Maintaining the integrity of warehouse floors in New Zealand and Australia is essential for safety and operational efficiency. Heavy machinery, constant foot traffic, and environmental factors can cause wear and tear on even the most durable concrete surfaces.
Early identification and repair of these issues can save time and money on extensive concrete floor repairs.
In this article, Tim Walker, Managing Director at CoGri Limited (NZ), looks at the top five maintenance issues commonly found in warehouse floors throughout Australasia.
1. Damaged Warehouse Floor Joints
Floor joints are critical for accommodating concrete shrinkage. However, they do represent a weak point of a floor and are often the number one issue that warehouse managers face.
There are two main categories of floor joint issues:
i) Issues with Armoured Joints
What are the main causes of damage to armoured joints?
Armoured joints are designed to protect the edges of concrete slabs from damage.
Unfortunately, they aren’t always effective – particularly if they suffer from misalignment or other issues during installation, high amounts of curl, or a nasty impact from forklift wheels, forks, or other equipment.
As well as construction challenges or accidents impacting an armour joint, we also come across issues where lower quality joint products fail due to build quality or a small amount of wear and tear – so, fair warning that not all armour joints are created equal and it’s best when building a new warehouse to stick with well-established brands like Isedio and Piekko and be wary of alternatives that don’t have a long term track record.
There has also been a trend for more complex joints with wave profiles being introduced to distribute loads more evenly across a joint …
… but in my experience, these can cause more issues than they solve.
In particular, we see far more installation problems with these wave-style joints. They are also often more susceptible to curl and to impact damage than a traditional joint.
Whilst the concept sounds good in theory, in the real world they are simply not performing as well as conventional armour joints.
Many are now being removed from brand-new floors due to various issues.
What are the consequences of damaged armoured joints in warehouse floors?
Damaged armoured joints lead to spalling edges and uneven transitions between slabs, creating bumps that disrupt operations and damage machinery like forklifts. Once the joint is damaged the issue will tend to worsen exponentially if not correctly repaired.
How to solve the problem of damaged armoured floor joints
Professional floor slab joint repair involves assessing the condition of the armoured joints, and typically cutting them out and reforming the joint arris (edges) with a high-quality epoxy mortar, such as CoGri Arris Repair Mortar or CoGri Rapid Mender.
For joints with wave profiles or cover plate-type joints, the repair will be much wider than for a traditional armour joint and is a lot more time-consuming and expensive.
ii) Issues with Saw Cuts
What are the problems associated with saw-cut joints?
Saw-cut joints are intentional cuts in the concrete to control cracking.
The saw-cut joint should be filled with an appropriate sealant to help support the arris (edge) of the saw-cut and also to stop it from filling with debris. Problems arise when these cuts are not carried out correctly during construction and ravel/spall from early cutting, are improperly spaced such that the joints open wider than is appropriate, or when the joint sealant deteriorates.
We have also seen examples of significant issues with saw-cut steel fibre slabs, particularly external pavements because, at a certain point, the steel fibres can yield, meaning there is no reinforcing acting across the sawn joint. At that point, the joint can start to deteriorate very quickly and will lose the ability to transfer load.
What are the consequences of neglected saw-cut joints?
Improperly maintained saw cuts can start to spall and chip away –
which often leads to very quick deterioration of the joint, posing tripping hazards and causing equipment damage or disruption. In worst-case situations, particularly in steel fibre slabs, the saw cut can lose its ability to transfer load and start to pump or fail structurally.
How to maintain or repair saw-cut joints
If attended to early, concrete slab repair and maintenance for saw cuts includes cleaning out the joints and refilling them with a suitable joint filler/sealant, such as CoGri Rapid Seal.
Regular inspections help ensure that the joints remain effective in controlling cracks. For saw cuts with more serious issues – for instance, large spalls, the joint needs to be rebuilt similarly to a damaged armour joint. In really bad cases, with structural failure occurring at a saw cut, the slab may require partial replacement, or dowels may need to be retrofitted at the saw cut to reinstate load transfer.
2. Cracks in Concrete Floors
What causes cracks in warehouse floors?
There is an old saying among concrete contractors and experienced engineers …
… “Concrete is grey, and it cracks”.
There is a myriad of reasons that concrete will crack – including non-structural cracking such as crazing, plastic shrinkage cracking, early thermal cracking, and restrained drying shrinkage cracking. Cracks can also be structural, caused by overloading of the slab, indicative of poor ground conditions, or due to design and construction issues.
What are the consequences of ignoring cracks in your warehouse floor?
Because of the wide range of possible types and causes of cracking, it is important to get an expert opinion (for instance from Face Consultants Ltd in New Zealand, or Australia) if cracks appear in your warehouse floor.
For example,
some types of cracking can be repaired once and for all using an appropriate repair solution, whereas others could be indicative of a bigger problem or ongoing issue. Therefore, any repair will only be temporary and might require more drastic action or regular monitoring and maintenance.
