Constructing a factory floor is a highly specialized process that requires precision, meticulous planning, and a thorough understanding of both materials and environmental factors. Mistakes made during construction can result in costly repairs, production downtime, and even safety hazards. Below is a comprehensive guide to common mistakes in factory floor construction, along with detailed solutions to help ensure the longevity and performance of your floor.

Inefficient Base Preparation:

The base layer of a factory floor is critical for its stability. If the soil beneath the concrete slab is not properly prepared or is unsuitable, such as using expansive soils like black soil, it can lead to major problems. For example, black soil tends to swell when it absorbs moisture and contract when it dries out. This swelling and shrinking cause movement beneath the concrete slab, which can result in cracks and structural failures.

What to do instead?

Conduct a thorough soil inspection before construction. If expansive soils are found, remove them and replace them with a suitable material. Ensure the base is properly compacted to achieve the desired density and stability.

The following steps need to be taken if the base has expansive soil:

2. Incorrect Concrete Mix Design:

The strength and durability of the factory floor heavily depend on the concrete mix used. A common mistake is using a concrete mix with a grade lower than M25. Such low-grade concrete does not have sufficient compressive strength to withstand the heavy loads and constant wear and tear typical of factory environments. This can lead to premature cracking and floor failure.

What to do Instead?

Concrete of grade M25 or higher is engineered to withstand higher compressive forces, making it ideal for factory floors where heavy machinery, forklifts, and other equipment exert constant pressure. Always use a concrete mix of at least M25 grade for factory floors. Collaborate with a structural engineer to ensure that the mix design is appropriate for the specific load requirements of your factory.

3. Impurities in the Concrete Mix:

By definition, concrete is a homogeneous mix of cement, sand, and aggregate. Sometimes, we add certain additives to alter the curing time, strength, etc.

However, under no circumstances should concrete contain impurities such as wooden flakes, sawdust, or similar materials.

While treating floors, we often find wooden pieces embedded in the concrete, which is clearly a mistake made by contractors. Contaminants such as wooden pieces or debris in the concrete mix can lead to serious problems later. For example, wood embedded in concrete can absorb moisture and swell, creating internal pressure that can crack the concrete from within.

What steps to take:

Use clean, sieved sand and thoroughly inspect all aggregates to ensure that no foreign objects make their way into the mix. This results in a more uniform and stable concrete structure. Ensure that all materials are carefully checked before mixing. Use sieved sand to eliminate debris and regularly inspect the mixing equipment to ensure it is free of contaminants.

4. Improper Curing:

Curing is a critical step in concrete construction that involves maintaining adequate moisture in the concrete after it has been poured. Inadequate curing can lead to a weak surface that is prone to cracking, dusting, and other defects because the concrete does not fully hydrate, resulting in reduced strength.

Common Mistakes in Curing Concrete:

Proper curing ensures that the concrete continues to hydrate, increasing in strength and durability over time. Keeping the concrete moist during the curing process prevents premature drying, which can cause surface cracks.

You can also contact your contractor or structural engineer to recommend plastisizers and curing compounds for a fast curing process in minimum time.

5. Not Using Polypropylene (PP) Fibres

Factory floors are subject to heavy traffic, and without reinforcement, small cracks can quickly turn into larger structural issues. PP fibres, when added to the concrete mix, act as micro-reinforcements that help distribute stress and prevent crack propagation.

Also, in case of small cracks, fibres hold concrete together and don't let the cracks propagate.

PP fibres increase the tensile strength of concrete, making it more resistant to cracking. These fibres hold the concrete together when cracks begin to form, preventing them from spreading.

Add PP fibres to the concrete mix during preparation, following the manufacturer's recommendations. Ensure even distribution of the fibres throughout the mix to reinforce the entire structure.

As a rule of thumb, the recommended ratio for PP fibres is 100 g per cement bag.

General recommendation  is to use PP fibres of > 24 mm while using in concrete floors.

You may also contact your structural engineer for any special use cases.

6. Manual Levelling of Concrete:

Manually levelling concrete can result in uneven surfaces, even when performed by skilled workers. These undulations can cause machinery and equipment to bump or jolt, leading to increased wear and tear on both the floor and the equipment.

Advanced tools like a LASER screed, Trimex, or Vibratory Double Frequency (VDF) machines provide precise control over the levelling process, ensuring a perfectly level surface and eliminating human error.

Ask your contractor to use  the necessary equipment to level the concrete floor. Ensure that operators are trained and skilled in using these tools to achieve the best results.

7. Incorrect Design and Placement of Expansion Joints:

Concrete expands and contracts with temperature changes, and without properly designed and placed expansion joints, these movements can cause uncontrolled cracking.

Expansion joints allow controlled movement of the concrete, preventing random cracks. Proper placement and design of these joints ensure that the floor can expand and contract as needed without damage.

Work with an engineer to design an expansion joint layout that accommodates expected floor movement. Place joints at regular intervals and in areas where movement is most likely.

Read more details about this on our article <Write article heading and add link for the same>

8. Cutting Expansion Joints Too Late:

If expansion joints are not cut within 24-48 hours of pouring the concrete, the floor may start cracking on its own as it cures and shrinks. These uncontrolled cracks cannot be corrected later

Cutting expansion joints within the first 24 to 48 hours after pouring allows the concrete to contract naturally, reducing the risk of uncontrolled cracking.

Use a concrete saw to create clean, precise joints.

Read more details about this on our article How to Create and Maintain Long-Lasting Expansion Joints for a Factory Floor - https://www.rezovate.com/blogs-for-industries/how-to-create-and-maintain-long-lasting-expansion-joints-for-a-factory-floor

9. Using the Wrong Floor Topping:

For factory floors, not all surface toppings are suitable. Epoxy and polyurethane (PU) toppings, though popular, often lack the abrasion resistance required for heavy factory use. Over time, these coatings can wear down, exposing the underlying concrete to damage.

Specialised treatments like Odus offer higher abrasion resistance and durability compared to standard epoxy or PU coatings. These treatments are specifically designed for the harsh conditions of factory environments.

Read more details about this on our article - Odus Treatment vs Concrete Polishing - https://www.rezovate.com/blogs-for-industries/odus-treatment-vs-concrete-polishing

Consult with flooring experts to choose the right topping for your factory floor. Consider the type of machinery, nature of operations, and expected traffic when selecting a surface treatment.

Conclusion

Constructing a durable and long-lasting factory floor requires meticulous attention to detail and adherence to best practices. By understanding and avoiding these common mistakes and implementing the correct solutions, you can ensure that your factory floor will perform reliably under the demands of industrial use. Whether it's choosing the right materials, following proper construction methods, or using advanced technology, every step matters in creating a floor that will stand the test of time.