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A first in Europe! Laser Screed & Post TensioningInnovative flooring makes all the difference at WM Morrison Supermarkets PLC
Demand for high performance flooring solutions is increasing as retail developers seek out specialist contractors who are able to complete often complex on site installations quickly and efficiently.
While fast and efficient construction is especially important for most commercial construction projects and can significantly reduce costs, developers also need to ensure that all regulatory requirements are met and optimum quality is achieved. Adhering to quality and best practice standards enables them to minimise the need for any future maintenance. By selecting specialist contractors that are prepared to invest in hi-tech, high performance solutions, using the best quality building materials, they can have the best of both worlds – efficiency and quality.
Stanford Industrial Flooring Ltd, the Midlands-based flooring contractor, was recently contracted by Carillion Building to design and install an innovative flooring solution for a new 70,000 m2 distribution centre in Kettering for WM Morrison Supermarkets PLC, one of the UK’s leading food supermarket chains. The contract required a high performance flooring solution, to meet all relevant regulatory and best practice standards, capable of carrying Morrisons’ sophisticated racking and material handling systems.
For part of the contract, in an area of 42,000m2, Stanford specified a highly innovative construction method, which involved the on site production of post-tensioned concrete slabs using laser screed machine technology. Using this tried and tested technology the contractor was able to ensure a high standard finish, while drastically reducing the overall production time from around 72 days to just 24 days. However, the solution was also complex and required a high standard of technical delivery.
Kevin Louch, technical director, Stanford Industrial Flooring Ltd, said:
“Our experience in applying laser screed machine technology enabled us to use this advanced construction system to manufacture post-tensioned slabs on site for the first time in Europe. As well as ensuring a quality finish, built to meet the specific requirements of the site, the construction system enabled us to complete the contract in just four weeks and using traditional methods would have taken three times as long.
“In order to complete the project successfully, we worked closely with Tarmac, who were able to provide reliable deliveries of ready-mixed concrete on a daily basis, ensuring back-up or contingency supplies were available if needed.”
The Tarmac team advised on the specialist requirements of the project from start to finish and in particular, on techniques for applying low shrinkage mixes. As leading providers of construction materials and services, Tarmac supplied around 250m3 of ready-mix concrete a day for the duration of the four week contract. The supplies were provided in 6.0m3 and 8.0m3 truck mixers from a single, dedicated batching plant, only six miles away from the construction site and timings could be varied to ensure the product arrived only when it was ready for use.
Rick Thurlow, area technical supervisor at Tarmac comments:
“The specialist nature of this project required a flexible response and we were able to ensure the local delivery of bulk quantities of quality ready-mix concrete as needed. As market leaders in concrete production and delivery, we know how to achieve the ideal mix for the job and we were pleased to share our expertise with Stanford.”
As well as the post-tensioned concrete slab, the contract also involved laying traditional sections of concrete slab in some areas and special joints were designed, made by Permaban, incorporating durable cover plates to allow for any potential lateral or longitudinal movement.
On completion, the entire project area was surveyed to demonstrate its compliance with the best practice standards of quality and safety. In particular, the project fulfilled the standard set by the Concrete Society for the performance of laser-screed machine floors – the TR34 3rd Edition free movement tolerance of FM2 Special.
Throughout the project, innovation and commitment to quality have been the driving forces for Stanford and for Tarmac. Rick Thurlow said:
“Supplying building materials for large scale construction projects is part of a daily business and this contract required a more tailored approach. We recognised that Stanford were aiming to achieve a highly innovative solution, which could potentially change the way that large scale concrete slab installations are carried out in the future and we wanted to be part of their success.”
Kevin Louch adds:
“In completing this contract, we have achieved a first for industrial flooring technology in Europe. We have been able to demonstrate the efficiency of laser screed technology and its suitability for large scale contracts.”
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