Concrete mezzanine floor: the solution for working with robotics
In recent years we have seen an increase in the use of robotics in warehouses. By robotics we mean, for example, a shuttle system or conveyor technology. We mainly see an increase in requests for mezzanines in combination with robots The finish of a regular mezzanine often does not meet the requirements when using robotics.
In order to anticipate to the development of robotization and the needs of our customers, we have designed a mezzanine 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 sustainability.
A mezzanine in combination with a shuttle system, has challenges in terms of flatness and stability of the surface. The vibrations and deflection of a standard floor can cause the system to malfunction. This mainly happens with a standard intermediate floor with, for example, chipboard.
A concrete floor can be installed up to flatness class 4. 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 4 times as large as a chipboard floor.
We have researched in the field of; “point loads”. A point load is a concentrated load at one specific point. The weight of a shuttle, in combination with the movement of products, 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 system to function properly. With the use of a concrete mezzanine, the influence of the shuttle on the floor is much less than a chipboard mezzanine.
We also conducted research into the sustainability of the concrete floor. A shuttle system frequently runs on 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 lasts up to fifteen years. This results in wear and tear, which results in expensive repairs.
A concrete floor hardly wears. If this does happen, the worn spots are easy to repair. The investment to fix these areas on a concrete floor is much lower than when using, for example, chipboard (conventional flooring).
Test, test, test
The research and innovations took place in our test room in Bleiswijk. But we don’t stop here! We can perform many more durability, wear-and-tear and other tests. We like to translate the specific wishes and needs from the client into a test case. In this way we can meet your wishes, so that your investment is more than worth it.
Project Indoor Farming
At the moment we are finishing a project with a mezzanine with concrete finish. It concerns a building of 3,500 m² and includes a concrete mezzanine of 3,000 m². 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, for example, a factory hall, office, warehouse or shop. The challenge during this project was the climate and conditioning of the compartments. A concrete mezzanine was therefore the 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 floor with steel and concrete.