Project Key Facts
- Project Type - Cold Store
- Location - Grangecastle
- Products - Alpha Joint 4010, Quatrz Dry-Shake
- Client - Cuisine De France
- Engineer - Malone O'Regan
- Main Contractor - Bennett Construction
Konfloor LTD were contracted to design, supply and install jointless steel fibre reinforced floor slabs to a new 45,000m² production & cold store facility for Cuisine De France new global headquarters.
The slabs to all areas of the facility had to be constructed on consecutive days over a 5 week period. Panel sizes averaged 1,900m² with an average 380m³ concrete poured per day.
The production area had a 190mm jointless slab reinforced with 40kg/m³ of Dramix 65/60 steel fibres. This slab design allowed for various point loads from machinery and racking the heaviest of which was 250kN on a 200mm x 200mm base plate. Due the jointless nature of the slab & heavy loadings Permaban's Alpha Joint 4010 was selected. A natural colour dry shake was applied at 5kg/m² to act as a fibre suppressant and surface hardener.
The cold store, which would eventually be cooled to -25c, had an initial 100mm concrete heater mat that encased the glycol heating pipes. Two layers of insulation totalling 500mm deep were then placed on the heater mat. The finished floor had a 250mm jointless slab (again reinforced with steel fibres) To accommodate racking leg loads of 190kN back to back on a 275mm square base plate.
All areas of the building required the slabs to be constructed to FM2 “special” tolerance. To ensure this was achieved Konfloor utilised their SXP laser screed which was equipped with high flotation tyres to enable it travel over the underfloor insulation without damaging it.
The floor slabs to all areas were constructed within the 5 week programme and the finished slabs were surveyed by FACE Consultants confirming FM2 “special” tolerance had been achieved.