The Importance of a High Quality Warehouse Floor

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Warehouse flooring can easily be overlooked but the quality and strength of the warehouse floor plays a crucial role in installing efficient and effective automation systems.

As with any building if the foundations are not good enough the whole building is at risk of failure – the quality and strength of the warehouse floor is effectively the foundation for your automations system(s); get it wrong and everything is at risk!

10 Key Considerations in Designing a Warehouse Floor

Level, Even Surface for Movement: Automation systems, such as robotic equipment and conveyor belts, rely on smooth surfaces to move efficiently. Uneven or damaged flooring can strain equipment, cause damage and reduce lifespan which can lead to interruptions and slowdowns in automated processes. A level and well-maintained floor ensures seamless movement of automated machinery and prolongs their life. This is equally true for VNA AGVs and FLTs. Floor finishes should be laid to the standard most appropriate to the type of automation equipment that forms the proposed solution, (e.g. Automatic crane systems usually require a lower floor standard than automatic shuttle systems.)

Accuracy in Navigation: Automated systems often use sensors and cameras for navigation. Even minor bumps or unevenness in the floor can lead to misalignment, causing navigation errors. Smooth, level flooring is essential for accurate navigation, ensuring that automation systems can move precisely as programmed.

Safety of Equipment and Personnel: A flat and stable floor reduces the risk of accidents. Automated equipment, especially robots, can be sensitive to shifts or vibrations. If the floor isn’t stable, it can lead to equipment malfunctions or even accidents. Moreover, a level floor prevents tripping hazards for employees working around automated systems.

Durability: Automation systems, particularly heavy machinery, can put significant stress on the flooring. Durable and high-quality flooring materials are necessary to withstand the constant movement and weight of automated equipment. Proper flooring can prevent wear and tear, ensuring the longevity of both the floor and the automation systems.

Wear Characteristics: The increasing use of AGVs and AGMs will, as a result of the functionality of the guidance controls, result in consistent and repeated travel along the same optimised routes, this can cause disproportionate amounts of wear, this is particularly prevalent at junctions in the route where the drive wheels re-orientate their direction, resulting in grinding.

Strength-Load Bearing. It is important that the floor loading is sufficient to take both the imposed loads and the uploads that the automation will impose (both UDL and Point Loads) this may require some degree of re-inforcement. It is equally essential to understand the nature of the slab construction as this may affect the ability to install wire guidance (if necessary) and/or the depth and type of fixings that can be used.

Easy Maintenance: Maintaining a level floor is generally easier than dealing with a damaged or uneven surface. Easy maintenance is essential for minimizing downtime. Regular maintenance of the flooring ensures that automation processes can continue without unnecessary interruptions.

Optimized Efficiency: A well-designed warehouse floor layout, including appropriate markings and divisions, can enhance the efficiency of automation. Clearly defined paths and zones on the floor help automated systems to navigate and operate optimally, leading to faster order fulfilment and streamlined warehouse operations.

Cost-Effectiveness: Investing in high-quality flooring initially might seem like an added expense, but it can save money in the long run. Proper flooring reduces the wear and tear on automation equipment, leading to fewer repairs and replacements. It also minimizes the risk of accidents, which can result in costly damage to both equipment and inventory.

Capex & Timescales. It is important when selecting an automation system that the floor finish and loadings required for each specific system, are fully taken into account in relation to the overall capital cost and timescale for your project

In summary, the correct warehouse flooring is a fundamental prerequisite for automation because it ensures the smooth movement of equipment, enhances safety, prolongs the life of machinery, and ultimately contributes to the overall efficiency and cost-effectiveness of automated warehouse operations.

For more information on warehousing and automation please visit our services page

Logistics and Supply Chain Consultants: Experience you can trust

“Bisham used their experience & expertise to ensure we sourced the right partner and took a safe path through supply chain transformation, which ultimately allowed us to meet our strategic supply chain objectives”

Justin Porter, GM Finance & Operations 

Pioneer DJ Europe

“Brammer has worked with Bisham Consulting on a number of projects over the years. I have invariably been delighted with their approach and the quality of their output. Bisham Consulting has supported Brammer on new warehouse design and delivery, the implementation of warehouse systems, and facilitated the definition of supply chain strategy. All the members of the Bisham Consulting team that we have worked with, and continue to work with, are experienced and pragmatic. They are intellectually rigorous, but with a real-world approach to solving sometimes very complex problems.”

Nigel Trend, Director of Business Integration


Bert van den Berg, Service and Parts Development Director
Hiab USA Inc.

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