A robust, level concrete slab is the backbone of any factory or warehouse facility. We construct factory slabs in Perth that meet the demanding needs of industrial operations.
From supporting heavy machinery and racking systems to enduring constant forklift traffic, our concrete factory floors are designed for strength, durability, and long-term performance.
With our professional approach and knowledge of industrial flooring standards, we ensure your new factory slab can handle the load, literally, and provide a safe, even surface for all your operations.
Factory and warehouse slabs differ from typical residential slabs in both thickness and reinforcement. These industrial concrete slabs are usually thicker and use higher-strength concrete to support heavy loads. For example, a standard warehouse slab might be 150mm to 200mm thick for moderate loads, whereas a workshop housing very heavy machinery or trucks might require 250mm or more. The concrete grade is often 32 MPa or higher for industrial floors, providing extra compressive strength and surface hardness. Steel reinforcement is critical: we commonly use steel mesh (e.g., SL82 or SL92 mesh) or even double layers of mesh in heavy load areas. In some cases, steel fibre reinforcement can be added to the concrete mix to enhance load distribution and crack control. Our Perth factory slabs are engineered to carry point loads from equipment and pallet racks, as well as uniformly distributed loads from the storage of goods.
An important aspect of factory slabs is flatness and levelness. A flat floor ensures safe forklift operation and prevents equipment misalignment. We achieve high flatness by using laser-guided screeding techniques and experienced finishers who understand how to avoid bumps or dips. In large open areas like warehouses, we often pour using the latest ride-on trowel machines and screeds to get an even finish. Where specified, we can meet strict floor flatness specifications (such as FM or DM classifications for defined traffic paths), which are required for high-bay warehouses with very narrow aisles.
When designing a factory slab in Perth, we consider both the loading requirements and the ground conditions. Many industrial areas around Perth (like Kewdale, Welshpool, or Wangara) have sandy soils, which provide good support but also require proper compaction of the subgrade. We ensure the sub-base is well compacted and often incorporate a layer of crushed limestone or roadbase beneath the slab for added stability and as a leveling layer. A vapor barrier (plastic sheeting) is usually placed under interior slabs to prevent ground moisture from migrating into the slab, which can be important for protecting goods and equipment from dampness.
We also incorporate control joints (sawn or formed) and expansion joints at appropriate intervals. These joints help manage concrete shrinkage and thermal expansion, preventing random cracking. For a factory floor, joints might be cut at 6m to 8m grids shortly after pouring, depending on slab thickness and reinforcement. We can also use dowel bars or keyed joints to transfer loads across joints so that forklifts can pass smoothly without slab edges deflecting. In some projects, to minimise joints for very high traffic, we might use post-tensioned slabs or large pour techniques, but traditional reinforced slabs with well-planned joints are the norm and have proven effective for most industrial uses.
The surface finish of a factory slab is typically machine-trowelled to a smooth, hard finish (often called a burnished finish). This makes it easy to clean and resistant to wear. However, if a non-slip surface is needed (for example, in areas prone to wetness or outdoors), we can provide a textured finish or apply non-slip treatments. Additionally, in facilities dealing with certain chemicals or food processing, we can apply sealers or epoxy coatings on the concrete surface to protect it and meet hygiene requirements.
Our factory slab construction follows a systematic process. After site preparation and subgrade compaction, we set up edge forms or utilise existing footings/walls as boundaries for the slab. We then laid reinforcement. Large sheets of steel mesh are placed and secured up to the correct height (usually about one-third slab depth from the bottom). If required, extra rebar is added in high-stress areas like column locations (often referred to as moment reinforcing or re-entrant corner bars around columns to prevent cracking).
When it’s time to pour, we mobilise a crew and equipment suitable for large volumes of concrete. For example, a 1,000 m² factory slab 150mm thick requires 150 cubic metres of concrete, which we typically place with concrete pumps for speed and reach. We often divide the floor into pour strips so that construction joints are placed deliberately, or we can use continuous pours with planned saw-cut joints later. During pouring, our team uses vibratory screeds or laser screeds to strike off the concrete to the correct level. Then comes finishing: as the concrete sets, multiple passes with power trowels (helicopter machines) are done to smooth and harden the surface. We monitor the setting rate closely. Perth’s warm climate can cause concrete to set faster, so we sometimes adjust with set-retarding admixtures or work in the cooler early morning or evening hours for very large slabs.
Curing is extremely important for an industrial slab’s durability. We apply curing compounds or water curing to keep the slab from drying out too quickly, which helps achieve the desired strength and reduces surface dusting. We might cover the slab with curing blankets, especially if large sections are poured and it’s a hot day. By maintaining moisture, we also mitigate cracking. Once cured adequately (often 7 days of curing for a strong start, though concrete continues to harden beyond that), we perform saw cutting of control joints if they weren’t formed initially. These cuts are usually done within 24-48 hours of the pour to catch the concrete at the right time to induce cracks at the joints.
After about a week or two, the slab reaches a strength where heavy equipment can be brought on. We schedule joint sealing (filling the saw cuts with a sealant to keep out dirt and protect edges) as required. Then, the slab is ready for its service life, able to hold up racking, allow forklift traffic, and support machinery installation.
Our Perth factory slabs are built not just for immediate load requirements but for longevity. By using proper reinforcement and concrete strength, we ensure the slab resists wear and tear. A well-finished concrete surface can have a hard, stone-like polish if needed (we can even do polished concrete finishes for warehouses that want a dust-free, reflective floor). Regular use by forklifts typically causes some surface wear over the years, but our slabs have the depth of strength to allow re-grinding or coating in the future if the client ever desires to refresh the surface. We also pay attention to the environment within the factory. For instance, if exposure to acids or oils is expected, we might recommend a protective coating or a high-density concrete mix to reduce permeability.
In terms of load capacity, our slabs are engineered with a safety margin. For example, if a floor is intended for a uniform load of 50kPa (approx 5 tonnes per square metre) or specific point loads from racks, we ensure through design and often field testing (like using concrete cylinder tests to verify strength) that these capacities are met or exceeded. Industrial clients can feel confident storing heavy inventory or operating large machinery on our slabs. We also consider future flexibility: our designs often accommodate the possibility of adding more loads later or reconfiguring the space.
