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The global warehousing sector has undergone a dramatic transformation in recent years driven by an explosion in e-commerce activity. Leviat’s Sales Director, Paul Whitehead, examines the growth in mega-warehouses, distribution, and logistics centres and what this means for the design and performance of industrial concrete floors that have become critical to their daily operations.

The aptly named ‘Amazon effect’ has altered the very concept of the traditional warehouse. The dramatic rise in e-commerce sales and online-only retailers coupled with customers’ demands for next or same day deliveries, has driven the need for large physical storage spaces that allow the rapid and smart processing of goods. It is estimated that 150,000,000 sq. ft of extra warehouse space will be needed by 2035 which is equivalent to 2160 football pitches or 1500 large warehouses.

Today’s mega-warehouses are being built near major transport arteries linking them to global transport networks. These mega-warehouses are open 24/7 with traffic movements a continuous feature. Not only do they cover a greater square footage than their predecessors, but they are also taller to account for the huge racking systems that automation has allowed for, such as automated packaging systems, shuttle systems, racking systems and automated picking tech. Drones can be seen flying overhead to carry out inventories whilst automated guided vehicles (AGVs) carry, receive and transport goods.

The operational intensity of the mega-warehouse has placed greater demands on concrete floor slabs, particularly at free movement joints. These slabs must be able to manage increased load capacities to avoid slab failure which would then require expensive remedial work. A busy dock loading area or aisle being closed for repeated maintenance in a 24/7-hour logistics operation can result in costly remedial work and operational downtime.

Prefabricated Joints

To address these demands, a wide range of approaches to joint design have emerged including engineered innovations such as Isedio ProGuardJoint, a prefabricated leave-in-place permanent joint former and load transfer system which can eliminate the impact load entirely, ensuring that Material Handling Equipment is always in contact with both sides of the joint as it is traversed. Designed specifically for high performance internal and external concrete floors, this system allows flooring contractors to cast fast and flat high performing concrete floors. It is used where a free movement joint is required but can be adapted to be used where a tied joint is required. Featuring a unique asymmetrical plate dowel design for superior load transfer, the system allows up to +/-20mm of longitudinal movement along the joint and 25mm maximum joint opening across all floor classes meeting the requirements of the Concrete Society’s TR34 (4th Edition) classifications.

Edge protection at joints is another critical area of development. This system provides heavy-duty reinforcement to slab panel edges by way of two back-to-back solid, high specification, cold drawn steel sections (40mm deep x 10mm wide). This solid steel edge protection is designed to prolong the life on any concrete floor. Slab edge protection is used only in the case of the formed free movement joints. These joints have edge protection to prolong the life of the exposed slab panel edges, as the slab panels shrink away from the joint during the curing process. Steel edge protection reinforces the edges of the slab panels against impact loads from mechanical handling equipment (MHE) or depending on joint design used, can eliminate the impact load entirely, ensuring that the MHE is always in contact with both sides of the joint as it is traversed.

Seamless Capabilities

Futureproofing a warehouse floor can offer long term operational benefits by providing the flexibility to change racking layouts to accommodate new product lines. Joint systems designed to minimise or eliminate dynamic loading when trafficked allow for a flexible layout of racks and ensures the floor remains seamless to the forklift driver. By investing in flexible jointing solutions at the outset, this can reduce the likelihood of remedial work and unwanted downtime.

Prefabricated joint solutions are typically manufactured in 3m lengths and may be supplied in a standard design or a bespoke design to suit a specific project’s requirements. For example, the divider plate which performs as a leave-in place formwork can be either designed as a fixed depth divider plate which is available in any size to suit a joint of 90mm upwards, or a two-part adjustable depth divider plate system that can be adjusted on site to the correct depth without the use of any tools.

Sealant-free Repairs

Increasing demands placed on existing warehouse concrete floors have led to a rise in the amount of damage to concrete either side of construction joints in medium to high traffic zones such as access doorways and dock loading areas. As a response,  long-term repair solutions for damaged construction joints are now available without the need for traditional joint sealing. Certain designs incorporate a leave-in-place, sealant-free joint solution that prevents debris from entering the floor, thereby reducing ongoing maintenance needs and avoiding disruption to operations in busy logistics centres, warehouses, and factories.

