast filling and resistance to various influences and loads. Next, we will take a closer look at their features, types and consider the manufacturing technology.

General information

Industrial premises are subjected to increased loads, frequent temperature changes, operation in conditions advanced level humidity, etc. Therefore, concrete industrial floors are made from special mixtures, and seals, heat and waterproofing materials are also used.

Such floors are especially in demand in stores and shopping malls. However, they are also used in private construction, for all kinds of outbuildings and garages, which are constantly subjected to significant loads.

The main types of industrial floors

All concrete coatings can be divided into two groups:

• bulk;
• Ordinary.

Not very reliable, as their surface is prone to cracking and abrasion. Therefore, they are not suitable for industrial use.

Concrete industrial self-leveling floors are of the following types:

Pouring technology

The technology of industrial concrete floors may vary, depending on the type of coating, however, most often it consists of the following steps:

• preparations;
• Enough difficult process laying and sealing the surface;
• hardening.

Now let's take a closer look at all these steps.

Training

The preparation of the base is carried out as follows:

• First of all, it is necessary to clean the surface of dust and dirt, as well as flaking and crumbling areas.
• Then the highest point of the surface is determined, from which it is necessary to measure the layer thickness of at least 10 cm. If the concrete is laid on sand, then the thickness of the screed must be at least 15 centimeters. The zero level should be marked along the perimeter on the wall.
• Next, reinforcement is performed, for this a special reinforcing mesh is laid or metal bars. The reinforcement should be located in the thickness of the concrete, so wooden bars are placed under it.
• Then the beacons are installed, which are used as a special metallic profile. Installation of beacons is carried out on lumps of gypsum mortar. For the accuracy of installing the rails, self-tapping screws can be screwed along the edges, which will allow you to adjust the height of the beacons from the floor.
  As a result, all beacons should be located in the same horizontal plane and correspond to the zero level.
• In conclusion preparatory work, a damper tape is glued to the wall around the perimeter at the junction of the floor with the wall.

fill

Fill instructions are as follows:

• The solution is distributed over the floor and leveled by the rule.
• Concrete must be compacted using vibrating screeds or internal vibrators.
• The final leveling of concrete is most often carried out using the rule. I must say that even when using modern concrete pavers, experts do not completely refuse to level the surface with their own hands using the rule of thumb.
• After pouring, it is necessary to give the surface time to "survive". As a rule, this takes about 6 hours.

Advice!
Before pouring the floor, it is necessary to provide openings for communications.
If this is not done, then later you will have to perform diamond drilling holes in concrete.

hardening

Next, hardening dry mixes are rubbed into the surface - topping. This operation can be performed manually or with the help of special carts. After applying the topping, it is polished with an aluminum rule or special machines.

In the photo - topping

Note!
To ensure uniform drying of concrete, it must be periodically moistened with water during the first 10 days using a paint roller.

After the concrete has hardened, if the surface area is large, perform expansion joints. For this, reinforced concrete is cut with diamond wheels.

If self-leveling floors are used as reinforcement, it is necessary to wait for the concrete to dry completely, and then pour liquid solution and level it with a special roller with spikes.

Here, perhaps, are all the main features of the implementation of industrial concrete flooring.

Conclusion

An industrial concrete floor is a reliable coating that can withstand very heavy loads and operation in adverse conditions. There are several options for obtaining such a coating, each of which has its own advantages and disadvantages, so the choice should be made depending on the tasks assigned to the floor covering.

From the video in this article you can get Additional information on this topic.

The floor cloth plays one of the key roles in the arrangement of the premises of the production workshop.

Workshop floors can be various materials. The choice of them and technology depends on the conditions under which industrial floors for the workshop will be used.

Requirements for floors in production halls

There are special requirements for workshop floors. Their main property should be quality. The performance of facades, walls, structures of the building itself also influences the decision on the issue of future coverage, because the floors are the basis of all this.

In workshops, they must withstand significant mechanical loads. If in industrial premises traffic is provided, the floors here must have the same properties as industrial floors for parking lots.

