Technical Data

CLF Superflat Floors

LASER GRINDING, FLOOR SHAVER, SELF-LEVEL SCREEDS AND FLATNESS MEASURE FOR SUPERIOR, SUPERFLAT FLOORS

Flatness is all-important in many warehouse floors, where the main challenges are the efficient use of space, equipment and labour. Very Narrow Aisle (VNA) racking systems maximise space utilisation. Warehouses with high racking systems need to have exceptionally flat floors as even the slightest inconsistency at ground level can have significant consequences for the operation, as an uneven surface may cause the vehicle to tip, or stock may be packaged unevenly, and create safety hazards for employees.

There are essentially two methods for defining floor flatness requirements. Floors are divided into Free Movement Areas (FM) and Defined Movement Areas (DM).

• TheFMcriteriaiswheretrucksoperateatlowlevelinrandom,non defined directions, when moving such as marshalling areas, block stacking areas and aisles greater than 2.8m wide.

• DMareasrefertosystemswherethetrucksareconstrainedtodefined, fixed paths such as Very Narrow Aisle (VNA).

These specifications can be reached through a number of methods.

LASER GRINDING

Top of the range laser grinding machines incorporate three and four headed planetary grinding heads, used for the preparation of almost any concrete surface. The grinding machines use diamond grinding technology in conjunction with an advanced dust extraction system to grind, remove, smooth, hone and polish a concrete, stone or marble surface

The machinery is designed for dry and wet operation in a wide variety of applications. This includes the removal of residual contact adhesives – such as bitumen - from concrete slabs after the removal of previous floor coverings such as carpet, vinyl and parquetry. The machinery can also be used for the removal of residual cement-based adhesives used when laying ceramic and porcelain tiles. The machinery easily removes paint or epoxy coatings from concrete slabs, together with trowel marks and other surface irregularities, and will enable the smoothing of rain-damaged slabs and exposed aggregate in worn concrete.

SF 01

These laser grinder machines are described as a unique balance of design and tooling. Combined with the patented twin motor Dual Drive Technology, it provides users with unmatched control, power and multifunctional range of applications.

Capable of high production rates, with its 12,5 kW of grinding power, CLF’s large fleet is capable of grinding up to 1000 m2 per day.

The grinding machines offer:• Reliability• Highproductionrates• Lowconsumablecostpersquaremetre• Enhancedoperatorcontrol• Dustlessapplicationforbothpreparationandpolishing

applications.

Floor grinding

Grinding the aisles at Dischem’s DC to DM specifications

BETTER SOLUTIONS FOR CONCRETE FLOORS

Superflat Floors

Theradio-controlled950RXlasergrinderwhichisdesignedforgrinding large areas, while built-in dust extractors ensure that work can be carried out more safely and efficiently

The 500 manually-operated laser grinder is powered by a 4 kW motor and has a grinding pressure of up to 130 kg.Automatic Levelling Laser (ALL) system. The ALL system consists of a rotation laser and a mounted receiver, which automatically controls the machine during the grinding process, thereby ensuring that the floor surfaces are ground to an accuracy level of up to FM1 and CAT1 flooring. The ALL system is ideally suited to warehousing applications with high bay storage facilities, where forklifts are required to raise stock to high levels.

FLOOR SHAVER

In the field of grinding, the Floor Shaver is the machine with the most highly developed technology. It provides the perfect solution for a fast, safe and superflat grinding of your warehouse floor. The Floor Shaver works completely automatically with a precision and speed far superior to anything else on the market - and all this at an extremely competitive price per meter of aisle treated.

Advantages:• 100%automaticandiscontrolledwithoutinterferenceby

the human hand. This guarantees utmost precision with consistency in quality

• Itoperateswithoutacombustionengine,andisthereforeamuch more environmentally friendly solution

• Itoperateswithoutapplyinghydraulicoil• Itcreatesverylittlenoise• Itisextremelyflexibleandcanbeusedunderthemost

difficult of circumstances• Itiscompactandfast,minimizingthetimeneededfor

preparation• Ithasahighcapacity–everyFloorshavercangrindupto

200 meters per day• GuaranteedDIN15185andVDMA• Guaranteedoperationalspeedafterultraflatgrinding.

Technical Data SF 01

FAST TRACK PUMPABLE SELF-LEVELLING SCREED

Self-level screed is a rapid hardening cement based screed for levelling floors where quick setting is essential. The self-level screed can be hand applied by trowel (0 - 20mm) or can be pumped (4 - 20 mm). For pumped applications, an 8 mm average thickness would be a typical expectation on a reasonably level base.

Self-level screeds can be used for fast-track refurbishments and new construction and for smoothing floors in areas subjected to heavy loads, such as factories, workshops, warehouses and distribution centres.Top of the range laser grinding machines incorporate three and

four headed planetary grinding …

The Floor Shaver can fit into narrow aisles and grind the specific area to exact tolerances

The Floor Shaver can grind up to 200 m per day

Superflat Floors

Advantages• Quicksetting• Self-levelling• Canbepumpedupto2000m²perday,undersuitable

conditions• Walkonafter2-4hoursundernormalconditions.• Cannormallyapplycoveringsontoa10mmthickscreedafter

24 hours.• Pumpableorhandlaid.• Singlepackjustaddwater.• Proteinfree,willnotharbourbacteria.

