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Warehouse / logistics

Warehouses live or die by their floor slab: dusting, worn joints and broken edges slow every forklift. Racking anchors, crane rails and a dry roof complete the job.

Warehouse cut in section with pallet racks, with the floor slab surface and its joints highlighted in orange

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Solutions in build order

What this project needs, step by step

Low-pressure sprayer coating a fresh concrete slab with curing compound while water evaporates from the uncoated part Concrete curing Curing keeps water in young concrete so it gains strength and does not crack or dust. In Pakistan's heat and dry wind it must start within minutes of finishing, by wet curing or a sprayed curing compound. 7 steps Fresh concrete slab with hardener powder scattered and power-trowelled into a hard top skin, and a sealed saw-cut joint. Warehouse floor hardeners (dry-shake) New warehouse and factory slabs get a hard, dust-free wearing surface when a dry-shake hardener is trowelled into the fresh concrete and cured straight away. Existing dusty slabs can be densified with a liquid hardener. 7 steps Floor section: concrete slab, primer, thick epoxy layer and a top coat being rolled on, with a sealed floor joint. Epoxy industrial floors Epoxy floors give factories, warehouses, workshops and labs a seamless, dust-free and easy-to-clean surface. Success depends on a strong, dry slab, mechanical preparation and a trained applicator. 7 steps Floor joint with steel edge angles and orange sealant over a foam rod, and a heavy wheel rolling towards it Floor joints in car parks, warehouses and roads Saw-cut, expansion and connection joints in floors that carry people, cars, forklifts or trucks. The sealant must take both traffic and movement, and the joint must be sized for it. 6 steps Existing concrete with resin-filled drilled holes holding new steel bars and a threaded rod fixing a steel plate. Chemical anchors, rebar & dowels Chemical anchors fix bolts, threaded rods and new reinforcement bars into existing concrete or masonry for extensions, railings, machines and services. Load capacity depends on the design, hole cleaning and base material, so safety-critical work needs an engineer. 7 steps Crane rail on a continuous grout bed along a concrete runway beam, with crane wheels running on the rail. Crane rail & runway grouting Overhead and gantry crane rails in workshops, steel mills and ports sit on grouted sole plates fixed with holding-down bolts. A high-strength, non-shrink grout with good fatigue and impact resistance keeps the rail level under repeated wheel loads. 6 steps Steel column base plate with grout poured from a raised box on one side, flowing fully underneath to the far side. Base plate & bearing grouting Steel columns, bridge bearings and equipment sit on a layer of non-shrink grout that carries the load into the foundation. Choose the grout by gap depth, mix it with only the specified water, and pour it continuously from one side. 7 steps Flat roof section with an exposed coating on the slab, turned up and over the parapets and into the drain outlet. Exposed roof waterproofing A liquid-applied membrane that stays open to sun and rain on a flat or sloped concrete roof (chhat). Use it on a new roof once the slab is 28 days old, or to refurbish a leaking roof before the monsoon. 6 steps Two concrete slabs on columns with a gap between them sealed with orange sealant over a round foam rod Building expansion and movement joints The gaps between building blocks, slabs, walls and roofs that let the structure expand, shrink and settle. They need a sealant or tape matched to the movement, a correctly sized joint and a backer rod, or water gets in and edges break. 7 steps