The cloth in shops will give in to influence of vibration, chemical "attacks" of any liquids, oils, greasings. AT various types production also uses acids, solutions of alkalis and salts, varnishes, solvents - such substances can get on the floor in different quantities and destroy it.

Hopes are pinned on floors in workshops that they will not react to temperature changes. This is especially true for rooms with access to the street. The areas adjacent to the exits need to be strengthened additionally. Cold-resistant, of course, should be floors in freezers and cold rooms.

For workshop coatings, abrasion resistance is relevant. They are regularly subjected to pedestrian and traffic loads. They can get various abrasive substances that contribute to abrasion. Therefore, the thickness of the floor in garages and transport shops must correspond to mechanical loads.

Durability and high maintainability - that's what is required from the floors in the shop. In addition, they still need to be arranged so that the repair itself can be carried out without stopping. production process, which is very important.

The floors in the workshop are necessarily non-slip, so their surface is made rough. Cleaning and cleaning is the easiest. For example, floors in food production need to be cleaned quite often, so the sanitization process should not be time consuming.

Since people are constantly working in production shops, an important indicator is appearance floors. From him, to some extent, at least accuracy and aesthetics are expected.

Sometimes, in order to take into account all the features of the production process, the floors on different areas workshops should be arranged from different materials.

Self-leveling floors in production halls

Today, self-leveling floors are often used in workshops. Materials - polymer, then the canvas will please with strength, fire safety, wear resistance.

On the self-leveling floors there are no seams in the workshop, so dust does not accumulate on them, and they retain their original aesthetic appearance for a long time. Polymer floors in workshops are characterized by the absence of dents and other flaws on them.

Self-leveling floors are poured directly onto a specially prepared concrete base. Therefore, they are simple in the device. Low material consumption and high quality characteristics make them cost effective.

Screed floors are used chemical industry, because their resistance to chemicals can be envied.

The texture of the self-leveling floor in the workshop can be smooth and rough - thus, sliding is regulated.

Cleaning is done by floor washing machines or by hand. Wherein detergents and hot water will not damage the polymer sheet.

Polyurethanes or epoxides are used for the installation of self-leveling floors in production shops. The sphere of use of polyurethane coatings is woodworking, machine-building, machine-tool workshops. They are anti-vibration resistant. Epoxy floors are indispensable in the premises of the food, pharmaceutical and chemical industries, as they are resistant to chemicals.

Concrete floors in workshops

Concrete floors in workshops are often laid in the so-called pure form, when the screed itself already serves as the floor. Since the composition has a loose structure and easily absorbs moisture and various chemical solutions, then it is better to strengthen the top layer with the help of toppings or impregnations.

Topping for the floor in the production hall can be of any type - depending on the expected loads. In workshops where they are insignificant, quartz topping is enough. But if the production process involves heavy loads on the canvas, then it is better to use a corundum or metal shaving topping.

A dry floor screed is unlikely to be suitable for coating in production workshops. It does not tolerate moisture well, therefore, due to contact with water and other liquids, it is easily destroyed. In principle, such a screed is acceptable, but only in those workshops where moisture on the floor is excluded.

Impregnation of concrete can be carried out with polymer mixtures. Such floors acquire the properties of dustlessness, elasticity, water resistance, strength.

Workshop floors experience chemical, mechanical and thermal stresses. Respectively flooring for industrial premises must be suitable, durable and able to withstand heavy loads that can destroy the floor. Great for this - polymer industrial floors.

For the food industry, there are separate types of floor coverings. It all depends on the direction food production. Below you can find more relevant information by following the industry areas and the link:

• Industrial screeds for meat processing plants
• Industrial seamless floors for fish production
• Floors for breweries
• Polymeric antioxidant floors for dairy industries
• Floors against high temperatures for bakeries
• Inexpensive, budget industrial floors for food production

Polymer self-leveling floor perfect for production, workshop, industrial building for the following objective reasons:

• Resist mechanical stress movement of loaded carts, cargo carts - metal, rubber wheels, heavy foot traffic
• High degree of wear resistance;
• Durability of polymer self-leveling floor
• Anti-slip property
• Not subject to chemical attack
• Elasticity - absorb impact loads
• Resistance to low, high temperature conditions, sharp fluctuations
• Antistatic coatings
• Wide range of coating types
• Eco-friendly flooring - for safe operation in the pharmaceutical and food industries.

