We cast and reinforce concrete floors for production, warehouse, and industrial buildings, as well as private properties. We handle substrate preparation, reinforcement, casting, and surface treatment, ensuring no gaps between work stages.
What the casting of a concrete floor includes
- Substrate preparation and leveling
- Installation of reinforcement mesh
- Installation of heating pipes, if the floor is to be heated
- Casting and compaction of concrete
- Surface smoothing with a power trowel
- Cutting of joints
Industrial floors and residential floors
Industrial and warehouse floors are expected to have high load-bearing capacity and a dust-free surface, as machinery moves and goods are stored on them. For such floors, the thickness of the layer, reinforcement, and wear resistance are crucial.
Requirements for residential floors are different. What matters there is flatness and what goes under the top covering, as tiles or parquet do not forgive unevenness. The layer thickness, reinforcement method, and concrete grade depend on the intended use and will be agreed upon before work begins.
Reinforcement
Concrete withstands compression well but performs poorly under tension.
Steel mesh is installed at a specific height before casting and works exactly where it is placed. Fiber reinforcement is mixed into the concrete and distributed throughout the entire mass. Which one is suitable depends on the load and the floor construction. For heavier loads and at the edges of the slab, steel mesh remains the standard choice.
Steel mesh or fiber reinforcement for an industrial floor?
On the floor of an industrial or warehouse building we use steel mesh or bar reinforcement when the load arrives at points: the legs of heavy racking, lifting equipment traffic, machine bases. On a slab with an evenly distributed load, and to control shrinkage cracks, either fiber reinforcement or steel mesh will do. On a larger industrial floor the two usually go together, fiber through the whole mass and steel mesh where the load is highest.
| Situation | What we use |
|---|---|
| Heavy racking, point loads, lifting equipment traffic | Steel mesh or bar reinforcement, with fiber where needed |
| Even load, control of shrinkage cracks | Fiber reinforcement or steel mesh |
| Slab edges and joints | Steel mesh, also when the slab has fiber |
| Residential floor and a small area | Fiber reinforcement or light mesh |
The reinforcement method is agreed before casting, because the layer thickness and the joint spacing follow from it. Send the use of the building and the expected load, and we will tell you which one suits.
Joints and cracking
Concrete shrinks as it cures, and that shrinkage has to go somewhere. If joints are not cut, cracks will appear wherever the concrete ‘decides’. A cut joint gives the crack a set place where it does not get in the way. Joints are cut when the concrete is hard enough for it, but before the shrinkage has built up tension.
In an existing floor we cut joints and openings with diamond sawing.
How the price is determined
The price is determined by the size of the surface, layer thickness, reinforcement method, substrate condition, slopes, and surface treatment requirements. A smaller surface costs more per square meter than a large uniform area, as preparation and equipment transport costs remain the same. Provide the surface area and the building’s intended use, and we can provide a price.
Frequently asked questions
How long should one wait after casting?
You can usually walk on it the next day. Concrete only bears full load once it has reached its full strength. Floor coverings should not be applied until the floor is sufficiently dry, as moisture would be trapped underneath. We will agree on the exact waiting time on-site, as it depends on the thickness and the conditions of the room.
Do you also perform casting over underfloor heating?
Yes. The piping is installed before casting, and it affects the thickness of the layer.
Should I reinforce with mesh or fiber?
Under point loads, for example the legs of heavy racking and lifting equipment traffic, steel mesh or bar reinforcement. Against an even load and shrinkage cracks, fiber or steel mesh. On an industrial floor we often use both, see the table above.
Why does the floor crack?
The most common reason is shrinkage that has not been accommodated by joints. Another reason is the substrate, which may have uneven load-bearing capacity and sink in certain areas.
Can you cast over an existing floor?
It depends on the condition of the old floor and how much additional height is permitted. Send a few pictures and let us know how much space is available, and we will tell you if it is feasible. If the old floor has to come out first, we do that as well, see demolition work.