Warehouse operations will continue to expand in both scale and complexity and so the performance of concrete floors will become a critical factor in ensuring a facility’s long-term functionality and efficiency. Innovations in joint design, such as prefabricated formers and load transfer systems to sealant-free repairs, can play their part in the operational resilience required by modern logistics facilities and safeguard against wear, downtime and costly repairs.

Leviat is proud to announce that Connolly products are now available in the UK. These leave-in-place formwork systems, including Key Joints, Expansion Joints, and Dowel Cradles have been available for over 30 years with constant innovation resulting in this comprehensive range of products designed to improve efficiency, accuracy, and durability in concrete pours—from residential footpaths to large-scale industrial slabs.

“We’re excited to bring the proven technology and engineering of Connolly products to the UK,” said Masoud Hashemi, Global Product Manager, Floor Joints and Shear Dowels at Leviat. “Our systems have been trusted across Australia and New Zealand for decades, and we’re confident they will bring significant value to the UK’s construction and infrastructure sectors.”

The UK launch includes a range of Connolly Key Joints (for contraction joints) and Connolly Expansion Joints (for expansion joints) in slab on ground applications. Backed by Leviat’s technical support for contractors and engineers, these products will be available directly and through local distributors.

For more information, please see our product literature below, visit Leviat.com or contact us on info.isedio.uk@leviat.com.

• Connolly EXJ Expansion Joint System Brochure
• Connolly Key Joint Datasheet

Engineered connection specialist, Leviat, has extended its market-leading Isedio range of industrial leave-in-place formwork joint systems with the launch of Isedio ProGuardJoint, an armoured edged protection and load transfer jointing system, specially designed to provide impact-free and smooth transition across concrete floor joints in high traffic industrial factories and warehouses.

Conforming fully with The Concrete Society’s TR34 4th edition, guide to design and construction of warehouse floors, the new Isedio ProGuardJoint reflects the growing customer preference for impact-free transition, featuring two wave-shaped top strips, precision machined to create sharp edges and a flat top surface, to ensure smooth, impact free transition of hard nylon wheeled abrasive materials handling equipment.

Supporting the steel top strips, which are anchored by shear studs to the concrete arrises on each side of the joint, are upper and lower divider plates, connected by a special fastener that allows simple adjustment to suit different slab depths. Special asymmetric plate dowels and sleeves transfer the load across the two adjacent slab sections, whilst allowing for up to 20mm lateral movement in each direction to accommodate contraction of the slabs. An adjustable intersection post is available for different slab depths, to create corners and 3-way and 4-way connections.

The joint is designed such that, once cast in situ, the two slab panels on either side begin to cure and shrink, at which point the joint separates, with one slab panel housing the sleeve and top strip and the other, the top strip divider plate and dowel. The dowel, embedded in both slab panels, bridges across the joint, providing load transfer, whilst the special wave pattern allows for 25mm joint opening, maintaining impact-free wheel transition across the joint.

Further information on design capacities, material specifications and tolerances are included in the Isedio ProGuardJoint Product Data Sheet and Load Transfer Information Sheet, both of which are available to download here.

Paul Whitehead, Sales Director for Isedio products at Leviat, looks at the five most important considerations for the specifier when it comes to concrete joints and how cracks can be controlled and minimised.

In a world of fast-track construction, the demands a concrete floor will encounter whilst occupied can be considerable. This is why the specification and installation of armoured joints are such critical considerations for commercial and industrial concrete floors.

For logistic centres and distribution warehouses, the integrity of concrete flooring has never been more important as any downtime will impact the bottom line for businesses, many of whom operate 24-7, 365 days a year.  Floor joints have become a significant feature for Facility Managers, Structural Engineers and Flooring Contractors in these high traffic environments as they allow safe transfer of loads, and accommodate the natural shrinkage of concrete as it dries.

The scale of these buildings also continues to grow becoming larger and taller, resulting in higher loading demands on floor slabs. The selection of or positioning of the wrong joint products could result in costly repairs, once the building is in use.

As an example, a common joint armouring cost for a typical 50,000m² concrete floor, would make up approximately 2-2.5% of the overall floor slab cost which is minimal. However, not selecting the correct product from the outset can result in downtime later down the line, increasing costs overall. Imagine having one or two aisles out of action for health and safety reasons, due to joint and material handling equipment damage, for several weeks in a 24-7 operation. The loss of revenue due to downtime could be huge. This is why even small details can have significant consequences in these warehouse environments.