Depending on the above requirements for your premises, we select the most suitable look(epoxy or polyurethane resin) flooring and the type of self-leveling floor that will match in all respects.

Pouring industrial floors

As polymer floors for industrial premises and workshops, the specialists of the SOP company use the following types of self-leveling floors :

• The device of a highly filled self-leveling floor- monolithic coating with the addition quartz sand surface rough or smooth. The color is selected according to the RAL table.Industrial floor thickness from 1 to 6 mm.
• The device of a thin-layer polymer floor- smooth polyurethane two-component mixture with a thickness of 0.3 to 0.8 mm.
• Strengthening the top layer of concrete- compaction of the top layer is achieved by grinding and saturating the concrete with polyurethane impregnation deep penetration. flat concrete surface takes on a shine.
• Antistatic device(conductive) floor- smooth, colored flooring, easy to clean and according to electrical conductivity DIN IEC 61340-4-1. Coating thickness ranges from 0.6 to 2mm depending on requirements.
• Anti-slip coating - rough polymer floor with the addition of quartz sand or ceramic balls. Significantly increases the rate of adhesion to the floor.

More detailed information you can get by calling one of our specialists. At Free check out technologist to your facility in Moscow and the Moscow region, he will select the appropriate coating, taking into account the operating conditions of the premises and the loads on the floor.

The cost of work on the installation of self-leveling floor

The cost of installing industrial floors for industries depends on several factors.
These are factors such as the technical condition of the base, concrete strength, requirements for wear resistance, surface and special conditions for self-leveling floors, working conditions of specialists, location of the object - Moscow and the Moscow region - one price, for other regions of Russia, an alternative cost for installing industrial floors and many other factors affecting the cost of the floor. In details .

Works on the installation of industrial floors were successfully implemented by the specialists of the company "Creating an Excellent Floor":

• at food enterprises, incl. meat processing, dairy and tobacco industries
• at the enterprises of chemical, pharmaceutical, pulp and paper, light industry
• at enterprises of mechanical engineering and metalworking and woodworking
• in the electronics industry
• at the enterprises of the nuclear industry and energy

Our works:

Milk production (Dmitrov)
Production of spare parts for buses (Moscow region)

Can be found on industrial enterprises, warehouses, workshops- wherever large areas a device is required that is reliable, resistant to loads, aggressive environments, temperature changes, etc. Floors are one of the most important elements of any building, and the efficiency of the production process and the health of workers directly depend on their quality and condition.

For industrial premises represent one of the most best options flooring, as they have a high degree hygiene, chemical resistance and low abrasion resistance. In addition, they are easy and clean.

Epoxy, polyurethane and methyl methacrylate industrial floors

There are many various kinds industrial polymer coatings. By type of material can be distinguished epoxy, polyurethane and methyl methacrylate floors. Also, polymer floors can be made of other materials, but these can hardly be used when installing floors in industrial premises.

In industrial premises, the most common based epoxy resins having increased strength, antistatic, moisture resistance, adhesion to various grounds and wide color spectrum. The disadvantage of epoxy floors is their low elasticity, which is why such coatings cannot be used under negative temperatures, strong vibration and shock loads.

Polyurethane floors elastic and hard at the same time, which allows them to be used in industrial premises with a moving floor or constant vibration. Polyurethane is able to withstand high abrasive loads, but is not able to cope with strong chemical influences.

Methyl methacrylate floors have excellent appearance, high temperature resistance, impact resistance and water resistance. One of the main advantages of methyl methacrylate is their ability to quickly cure - they can be ready for use in just a few hours. In addition, methyl methacrylate coatings can be laid at low temperatures. The disadvantages of acrylic floors include their rather high cost, the complexity of the work and not the highest abrasive resistance.

