Concrete Flooring Site Preparation, Starting Work & Tools in Saudi Arabia

Concrete Flooring Site Preparation and Tools

The strength and durability of a warehouse or factory floor depends not just on the concrete mix, but also on how well the site is prepared, how the work begins, and the tools used in execution. Improper preparation can lead to cracks, uneven surfaces, and early deterioration.

At DTC General Contracting, we specialize in end-to-end concrete flooring solutions across Saudi Arabia. From site preparation and mix design to pouring, screeding, and finishing, we use advanced tools and methods to ensure long-lasting performance.

Step 1: Site Preparation for Concrete Flooring

Before pouring concrete, site preparation is essential to ensure stability, load-bearing capacity, and floor flatness.

Subgrade Preparation

• Clearing and leveling the site to remove vegetation, loose soil, and debris.

• Compaction of subgrade using rollers to achieve required density.

• Application of a proof-rolled base layer to detect weak spots.

Sub-base Installation

• Placement of a granular sub-base layer (150–200 mm) to distribute loads.

• Level tolerance maintained within ±25 mm across large areas.

• Use of moisture barriers or polythene sheets to prevent water loss from concrete.

Formwork and Surveying

• Perimeter formwork or laser-guided string lines are set up.

• Surveying ensures grid accuracy for column layouts, racking systems, and machinery bases.

Step 2: Starting Work on Concrete Flooring

Once the site is ready, execution begins with precise planning.

Concrete Mix Delivery

• Mix design (30–40 MPa for warehouses/factories) delivered in transit mixers.

• Admixtures like plasticizers and shrinkage reducers added for durability.

Pouring the Concrete

• Concrete is poured in strips or panels to control shrinkage and joint placement.

• Large areas often use laser screed machines for speed and accuracy.

Compaction and Screeding

• Internal vibrators remove trapped air for strength.

• Laser screeds level the surface with millimeter precision, meeting TR-34/FM2 flatness standards.

Finishing the Surface

• Ride-on trowels used for floating and finishing.

• Surface hardeners and curing compounds applied for strength and dust-proofing.

Step 3: Tools and Equipment for Concrete Flooring

Modern industrial flooring relies on advanced equipment for quality and efficiency.

Key Tools Used

1. Laser Screed Machines

   • Provide high flatness for warehouses and factories.

   • Increase pouring speed to 4,000–5,000 m²/day.

2. Ride-On Power Trowels

   • Used for finishing and polishing large slabs.

   • Delivers smooth and durable surfaces.

3. Vibrating Screeds & Internal Vibrators

   • Ensure compaction and removal of air voids.

   • Improve strength and reduce cracking risks.

4. Cutting and Jointing Tools

   • Diamond saws for contraction joints.

   • Sealant tools for joint filling and protection.

5. Curing Systems

   • Spray-applied curing compounds.

   • Sometimes water-curing blankets used in high-heat conditions.

6. Survey & Testing Equipment

   • Laser levels for grid alignment.

   • FF/FL meters for flatness and levelness testing.

Challenges in Saudi Arabia’s Climate

Concrete flooring in Saudi Arabia faces unique conditions:

• High temperatures accelerate water loss, increasing shrinkage cracks.

• Coastal zones (Dammam, Al Khobar) require sulphate-resistant mixes.

• Cold storage facilities need reinforced, insulated flooring to prevent thermal cracking.

DTC addresses these challenges through:

• Shrinkage-reducing admixtures in mixes.

• Steel Fiber Reinforced Concrete (SFRC) for jointless slabs.

• Epoxy or PU coatings for dust and chemical resistance.

DTC Project Examples

• Al Saif Cold Storage Warehouses – Dammam
  Flooring executed with SFRC + laser screed technology for insulation and durability.

• Kameyat Specialties Factory – Dammam
  Heavy-load factory flooring built with optimized mix and curing to reduce shrinkage.

• AMC Factory – Dammam
  136,000 m² flooring completed with laser screeds and ride-on trowels for smoothness.

• Tiypa Mall – Al Khobar
  Commercial floors finished with epoxy coatings for long-term aesthetics and strength.

Benefits of Proper Site Preparation and Tools

• Durability: Strong, crack-resistant floors.

• Efficiency: Faster project completion with laser screeds.

• Safety: Dust-free, non-slip surfaces improve worker safety.

• Cost Savings: Reduced rework and maintenance.

• Future-Proofing: Flat floors support automation and racking systems.

Conclusion

Successful concrete flooring for warehouses and factories in Saudi Arabia starts with thorough site preparation, continues with precise execution and joint design, and relies on the right tools.

By combining laser screed technology, SFRC mixes, and advanced curing methods, DTC delivers floors that meet the highest standards of strength, flatness, and durability.

Call to Action

Looking for expert concrete flooring contractors in Saudi Arabia?
Partner with DTC for industrial-grade site preparation, advanced tools, and durable factory & warehouse floors.

📞 +966 566 41 1325
📧 info@dtc.sa
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