Industrial Flatwork
Laser-screeded, super-flat floors built for racking, robotics, and mission-critical warehouse operations.
Applications
Project Timeline
A 100,000 square foot warehouse floor proceeds through five phases. Phase 1 – Site Prep (3-5 days): Fine grading, proof-rolling subgrade, correcting soft spots, and verification testing. Phase 2 – Subgrade & Base (1 week): Installing and compacting aggregate base course to 95% density, laser-level verification of elevations, and coordination of embedded items like floor drains or utility penetrations. Phase 3 – Pour & Laser Screed (2-3 days): Concrete placement typically divided into 2-3 pours of 30,000-50,000 SF each, laser screed operation, and initial floating and screeding. Large floors may require multiple pours on successive days. Phase 4 – Finishing & Joints (2-3 days): Power trowel finishing in multiple passes, sawcutting control joints 12-24 hours after placement, and protection during initial curing. Phase 5 – Cure & Testing (1-2 weeks): Concrete curing and protection, joint sealing, final cleaning, and FF/FL testing and documentation at 14-28 days. Total timeline: 4-5 weeks from mobilization to certified super-flat floor ready for racking installation. Accelerated schedules possible using high-early strength concrete. Weather impacts include delays for rain and extra precautions for hot or cold weather pours.
Technical Specifications
Denton Area Considerations
Denton's climate requires careful concrete curing management – summer heat accelerates curing but risks rapid moisture loss requiring fog spraying and immediate curing compound application, while occasional winter cold snaps may require heated enclosures and accelerated concrete mixes. Climate-controlled curing blankets or temporary enclosures help maintain consistent temperature and moisture for optimal results. Scheduling around North Texas weather patterns is important – avoid monsoon season (May-June) when heavy rains can delay projects, and prefer spring and fall weather windows for large floor pours. We coordinate closely with local concrete suppliers (several quality ready-mix plants in Denton area) to ensure consistent concrete mixes and reliable delivery – a 50,000 SF pour requires 600-800 cubic yards delivered continuously over 8-10 hours. For occupied facilities, we coordinate timing around operational schedules and coordinate with rack installation contractors on sequencing. The booming e-commerce and logistics market in the DFW area means high demand for super-flat floors, and project scheduling should consider lead times. Coordination with building mechanical systems is important – many warehouses have radiant heating or under-slab insulation that must be installed before concrete. Local building officials are familiar with industrial floor construction and inspect for proper reinforcement and base preparation.
Frequently Asked Questions
Featured Projects
Denton E-Commerce Fulfillment - 200,000 SF Super-Flat Floor
This high-profile e-commerce fulfillment center required exceptional floor flatness for automated storage and retrieval systems with very narrow aisles and 35-foot high racking. Specifications included FF55/FL35 minimum across the entire floor with FF60+ in automated aisle zones, phased installation in four 50,000 SF sections coordinated with building construction and roof installation, coordination with rack installers on base plate locations and embed requirements, and strict timeline for holiday season startup – floor had to be complete and certified by September. We used laser screed technology for all placements, specified shrinkage-reducing admixtures and fiber reinforcement, minimized joints through large pour sizes (45,000-50,000 SF per day), and provided comprehensive FF/FL testing with detailed reporting. The challenge was maintaining spec across the entire 200,000 SF – even one failing section would delay racking installation. We achieved FF57/FL37 average across all tested areas, with no sections below FF55.
Results:
Achieved FF57/FL37 average across entire floor. Completed 1 week early. Enabled on-time facility opening.
McKinney Manufacturing Facility - 80,000 SF with AGV Paths
A precision manufacturing facility requiring ultra-flat floors for automated guided vehicles (AGVs) moving components between work stations, plus standard industrial floor in general work areas. The design called for specialized AGV paths with FF65+ flatness embedded with guide wires for vehicle navigation, general manufacturing areas with FF45 flatness for normal operations, and integrated trenches for utility distribution and embedded anchor points for machinery installation. The AGV paths created significant complexity – the guide wires had to be installed during concrete placement with precise alignment and depth, then the concrete had to achieve exceptional flatness without disturbing the wires. We used specialized slot forms for wire paths, installed wires to exact specifications using laser alignment, coordinated with AGV supplier on installation requirements, and placed concrete in carefully planned sequences to minimize joints crossing AGV paths. The general floor areas used standard laser screed techniques with control joints on 40-foot spacing.
Results:
AGV paths exceeded FF65 specification. Zero leveling required for machinery installation.
Why Choose Us for Industrial Flatwork?
20+ Years Experience
Proven expertise in commercial concrete construction
Licensed & Insured
Fully licensed, bonded, and insured for your protection
On-Time Delivery
Projects completed on schedule and within budget
Quality Guarantee
Premium materials and expert craftsmanship guaranteed
Get Started Today
Free consultation and quote for your commercial concrete project.
Business Hours:
Mon-Fri: 7:00 AM - 6:00 PM
Sat: 8:00 AM - 2:00 PM
Service Areas
We provide industrial flatwork services throughout Denton and surrounding areas:
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