specifications for good quality concrete floor - tolerance rev j
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Face Construction Technologies, Inc.
CONCRETE FLOORS ASIA
Jeff Rogers
Specifications for Good Quality Concrete Floor Tolerance
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Why do we need good floors?
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Higher efficiency
Fewer trucks & operators needed
Increased productivity
More pallets moved each day
Reduced truck maintenance and breakdowns
Loads can be lifted and stored higher
Reduced floor maintenance
Less cracking & spalling
Clean and dust free
Safer to operate on -
Fewer wor
kplace injuries
Racking installation goes faster
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What is Flatness & Levelness?
FLATNESS (FF)
Relates to the bumpiness of the floor. An unflat floor is bumpy and wavy.
FF is measured over two 300mm slopes.
LEVELNESS (FL)
Relates to the tilt or slope of the slab. An unlevel floor is sloped or tilted. FL is measured over 3 meter spacing.
Ideally a floor should be constructed bothFL T and LEVEL.
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Floor Flatness Levelness
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Flatness & Levelness
Most users find that Flatness is more
important than Levelness.
Flatness comes from finishing tools and
techniques used, and from the concrete mix.
Levelness comes from formwork and strikeofftechnique and tools used.
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2 Types of FloorsRandom & Defined
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Random Traffic Floors~99% of all floors are Random Traffic
Traffic patterns can go anywhere on thefloor, in any direction.
Examples: Hotel Lobbies & Hotel Sleeping Rooms
Open Warehouses Office Space Factories & Assembly Plants Stores
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2 Types of FloorsRandom & Defined
Defined Traffic Floors
Only ~1% of all floors are Defined Traffic
Traffic patterns must always follow the exactsame path.
MHE is wire-or-rail guided Think of Railway Tracks
Older Defined Traffic Floors will show the path wear marks, skid marks on the floor
Example: High-Bay Narrow Aisle Warehouses
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2 Types of Floors
require 2 different types of specs
Random Traffic Floors: FF and FL (The F-Number System)
Gap under the Straightedge type specs
TR-34 Free Movement
Defined Traffic Floors: Fmin (Part of the F-Number System)
TR-34 Defined Movement
We will talk about specs for both types of floors
We will talk about all 3 tolerance methods
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Random Traffic Floors
The F-Number System FF FL
The F-Number System was invented byFace Construction Technologies, Inc.
FF Measures Flatness
FL Measures Levelness(Local Levelness) ACI (American Concrete Institute International)recommends the use of the F-Number system
How to measure Flatness?
Change in slope over a short distance If no change in slope, the floor is Flat. If slope changes a little, the floor is nearly flat. If slope changes a lot, the floor is not flat at all. A floor can be flat without being level
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F-Numbers
FlatnessBumpiness
FF
Levelness
Tilt
FL
F-Numbers are linear.An FF 40 is twice as flat as an FF 20 & half as flat as FF 80.
Most people agree that Flatness is much more important
than Levelness
Levelness is generally specified ~2/3 to 3/4 of Flatness
Flatness is almost always specified higher than Levelness
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The Change in Slope
is a Measure of Flatness
Not very FlatLow FF Number (FF 17) To get an acceptable floor, the bumps may need to be ground
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The Change in Slope
is a Measure of Flatness
Medium-High Flatness (FF 47)
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The Change in Slope
is a Measure of Flatness
Very FlatHigh FF Number (FF 94)
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The Change in Slope
is a Measure of Flatness
3 profiles comparedFF 17, 47, 94
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Many measurements are collected
to calculate FF (Flatness)
Data are collected in straight lines evenly spaced
over the floor in both directions
Must collect enough data to be statisticallysignificant
Software automatically calculates the change in
slope at every step
Software automatically calculates FF from the
raw data
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Difference in Elevation over 3 m spacing
is a Measure of Levelness
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Many measurements are collected
to calculate FL (Levelness)
Data are collected in straight lines evenly spaced
over the floor in both directions
Must collect enough data to be statisticallysignificant
Software automatically calculates the changes in
slope at every step
Software automatically calculates FL from the
raw data
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Typical Section (Pour)
F-Number Report
Job: NSWCML Surface: FREEZER
Combined Section Section: F3-----------------------------------------------------------------------------------------------
Measured FF: 72.93 Specified FF: 65 Min Local FF: 40
Measured FL: 54.69 Specified FL: 50 Min Local FL: 3018 percent exceeds minimum local FF of 40.