Surface preparationThe base slab or screed should be sound with a minimum thickness of 40 mm and with a minimum compressive strength of25MPa.Allsurfacesmustbeclean,mechanicallysoundandfree of laitance, dust, grease and oil. Vacuum abrasive blast cleaning is the preferred method of surface preparation. Wet grinding followed by vacuuming may also be used. All holes in the concrete or screed which are deeper than 40 mm should be sealed before applying an acrylic primer and then the screed.

Technical Data SF 01

Hardening and drying timesThe self-level screed can be walked on after 2 - 4 hours, and may be sanded at joints if required 24 hours after application.

Coverage1.7kg/m²permmthickness17kg/m²at10mm25,5kg/m²at15mm

Pumpable self-level screed is a rapid hardening cement

Can be pumped up to 2 000 m2 per day, under suitable conditions

Superflat Floors

ApplicationPourorpumpthemixovertheconcretesurface.Forpumpedapplication, ensure the continuity of electricity and water suppliedissecured.Pumpthescreedontothefloorinacontinuous operation, feeding fresh material into a wet edge. The screed will level out to a smooth, even finish. Where necessary, release small air bubbles from the newly laid screed with a trowel, spiked roller or a tee-bar. This practice must be adopted within 5 minutes of application to avoid interfering with the final levelling properties.

FLATNESS MEASURE

There are 2 basic floor categories – Free movement traffic and defined traffic. Defined traffic floors fall into 3 divisions – Superflat, Cat 1 and Cat 2 and specific to very narrow aisles (VNA) where forklifts and reach trucks travel 1.5m wide aisles between storage racks with the aid of a wire guidance system or rails. For these material-handling vehicles to operate effectively and economically strict surface regularity specifications (Property1,2and3)arerequiredsothattheappropriateperformance of the floor can be achieved.

OurRackTrackProfilographisusedtomeasurefloorsurfaceregularity, operates in the exact path of the truck and measures both transverse and longitudinal profiles.

How can one achieve a defined traffic aisle flat floor in existing distribution centres/warehouses?

1) Concrete Floor Grinding – either spot grinding of high spots orlaserlevelgrindingtoacertaindepth.OncetheRackTrackProfilographhasmeasuredthefloorforflatness,levelnessandtransverse properties laser level grinding would be the preferred option to bring the floor up to Superflat, Cat 1 or Cat 2 quality.

Some careful grinding considerations are that spot grinding can sometimes cause rutting and excessive laser grinding can result in exposing of the aggregate and potential weakening of the concrete and one would have to apply densifiers and sealers.

Technical Data SF 01

What also needs to be addressed is the fact that although grinding can bring floors to “within tolerance” and enough to satisfy the specifications – it can still leave warehouse users with a floor that has the worst possible surface regularity allowed within the confines of the specification.

Constant long-term wheel traffic will also damage the concrete surface.

2) CLF Superflat Solutions – planning for the future immediately – all in one solution that brings aisles to superflat condition and allows racking to exceed 13m.

• Grindingofaislestoremovecoatings,epoxies,loosescreeds. Also levelling of curled construction joints.

• EvaluationandstabilizationofconstructionandmovementjointsusingtheScancemJointStabiliser.Restorespositiveload transfer, quick and easy permanent solution

• RackTrackProfilographtomeasurethesurfaceregularityaccording to properties 1, 2 and 3.

• OverlayofScancemSuperflat:a. Fast clean pumpable installation – reduce loss of earningsb.Highabrasionresistancec.Highwearresistancetowheeltraffic–10xbetterthan

concrete and long lastingd.Extremelyhighsuperflatlevellingtolerancese. Total economy from application to ongoing maintenancef. Movement joints mirrored in the screed with CLF

prefabricated movement profile

• Longtermmaintenanceprogrammeoftheaislestoensureeconomy and efficiency

CLF Superflat Solutions will ensure your operation runs at maximum and safe efficiency.

CLF RackTrack profilograph in operation

Superflat Floors Technical Data SF 01

Examples of plots measuring floor data produced with the Rack Track floor profiling machine

CLF Concrete Laser Flooring Pty (Ltd)POBox2589,Witkoppen,Johannesburg,SA•www.concreteflooring.co.zaTel:+27117045557•Fax:+27114621456•E-mail:peter@concreteflooring.co.za

Theinformationgivenisbasedonknowledgeandperformanceofthematerial.Everyprecautionistakeninthemanufactureoftheproductandtheresponsibilityislimitedtothequalityofsupplies,withnoguaranteeofresultsinthefieldasNortonConstructionProductshasnocontroloversiteconditionsorexecutionofworks.