Painting, self-levelling and highly filled polymer coatings

In addition to the composition, industrial polymers can be classified by filling and layer thickness. Allocate:

Thin-layer or paint coatings having a thickness of up to 1 mm and low level sand content (up to 50%).

Highly filled floors having a thickness of 5-8 mm and high level sand content (80-85%).

Self-leveling or polymeric self-levelling are good decision for industrial premises with a high and medium level of mechanical stress. Such floors have high wear resistance and resistance to vibrations and aggressive environments. Self-levelling floors have smooth surface making them hygienic and easy to care for.

Paint or thin-layer polymers are used most often when it is necessary to avoid dust, protect industrial concrete floors from external negative influences or improve aesthetic properties. concrete base. A thin layer floor has a relatively low cost due to lower material consumption, however, it is subject to rapid wear and cannot be used in rooms with high humidity air and strong mechanical stress.

Highly filled polymeric floors, compared to other types of industrial floors, have the highest resistance to strong impacts, wear and various abrasives. The structure of such coatings in its properties resembles polymer concretes– coatings do not delaminate and do not crack even under high loads and significant temperature changes.

In addition to the composition, filling and layer thickness, polymeric ones for industrial premises can have a different texture: matte, glossy, rough.

How to choose a polymer floor for a production room

When choosing a polymer for a production facility, first of all, it is necessary to determine all the requirements and characteristics that the future floor covering must meet. After all, different polymer materials have different qualities, each of which is optimal for a certain type of room. For example, for freezers, printing houses and industrial premises with high humidity, polyurethane self-leveling floors are best suited, and for factory shops and laboratories with precision instruments and production machines - epoxy self-leveling floors.

As for industrial premises of pharmaceutical and Food Industry The best option would be methyl methacrylate floors. In addition, it is advisable to use such coatings in cases where the time interval between the installation of the floor and its commissioning should be minimal, but compatibility should be taken into account. performance characteristics methyl methacrylate floors and requirements for a production facility. are one of the best options for industrial workshops, warehouses and laboratories, as they are reliable, practical and have high performance and aesthetic qualities.

Recently, self-leveling floors have begun to appear in many apartments. Many have already appreciated their advantages, but not everyone realizes how often such self-leveling floors are used in industrial premises, their scope is quite wide. They are used in warehouses, hospitals, educational institutions and car boxes, industrial refrigerators and shopping centers, chemical and food industries.

The word industry is quite voluminous, it should be divided into several areas. And each direction has its own requirements and conditions for the floor surface.

At most enterprises, quite stringent requirements are imposed on floors in terms of resistance to temperature fluctuations, resistance to shock and constant physical impact, to the effects of chemicals or other aggressive environments.

Ordinary concrete pavements are far from always able to withstand the expected loads and that is why concrete bases are covered with a self-leveling floor.

Hard to find today the best alternative than self-leveling floor, because it does not require frequent repairs, and is quite simple to install.

By the way, if the repair of such a floor was needed -.

By pouring the floor at the enterprise, you create a seamless surface that hides minor irregularities, and much less time is spent on this than when installing the same concrete slabs.

By installing such a surface in a store, you can add a pigment component and give the desired color to the entire floor.

But as already mentioned, a self-leveling floor for industrial premises requires individual approach, depending on the requirements put forward and production conditions.

Let's look at the example of several main types of production

Alcohol production and food industry

At such enterprises, self-leveling floors must have anti-slip properties, be easily cleaned of contamination, and withstand both mechanical and chemical loads.

At the same time, such production is quite often checked by regulatory authorities for the presence of hygiene certificates, allowing the use of this type of floor mixture in the food industry.

Do not forget that even at the same enterprise, different workshops may have different requirements for flooring. For example, requirements for antistatic properties are likely.

For each section, the coating is selected based on the planned loads. In case of excessive loads, it is recommended to use self-leveling floors with methymethacrylate resins or epoxy mixtures.