28 percent exceeds minimum local FL of 30.---------------------------------------------------------------------------------------------------------
Run Name FF FL Readings
EW1 75.53 47.17 55
WE2 69.80 65.24 55
NS3 97.13 69.58 55
SN4 61.36 47.35 55
---------------------------------------------------------------------------------------------------------184 Z-Readings 220 Dipstick Readings
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AJB Group
Fillo Drive
Summerton
Project Summary Job Name: Fillo Drive
Surface: warehouse SOG
------------------------------------------------------------------------------------------------------------------
Measured FF: 86.26 Specified FF: 35.00 Min Local FF: 35.00
Measured FL: 63.25 Specified FL: 25.00 Min Local FL: 25.00
41 percent exceeds specified FF of 35.
42 percent exceeds specified FL of 25.
------------------------------------------------------------------------------------------------------------------
Total area of surface: 19200
Area measured: 5439
------------------------------------------------------------------------------------------------------------------Section Name FF FL Size
POUR1 90.46 83.52 663
POUR4 116.11 75.68 927
POUR9 148.55 100.97 668
POUR15 77.25 60.62 678
POUR17 63.94 57.59 941
POUR22 51.45 31.16 893
POUR25 65.50 41.70 668
Typical Project Summary (Overall)
F-Number Report
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TR-34 does not discriminate well
between good floors and bad floors
Almost everyone who has used both TR-34 &
F-Numbers prefers F-Numbers
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Only 3 choices are possible for Free Movement Floors
TR-34 Free Movement Specs
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Note that TR-34 always overemphasizes Levelness
and underemphasizes Flatness
Almost everyone who has used both TR-34 &
F-Numbers prefers F-Numbers
TR-34 Overemphasizes Levelness
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TR-34 Free Movement Limitations
Only 4 Spec choices are available
All 4 Spec choices are relatively low (No High Tolerance Available)
Far too much emphasis on Levelnessnot enough on
Flatness
Not enough statistical data collected for Levelness
In the past, collecting Levelness data required a 2nd(different) instrument and two people
Can collect data for TR-34 with Dipstick
Still takes longer than F-Numbers to collect data
Almost everyone who has used both TR-34 &
F-Numbers prefers F-Numbers
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Gap under Straightedge
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Straightedge Limitations
Straightedge test does not measure the utility of
the floor Only measures amplitude of flaws
Does not measure wavelength or frequency
Does not measure Levelness at all
The most common Straightedge Spec is 5 times
better than most floors Nobody can pass this spec
ACI recommends against using this spec try to avoid using Straightedge Specs
If you must use this spec, you can now collect
Straightedge data with Dipstick
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Defined Traffic Floors
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2 Methods of Measuring
Defined Traffic Floors
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Measuring Defined Traffic Floors
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Fmin Report
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TR-34 Defined Movement Specs
Only 3 choices are possible for Defined Movement Floors
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Floor Profilers
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Many different profilers
are available
Not all of them produce the
same quality results!
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Data from 3rd
Party Test Lab- 10 test lines repeated on the same floor
Collected with their 6-year-old Swiveling Profiler
Note that all profiles are identical
Be careful to choose a quality profiler
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Rolling Profiler Data from 3rdParty Test Lab - 10 test lines on the
same line on the same floor Collected with their new model Rolling Profilerthe most expensive
profiler available
Which profile is the correct one?
Each profile is different, & F-Numbers are all different
Be careful to choose a quality profiler
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Data from Face Company - 10 test lines on the same floor
Collected with 8-year-old Swiveling Profiler Different Swiveling Profiler, different operator
Note that all profiles are identical
Be careful to choose a quality profiler
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Merged Data from 3rd
Party Test Lab & Face Company- 10 test lines on the same floor
Collected with 6 & 8-year-old Swiveling Profilers
2 Different Profilers, 2 different operators, same floor
Note that all profiles are still identical
Be careful to choose a quality profiler
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Closing Remarks
Choose a measuring system (Spec type) that
meets your needs.o Be careful to ensure that you specify a high enough flatness
o And dont overspecify levelness.
o ACI strongly recommends F-Numbers.
TR-34 has several limitations that detract
seriously from its utilityo Far too much emphasis on Levelness
o Not enough data for statistical significance
o
Too few spec choices
Gap Under the Straightedge specs just dont
work wello Dont use this system if you can use any other
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Closing Remarks
If you dont measure the floor, you wont know if
the floor meets your spec.
Use an instrument that is both precise and
accurate.o Poor quality instruments lead to disputes.
Measure and report results promptly to all
concerned parties.
Concrete floor companies can learn from theprofiles & F-Numberso They can improve their floors based on the data and profiles
from the instrument.
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References
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ACI 117o StandardSpecifications for Tolerances for Concrete Construction
ACI 302.1Ro
Guide for Concrete Floor and Slab Construction
ASTM E-1155o StandardTest Method for Measuring Flatness & Levelness of Floors
Technical Report # 34o
Guide to Design and Construction (The Concrete Society)
ACI 360o Guide to Design of Slabs on Ground