Max Wild, DE
PROJECT TYPE
Industrial/Logistics
APPLICATION
Jointless floor
PARTNERS
Flooring contractor: G.v.G/aii
Concrete supplier: Schwenk
Owner: Max Wild
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20 000 m², 4 nights,
1 jointless industrial floor

For a new 20 000 m² industrial facility in Southern Germany, Max Wild needed a floor capable of handling exceptionally demanding operations, including a special forklift weighing up to 72 tonnes. The solution combined Dramix® 4D steel fibres with engineered mesh reinforcement to create a fully jointless industrial floor.

The challenge

 

The biggest challenge was not simply supporting heavy loads. It was dealing with what traditionally represents one of the most vulnerable parts of an industrial floor: the joints. Instead of trying to reinforce them, the proposed approach was more fundamental: eliminating the joints from the main floor areas. That created a challenge. The 20 000 m² floor was divided into 4 areas of approximately 5000 m², and each area had to be poured continuously to achieve the jointless concept.

Linder, North Carolina, US

The solution

 

GvG developed a jointless flooring concept combining Dramix® 4D with a specifically engineered reinforcement mesh layer and a carefully designed subbase. By eliminating conventional dowelled joints across the main floor areas, the solution avoided creating highly loaded joint transitions for the heavy forklift while providing the structural performance required for demanding industrial use. Execution was as ambitious as the design: four 5000 m² pours in four nights. Each 5000 m² section had to be completed as one continuous pour. Work started at 5pm and was completed around 3am the following morning. Two concrete pumps operated simultaneously, with a third available as backup. This redundancy was critical because once a jointless pour started, stopping was not an option. Removing joints offers benefits beyond the original heavy-forklift requirement. Jan Martens (G.v.G) highlighted the growing use of automated logistics vehicles with small wheels. For these systems, joints and surface irregularities can become an operational obstacle, making smooth and jointless surfaces increasingly relevant for future industrial facilities.

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