Such coatings are well cleaned and are resistant to mechanical stress. To create an antistatic effect, copper plates are laid in the floor, then they are covered with a conductive layer.

car washes

Application in the garage

The use of self-leveling floors in car washes is almost mandatory.

Such a floor will not require repair for a long time, and will have excellent water repellency, compared to the usual concrete pavement despite constant contact with water, salts and various cleaning chemicals.

Cars will constantly drive on such a surface, which means that the properties of resistance to abrasion will come in handy. A separate item is anti-slip properties, constantly wet floor, they will be very useful, and will help to avoid accidents.

Chemical industry

Self-leveling floors for industrial premises in the chemical industry differ in their characteristics, since the main emphasis is not on mechanical stability, but on temperature changes and on the effects of chemicals.

The use of conventional concrete bases in such conditions is not possible, as they quickly deform.

The composition of the mixture is selected for specific chemical substances This process is best left to professionals.

For example, if exercise stress will be limited only by the weight of a person, and exposure to strong acids is not expected, then the concrete base is coated with additives to enhance chemical resistance.

Conversely, if the movement of mechanized devices is planned, and the risk of spilling acids is high, then it is necessary to use a composition with an epoxy compound with the addition of quartz sand.

Warehouses

In warehouses

Self-leveling floors in warehouses make it possible to forget about repairs for many years, but it should be remembered that the period of use, first of all, depends on the load.

If some part of the floor is subjected to heavy loads very often, experiences shock and vibration, thermal or chemical influences, then this part will collapse much faster.

floor coverings storage facilities require resistance to abrasive substances, since sand and moving electric cars create a lot of friction. The movement of goods is associated with the risk of falling of these very goods, which means that the resistance to point impacts should be increased.

Anti-slip properties will prevent work injuries. The appearance of the floors is also important; it is allowed to pigment the mixture with a suitable color tone.

Recommendation: Polymer coatings do not tolerate poor preparation of the substrate. It is impossible to pour the polymer on a dusty surface with cracks, all shortcomings must first be eliminated, the base must be dedusted and the entire surface thoroughly primed to improve adhesion properties.

Under your conditions, trust the professionals. They will help you decide on all the necessary additives and will be able to make a mixture just for you.

Briefly about installation

The requirements for the installation of self-leveling floors in residential premises are incomparable with the installation of floors in production.

The surface to be increased load, must have a base suitable for this load. It can be high-strength concrete or concrete plates; concrete surface using dense fillers such as granite, quartz; fiber reinforced concrete.

Regardless of the type of base, it is subject to requirements for tensile strength, it must be at least one and a half megapascals, so that when loaded on polymer coating base is not cracked.

The base must have good properties adhesion so that the polymer does not peel off. It is extremely important to observe the humidity of the concrete base, it should not exceed four percent, since the moisture remaining in the base during evaporation can affect the adhesion to the polymer. And it will be difficult to predict where the vapors will break through the surface or the polymer coating will simply swell due to high blood pressure from below.

Filling the floor in enterprises is a rather voluminous work that requires some mechanization. We do not recommend doing it on their own, it is better to involve specialized companies for this.

If construction bulk coating in the workshop of the enterprise coincided with a negative street temperature, then in this case you can continue to work.

A mixture with methyl methacrylate substances allows installation up to minus thirty degrees Celsius, without the use of so-called "heat boxes".

Such coatings are the only modern solution for filling the floor in the cold season. Their high cost is offset by the ability to continue installation regardless of temperature.

Summing up, let us once again denote that industrial floors are designed taking into account the type and strength of the expected impacts and a number of other conditions that may be put forward depending on the place of operation.

Designers in their work on industrial and civil buildings, use SNiP II-B.8-71, containing about a hundred of the most commonly used types of floor coverings.

The main requirements are as follows:

• Resistance to mechanical and physical stress.
• Availability of hygienic and sanitary certificates.
• Economic efficiency of investments.
• The appearance of the resulting surface should not require additional costs.

This article is not technical instruction or methodology for the arrangement of floors in industrial enterprises. Here we have summarized the main aspects that you need to pay attention to.