A concrete mezzanine floor: the solution for working with robotics
In recent years we have seen an increasing growth in the use of robotics in warehouses. By robotics we mean, for example, a shuttle system or a conveyor technology. We mainly see an increase in demand for mezzanines (floors) on which robots are used. But the finish of a standard storey floor often does not meet the requirements when using robotics. In order to grow with the development of robotization and the needs of our customers, we have designed an intermediate floor that is suitable in combination with robotics. This system, constructed from steel and concrete, has been tested in our experience center in Bleiswijk. These tests focused on aspects such as stability, point load and durability.
A storey floor that a shuttle system drives over has challenges in terms of flatness and stability of the surface. Vibrations are transmitted to the floor and if the surface bends, the system can malfunction. This mainly happens with a standard intermediate floor with, for example, chipboard.
A concrete floor can be installed up to flatness class four. The flatness of this finish is better than or equivalent to an architectural floor. Furthermore, concrete has a greater mass than traditional floor types, which means that vibrations are better absorbed. This mass is more than four times as large as a chipboard floor.
We have also conducted research in the field of a point load. A point load is a concentrated load at one specific point.
The weight of a shuttle, in combination with the products to be moved, results in a relatively high point load. As the shuttle moves across the floor, the floor must have minimal deflection and vibration for the shuttle to function properly. When using a concrete storey floor, the influence of the shuttle on the floor is much less than when using, for example, chipboard floor parts.
We also conducted research into the durability of the concrete floor. A shuttle system frequently runs a fixed path. The durability of the material used for a chipboard floor is limited to a low number of cycles, while a shuttle system, which lasts up to fifteen years. This results in wear and tear, resulting in expensive repairs. A concrete floor hardly wears out. If this does happen, the worn spots are easy to repair. The investment to treat these areas on a concrete floor is much lower than when using, for example, chipboard floor parts.
Test, test, test
We carried out the research and innovations in our test room (showroom) in Bleiswsijk. But we don’t stop here! We can perform many more durability, wear and other tests. We like to respond to special wishes and needs from the market so that we can develop these and test the result. We then convert the specifications of the customer’s project into a test set-up in our experience center. In this way we can answer specific questions so that the investment is more than worth it for you.
Project Indoor Farming
At the moment we are finishing a project with steel and concrete finishing. It concerns a building of 3,500 m2. This will include a concrete mezzanine of 3,000m2. In total, the storage space is over 8,500 m2, divided over three halls. In this project we are dealing with indoor farming. Indoor farming is stacked cultivation in layers in, for example, a factory hall, office, warehouse or shop. The challenge during this project was the climate and conditioning of the spaces. A concrete mezzanine was therefore a solution.
Specifications of the Indoor farming project
- Implementation of a combination of cold and hot rolled system
- Profile type C-400, IPE 600
- Floor type 50 mm. steel/concrete
- Local load 1,000 kg/m², 620 kg. concentrated load
- Suitable for conveyor technology
- Robotics on the floor
Test with us!
Do you have a case you would like to submit to us? We are always looking for companies willing to test and collaborate with us. Contact us via the contact form or call 079 – 361 06 63. We are happy to think along with you!
“We literally put our customers on a higher platform”
View the photos of a mezzanine with steel and concrete here