Cracks with widths that are roughly greater than 0.2 mm will tend to widen or chip and spall over time if not repaired – although this will depend on the type and volume of traffic at the crack.
Solving the problem of cracks in industrial floors
Appoint an expert in concrete floor repair to fill and seal cracks using specialised materials – typically polyureas or epoxies. In severe cases, sections of the slab may need to be replaced or resurfaced to reinstate integrity.
3. Surface Wear and Dusting
What causes concrete floor surface wear and dusting?
Continuous abrasion from small, hard-wheeled traffic, chemical spills (acids), and design or construction issues such as poor finishing or curing, can lead to a weak surface and delaminated warehouse floors.
What is the consequence of a worn floor surface?
Worn surfaces produce concrete dust which can be an issue for stock and staff within a warehouse.
In extreme cases, the surface can begin to wear away very quickly exposing aggregate and making the floor uneven, impacting forklift operations.
How to solve the problem of concrete warehouse floor wear
Warehouse floor repair options for weak and dusty surfaces include applying a new surface coating such as a CoGri Fastfloor IT pump screed, an epoxy coating, or densifying and trowel polishing the floor to extend the floor’s lifespan.
4. Spalling and Surface Pop-outs
What causes concrete floors to spall?
Spalling refers to the breaking or chipping of concrete surfaces, often resulting from physical impacts.
In warehouses, spalling and other surface damages frequently occur due to tenant activities such as:
- Damaged Bollards: Collisions with forklifts or vehicles can damage bollards, which in turn crack or chip the surrounding concrete.
- Gouging of the Surface: Dragging heavy equipment or materials can gouge the concrete floor.
- Bolt Holes: Installing equipment or shelving often requires drilling bolt holes into the floor. If not properly sealed or later removed when equipment moves, they leave the floor vulnerable to damage.
- Construction issues: Such as the inclusion of contamination like polystyrene, seeds, or clay in the slab during the casting and finishing process. These materials can create voids or weaknesses that lead to “pop-outs” on the surface over time.
There are also less common causes of these sorts of issues, like freeze-thaw damage that can occur with persistent cycling of freezing and thawing (such as at freezer door thresholds), or Alkali-Silica Reactivity in the concrete mix.
What is the consequence of surface damage to warehouse floors?
Surface damage compromises the floor’s integrity, and if a spall occurs in a trafficked area, it can impair the operation of equipment and also continue to degrade quickly.
Best solutions for floor spalling and surface pop-outs in your warehouse
Repairing spalled areas and surface damages involves removing any loose or damaged concrete and applying appropriate patching materials. For issues caused by deleterious materials, a thorough survey of the floor is recommended to make sure areas aren’t missed.
5. Steel Fibres Exposed on the Surface
What causes exposed steel fibres in concrete floors?
Steel fibres are often added to concrete mixes to enhance strength and durability.
However, improper mixing, finishing techniques, or excessive wear can cause these fibres to become exposed on the surface. This has become a very common issue in New Zealand, particularly when contractors are trying to cut corners or cut costs to be competitive in the floor market.
The consequences of exposed steel fibres:
Exposed steel fibres create a weak area of the slab’s surface that will be less durable and more prone to dusting or future spalling/chipping than the surrounding floor. They can also lead to rust spots on the floor, affecting both aesthetics and integrity.
In some environments, the exposed fibres can be a serious safety issue …
… for instance:
in a storage facility, where the fibres could inadvertently get mixed into animal feed or other products like bulk dairy powder.
How to solve the problem of exposed steel fibres in warehouse floors.
For isolated areas with exposed steel fibres, it may be possible to clip out the offending fibres and repair the small spall with an appropriate repair mortar. For large areas with exposed steel fibres, it may be necessary to apply an epoxy coating or pump screed as part of a comprehensive concrete floor repair and fully reinstate the long-term quality of the surface.
Why Preventative Measures Are So Important for Productive Warehouse Floors
Regular inspections and maintenance are vital in preventing common issues featured in this article.
Implementing a proactive maintenance plan helps identify problems early, reducing the need for extensive concrete floor repairs.
Why Choose Us for Your Warehouse Floor Repairs
We excel in providing comprehensive industrial floor repair services for warehouses in Australia and New Zealand, from minor crack fixes to complete floor slab joint repairs. Utilising industry-leading techniques and high-quality materials, we ensure your warehouse floor remains safe and fully operational.
Call us today for fast, friendly advice from an experienced and knowledgeable team of concrete flooring specialists.
Tim Walker
Tim Walker is the Director of Face Consultants (NZ) and CoGri Limited (NZ). He has two decades of experience in the industry and provides the link between the Logistics Industry and Property and Construction; matching the requirements of one with the capabilities of the other.Contact Tim and his team today or follow us on LinkedIn:
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