Large Pour Construction
Generally achieving flatness tolerances FM3 & FM4. Outputs for our manual lay techniques are normally up to 1,200m² being poured on a daily basis.
Our hand laying techniques can also be adopted to produce areas laid to falls allowing water etc. to run off to drainage discharge points, e.g. linear drains or gullies. This is particularly useful in warehouses producing drinks, in fish and meat processing areas etc. Areas of up to 1,000m² per day can be achieved dependent upon layout and falls.
Tighter tolerances can be achieved with careful planning and use of narrow bay construction.
Hand Laying Flooring Methods
Malin Floors have a highly skilled and experienced workforce that is capable of working not only mechanically but manually as well.
The skill sets and training of our teams allows us to carry out various hand laying methodologies with ease and in comfort knowing that whatever construction technique is adopted, our teams can execute the works with skill and achieving all the requirements of specification.
Reinforcement for this technique can also be traditional mesh and steel fibres. Traditional rebar solutions can also be catered for heavily loaded, suspended floor slabs.
The Malin Hand Laying construction techniques can also be used for producing External Hardstandings. Using this construction technique daily productivity can be doubled easily over the traditional long strip method. External areas are normally brush finished to provide a textured surface for traffic and ease grip during winter conditions.
Traditional Long Strip Construction
Our teams are sometimes called upon to use a traditional long strip method of construction whereby shuttered forms are laid out in long narrow strips, around 4-5m wide. This allows for greater level control typically down VNA racking areas where DM1 tolerances are called for and where the large bay Laser Screed methodology cannot be used. The narrow strips allow heavy highway floating and flattening techniques to be carried out across the long strip length of the individual slabs. Very high tolerance slabs used to be known as ‘Superflat’ or ‘Cat 1 slabs’.
Out put per day using this method is restricted to around 500-700m² per day per team.
Upper Floor Slab Construction
Malin’s highly skilled workforce often works on upper floor slabs on metal decking, pre-cast planks and many other different forms of decking.
Reinforcement can be positioned prior to casting slabs and usually takes the form of traditional mesh and some rebar located at strategic locations.
Malin do not supply the metal decking which is normally installed by the decking manufacturer prior to our arrival on site. Malin then install the reinforcement and place concrete. Output is normally based upon around 800m² per day although larger areas are possible under ideal circumstances.
Types of Work
A mechanised system of laying concrete floor slabs where a machine trims, levels and vibrates concrete up to 350mm deep with the correct specification concrete. Tolerances up to FM1.
High Tolerance Floor Slabs
Precision levelled slabs are often required for many types of installation. For Free Movement tolerances where very tight tolerances are required over the whole slab. This may well be for specialist equipment e.g. air cushion transport etc. are being used, we can lay slabs to FM1 (Free Movement). For racking areas the tolerance changes to Defined Movement and Malin can lay large areas of slab to DM1 (Defined Movement). With both specification Laser Screed construction methodology can be utilised.
Upper Floors and Mezzanines
These can be slabs on metal decking and pre-cast planks. These are normally laid using hand screed methodology. Alternatively, the smaller Laser screed systems, copperhead, S840 type machines can be used if access and egress can be provided. Tolerances depend upon stiffness of the supporting structure which includes structural steelwork and decking/planks.
Hand Screeded Flooring
Generally used for smaller areas of offices, small sheds etc. where the mechanised system cannot be used. Tolerances are generally FM3 or FM4
Specialist slabs situated inside an insulated panel box building. Sizes can vary from just a small unit inside a retail outlet to a whole building. The slabs are normally hand laid although the smaller Laser Screeds, Copperhead and S840 can be used if access and egress can be provided. Tolerances are dependant upon methodology used. If required very high tolerances, DM1 or similar can be achieved using the ‘long strip method’. More generally FM3 or FM4 tolerances are adopted using the hand lay systems.
Generally specified for outside slabs and roadways for traffic into and out of warehouses etc. The most common finish is a brush finish to provide a textured running surface for the vehicles using the hardstandings and roadways. Various techniques can be adopted using both mechanical Laser screed type systems and hand lay systems. These slabs are normally laid to falls into a designed surface water drainage system.
Ground Bearing Slabs
These slabs rely entirely on full support from the sub strata. The reinforcement detailing, and design is specific for controlling the drying shrinkage of the concrete.
Suspended Pile Supported Slabs
These slabs have reinforcement designed to distribute loadings into the concrete capable of spanning between a designed pile system. Reinforcement includes designed rebar, special designed mesh sheets and steel fibres etc.
Hydraulically Efficient Slabs to Falls
Mainly used in wet areas where the manufacturing processes include a washout water being drained away. Bottling plants, fish and meat processing plants all commonly use this system.
Multi Story Car Parks
Commonly laid to falls and having a brush type finish to provide grip for vehicles. Some carparks have other finishes applied to the finished concrete.
Waste Treatment Plants
Various configurations exist for waste treatment plants. Generally slabs are laid to falls but some areas are laid ‘flat’. Concrete has to be designed specifically for the type of waste being treated which can be very aggressive to concrete.
Various configurations exist for recycling centres. Generally slabs are laid to falls but some areas are laid ‘flat’. Concrete must be designed specifically for the type of waste being treated which can be very aggressive to concrete and extremes of temperature, up to 70º Celsius can exist between areas of concrete a small distance away. In other centres very aggressive machinery e.g. heavy face loading shovels, can be used and the concrete has to have a very ‘tough’ abrasion resistance. Joints need to be carefully considered.
Main Site Plant Resources
- 2 No S-22E Laser Screeds, these are the latest machines out of the world renowned Somero stable. Both machines have been upgraded to incorporate the latest roller plow head technology…….
- 2 No SXP-D Laser Screeds
- 2 No SXP Laser Screeds
- 2 No S-240 Laser Screeds
- 1 No S840 Laser Screed
- 1 No Copperhead X3
- 1 No Power Rake 2
- 1 No Miniscreed
- Numerous power float options to cater for all types and configurations of concrete floors.