Given the critical nature of floor joints in these demanding environments, it’s essential to understand the key considerations that go into their specification and installation.

Key considerations:

1. Correct product selection
   Precise engineering and correct product selection is crucial and typically involves a collaborative effort between the Flooring Contractor, Structural Engineer, and Flooring Consultant. For larger projects, a Flooring Consultant is usually appointed. These experts consider various factors, including traffic patterns (i.e forklift type and wheel specification), racking and layout, the presence of automation and robotics, and all material handling equipment. Even the product finish of the armoured joint – whether mild steel, galvanised steel, or stainless steel – plays a role in the decision-making process.
2. Aspect ratio and panel size
   While guidelines are not rigid, the optimal configuration for a slab panel is 1:1 or a maximum 1:1-1:5. Slab panels commonly range from around 25m x 25m or up to 40m x 40m maximum. It’s important to note that the larger the slab panel, the larger the joint opening.
3. Joint opening
   It’s essential to minimise the joint opening of armoured joints because the larger the joint opening, the more opportunity you have for joint impact and damage. Additionally, even impact free joints can become ineffective if the joint opening is not controlled. Typically, a 10-15mm joint opening is common but all joints will have limitations on what they can achieve.
4. Joint positioning and third party restraints.
   Concrete likes to shrink, move and crack, so positioning joints is important. When armoured joints are installed in locations where there are additional floor restraints to consider, this can restrict the joint opening, which could result in cracking. These aspects require careful consideration by both the Structural Engineer and Flooring Consultant.
5. Regulations and best practices
   In the UK and parts of Europe, the industry relies on a document known as TR34-4th edition, Concrete Industrial Ground Floors – A guide to design and construction which is currently in its fourth edition. While not strictly mandatory, it serves as a best practice guide for achieving the best possible concrete floor. It is often the case that prestigious projects typically require adherence to TR34 standards.

The stakes are high for all parties involved. An e-commerce business might want their floor insured for 10-15 years or more, with assurances that it won’t fail. This cascades down the chain to Structural Engineers, Main Contractors, and Flooring Consultants, all of whom need substantial insurance coverage to protect against potential failures in these massive facilities.

By carefully considering these factors, specifiers can select the most appropriate armoured joints for their projects, potentially saving substantial costs in the long run by avoiding premature failures, excessive maintenance, or the need for early replacement. Choosing the right floor joint from the outset can futureproof a concrete floor and lead to significant savings over the life of the building.

As 2023 draws to a close, Leviat would like to wish our wonderful customers and exceptional team a season filled with an abundance of joy, warmth, and cherished moments with your loved ones! We are immensely grateful for the collaborative efforts of our dedicated team and the unwavering support of our incredible customers.  

We understand that this period holds diverse meanings for everyone, and we celebrate the multitude of traditions and beliefs. Whether you celebrate Christmas, Hannukah, Diwali, Kwanzaa, Eid, or any other cultural observances, we wish you all a joyous, safe, and rejuvenating holiday season filled with love, laughter, and moments to treasure! 

Want to feel festive? Get in the mood for the holidays and watch this year’s Christmas video below!

Our offices will close at 5:30pm on Thursday 23rd December 2021 and re-open at our usual business hours on Tuesday 4th January 2022.

We wish you and your families a safe and relaxing holiday season and a very happy Christmas.
 
As 2021 draws to a close, we would like to sincerely thank everyone who has supported our business this year, including our customers for entrusting your projects to us and every member of our team for your dedication.

Certain to make a major impact at this year’s London Build exhibition (Olympia, 17-18th November 2021), is our Leviat stand. Leviat is a new name in the building industry, but a company with more than 275 years of combined construction experience behind it.

Formed in November 2020, Leviat brings together some of the world’s most well established and most trusted connecting, fixing, and anchoring brands, including, in the UK, Ancon, Halfen, Helifix and Isedio. The latest innovative product developments from each of these brands will be showcased on our stand (F32).

Completing our London Build 2021 line-up of innovative developments is Helifix SockFix, a mechanically grouted sock anchor system. These concealed, non-disruptive anchors help stabilise damaged masonry and preserve existing buildings in poor repair, as a more sustainable alternative to demolition.

This exciting line up of new products reflects Leviat’s expertise, skills and reach across a very broad spectrum of construction and heralds the company’s commitment to innovative construction which is, in every respect, better, safer, stronger and faster.