It may seem stretching credulity to say that before choosing wire-guided lift trucks one should consider potential floor problems because these could swing the choice of truck from one method of guidance to another, like optical or laser guidance that are independent of floor considerations. This gives an indication of just how critical and lulling floors can be to a company’s cost-effective warehouse operation over the long term yet there is still much floor neglect caused by the mistaken belief that a concrete floor is indestructible and so can be ignored.
Some floor problems, of course, cannot be foreseen, because they may not emerge until after some years of heavy duty usage. A good example is localised sub base compression. This can play havoc with wire-guided trucks because the floor construction joints become uneven and so cause frequent truck malfunctions. At one time the problem could have involved major costly and disruptive structural slab repairs. Today, however, high resin foam can be pumped into the voids beneath affected slabs, followed by rebuilding the joints with a high performance epoxy mortar. This method of pumping resin foam can even be used where large areas of a warehouse floor have dished owing to poor subsoil conditions, causing high bay racking to collide with high level VNA trucks. Previously, the solution would have meant very costly, disruptive pile driving.
Other floor problems are more readily obvious and usually relate to health and safety issues. A good cleaning and maintenance regime will not only reduce accident risks but it will also mean less repair bills for industrial trucks caused by pothole damage and slippery floors. It could even reduce warehouse energy costs. Cargo dust, for example, can be burned onto the polycarbonate lenses of high pressure sodium lamps owing to the lamps’ heat generation. With light performance greatly impaired, maintenance costs would rise.
As if all the problems associated with installed new and old floors were not enough, there are even cautionary tales before floor installation or repairs begin – the choice of the right provider. In this, one should avoid falling into the trap of choosing primarily on price because, as with choosing forklifts, it is the floor’s life cycle costs that should be given pre-eminence. Part of the problem in floor contractor choice is that comparing like for like is not always straightforward. To reduce the risk, one should consider using a specialist flooring contractor to take responsibility for the complete flooring package design, through production, with appropriate insurance guarantees. Buyers should ensure that they are being given quality materials fit for purpose.
Satisfying oneself on quality control procedures is important because any quality deficiencies cannot be eradicated and costly compromises are often the only solutions. It is most important to check that like is being compared with like because there are key differences between, for example, traditional sawn-cut slabs and ‘jointless’ SFRC slabs. Beware of promises, because there is no substitute for experience. A specialist contractor will show a quantifiable track record spanning all areas of the business and will be an active member of reputable associations. If a tender price is so cheap it seems too good to be true it probably is and relies on cheap, unskilled labour. A poorly installed floor could mean subsequent remedial grinding. And never forget that not only should your floor contractor have a good record but also a financially stable one.
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