Expert Talks - Jointless Steel Fiber Reinforced Floor
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Expert Talks - Jointless reinforced steel fiber floors

Jointless Industrial Floors: Smart, Strong, and Made for Modern Demands

Not all industrial floors are created equal. Some are designed for speed. Others for strength. But what if you could have both - along with long-term performance, low maintenance, and design flexibility?

That is exactly what jointless steel fiber reinforced floors deliver.

In the video, Chiara Minoretti, one of our Dramix® experts, offers a deep dive into one of the most versatile floor systems available today. Whether you are a developer, owner, or engineer, understanding the benefits of jointless floors could change how you approach your next project.

Three Main Floor Types - One Smart Choice

 

Steel fiber reinforced floors come in four main types:
 

  • Saw-cut floors, where contraction joints at 6 m spacings are cut to limit random cracking

  • Jointless floors, Floor area’s with only expansion joints at approximately 35 m square (+/- 1250 m²). 

  • Seamless floors, Floor areas without any contraction nor expansion joints. (Unlimited floor area)  

  • SigmaSlab® : A combination of Dramix® steelfibers and CCL post tensioning systems creating floor areas with expansion joints at approximately 120 to 140 m square. (+/- 15.000 m²) 

In this article, we will focus on the second type - the jointless floor - and explore why it has become the preferred option for many distribution centers and high-bay warehouses.

What Is a Jointless Floor?

A jointless floor is a large concrete slab poured without contraction joints. Instead of cutting the surface after pouring to control where cracks form, these floors are built to avoid cracking altogether during shrinkage.

This is achieved through a combination of smart detailing and strategic reinforcement. The slab is divided into large panels, typically between 1000 and 2500 square meters in size. These panels are bordered by special joint profiles that allow for controlled horizontal movement, protect the joint edge and maintain load transfer.

Each panel is poured in a way that allows it to shrink freely without restraint, thanks to two main strategies:

  • A sliding layer is placed between the floor and the subsoil, reducing friction
  • Joint profiles between panels allow slight horizontal movement during shrinkage
The use of the “sliding layer” reduced the tensile strain in the concrete. As long as this strain is kept lower that the maximum strain capacity of concrete, no random cracking will appear.

Reinforced from the Inside Out

What keeps a jointless floor strong and reliable is its reinforcement - and for these floors, steel fibers are the primary choice.

Steel fibers are added directly to the concrete mix before pouring. Resulting in an evenly distributed  reinforcement through the slab. Unlike mesh or rebar, which reinforces specific areas, fibers reinforce the entire section  of the concrete structure.

This brings several benefits:

  • Early-age crack resistance
  • Strength in all directions, not just along planned reinforcement lines
  • Simplified construction, as there is no need to place mesh which is labour intensive, time consuming and with health and safety risks. 

In areas of high stress, such as around columns, corners, and wall intersections, traditional rebar is added locally to prevent stress concentration cracking. This hybrid approach provides targeted reinforcement where it is needed most, without complicating the entire slab design.

Load Transfer Made Easy

The large panels are separated by joint profiles that might contain dowels or other means of load transfer. They allow one panel to transfer loads to the next 

This load transfer is vital for maintaining surface continuity and durability, especially in high-traffic environments like logistics centers.

It also reduces peak stresses at the joints and corners, resulting in thinner floors, compared to a traditional saw-cutted floor. 

Unlike traditional saw-cut joints, which can spall and degrade over time, these profiles are engineered for performance and longevity. They require only periodic maintenance, and most of the surface remains uninterrupted. 

Why Choose a Jointless Floor?

 

Several compelling advantages make jointless floors an increasingly popular solution.

 

1. Flexibility in Design and Layout
With no full depth saw cuts, jointless floors can be designed more freely. Equipment, racking systems, and automation lines can be placed wherever needed without concern for joint locations. This is especially useful in evolving operations or multi-use spaces where layouts change over time.

 

2. Higher Load-Bearing Capacity
By eliminating weak points such as saw-cut joints, jointless floors create a more continuous structure. The result is a floor that performs better under heavy loading, making it ideal for pallet storage, high racking, or heavy machinery.

 

3. Reduced Maintenance
Saw cuts can curl, and deteriorate under repeated traffic. Over time, this leads to costly joint repairs and operational disruptions. With a jointless system, maintenance is limited to the joint profiles, which are far more resilient and easier to manage.

 

4. Suitable for Any Foundation Type
Whether poured directly on compacted subsoil or supported by concrete piles, jointless floors offer flexibility during design and execution. This makes them adaptable to a wide range of soil conditions and structural requirements. For floors on piles the location of the expansion joints need special consideration and have an impact on the overall design. 

 

5. Fast and Economical Construction
Because steel fibers are mixed into the concrete and there is no need for labor-intensive mesh placement, jointless floors are faster to install. Labor hours are reduced, logistics are simplified, and the project timeline becomes more predictable.

A Popular Choice in Logistics and Warehousing

The performance characteristics of jointless floors make them particularly attractive for:

  • Distribution centers 
  • High-bay warehouses
  • Fulfillment and e-commerce hubs
  • Automated storage and retrieval systems

In these applications, floor flatness, durability, and reliability are essential. And with operations running around the clock, minimal maintenance and long service life are key to avoiding costly shutdowns.

The Most Cost-Effective Option Over Time

While the initial cost of a jointless floor may be similar to other floor types, its long-term advantages make it the most economical option in many projects.

When you factor in reduced joint repair costs, faster installation, and improved operational uptime, jointless floors often emerge as the lowest total cost solution.

This is why so many industrial projects now favor jointless designs - especially when supported by expert planning and high-quality materials like Dramix® steel fibers.

Final Thoughts

 

Jointless steel fiber reinforced floors are built for the realities of modern industrial operations. They are strong, adaptable, fast to build, and engineered for long-term performance.

 

With the right reinforcement strategy and thoughtful design, they provide the optimal balance between durability, efficiency, and cost.

 

If you are looking for an industrial floor that delivers more than just a hard and flat surface, a jointless floor reinforced with Dramix® is worth serious consideration.

Need Help Finding the Right Floor Solution?

 

At Bekaert, we partner with engineers, contractors, and investors to design industrial floors that match every need and priority. From concept to construction, we provide tools and expertise to help your project succeed.

 

Contact us today to contact a local Dramix® expert.

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