Super-Flat Warehouse Slabs
FF 50 / FL 40
Laser-guided screeding for narrow-aisle racking systems
Applications
- • High-bay warehouses with VNA forklifts
- • Automated storage systems
- • Narrow-aisle racking (10-12 ft aisles)
Typical Cost
$6.50-$9.50/SF
Industrial Floor Specialists
Industrial Concrete Slabs in Plano, Texas
Super-flat warehouse floors engineered for heavy racking, forklift traffic, and automated material handling systems. Our laser-guided screeding delivers FF 50+ flatness specifications that racking installers require. Over 600,000 square feet of industrial slabs poured across Plano warehouses, distribution centers, and manufacturing facilities. ACI Flatwork Finisher certified crews, F-number compliance testing, zero slab rejection rate.
600K+
Sq Ft Poured
FF 50+
Flatness Achieved
100%
F-Number Pass Rate
Zero
Slab Rejections
Warehouse Floor Construction for Plano Industrial Facilities
Industrial concrete slabs are far more sophisticated than standard residential slabs. Plano warehouse operators demand floors that support heavy racking systems (up to 20,000 lbs per post load), accommodate high-speed forklift traffic (8,000-12,000 lb lift trucks running 8-12 hours daily), resist abrasion from metal wheels and pallets, and maintain flatness specifications that allow narrow-aisle storage systems to function safely.
The difference between an acceptable slab and an exceptional slab often comes down to F-number specifications—industry-standard measurements of floor flatness (FF) and levelness (FL). A conventionally screeded slab typically achieves FF 20-25, adequate for conventional warehouses with wide aisles (14+ feet). But modern high-density storage with Very Narrow Aisle (VNA) forklifts requires FF 50 or higher—achievable only with laser-guided screeding equipment and experienced finishing crews.
Concrete Contractors of Plano specializes in super-flat industrial floors. We've poured over 600,000 square feet of warehouse slabs across North Texas, achieving consistent FF 50+ ratings with our laser-guided screed systems. Our ACI Flatwork Finisher certified crews understand the difference between "good enough" and "specification-compliant"—and we've maintained a 100% F-number pass rate across 40+ Plano industrial projects with third-party Floor Pro verification.
Slab Systems
Industrial Slab Types for Plano Warehouses
Standard Warehouse Slabs
FF 35 / FL 25
General purpose industrial floors for conventional forklifts
Applications
- • Distribution centers
- • Manufacturing facilities
- • Standard pallet racking (12+ ft aisles)
Typical Cost
$5.00-$7.00/SF
Heavy-Load Industrial Slabs
FF 25-35 / FL 20-30
Reinforced slabs for extreme point loads
Applications
- • Heavy equipment pads
- • Crane rails
- • Industrial machinery foundations
- • Cold storage facilities
Typical Cost
$7.00-$11.00/SF
Understanding F-Number Requirements for Your Plano Warehouse
Racking manufacturers typically specify minimum FF/FL numbers based on aisle width and lift height. VNA systems (10-12 ft aisles, 30+ ft lift heights) require FF 50+ because even small floor variations cause dangerous rack misalignment at height. Standard reach trucks (12-14 ft aisles) need FF 35-40. Conventional counterbalance forklifts (14+ ft aisles) can operate on FF 25-30. If you install racking before verifying F-numbers, racking installers may refuse to warranty the system—we've seen Plano developers forced to grind and re-level slabs at $3-$8 per square foot because floors didn't meet spec. Our approach: agree on target F-numbers during estimating, measure actual numbers at 72 hours post-pour, and provide certified reports before racking installation begins.
Technical Specifications
Industrial Slab Design Standards
All industrial slabs are designed per ACI 302 (Guide for Concrete Floor and Slab Construction) and ACI 360 (Design of Slabs-on-Ground). Below are typical specifications for Plano commercial and industrial facilities:
concrete Strength
- → 3,000 PSI: Light industrial, office areas
- → 3,500 PSI: Standard warehouses, retail
- → 4,000 PSI: Heavy forklift traffic, racking loads
- → 4,500-5,000 PSI: Extreme loads, abrasion-critical areas
slab Thickness
- → 5 inches: Office spaces, light industrial
- → 6 inches: Standard warehouse (most common in Plano)
- → 8 inches: Heavy racking, multi-level mezzanines
- → 10-12 inches: Extreme point loads, crane rails
reinforcement
- → 6×6 W2.9×W2.9 WWF: Light-duty residential or office
- → #4 rebar @ 18-24 inches O.C.: Standard commercial
- → Structural fiber (1.5-3 lbs/cu yd): Crack control, replaces WWF
- → Post-tension systems: Large slabs, expansive soils, no joints
joints
- → Control joints: Every 15-20 feet to manage shrinkage cracking
- → Construction joints: At logical stopping points (daily pours)
- → Isolation joints: At columns, walls, equipment pads
- → Sawcut timing: 4-12 hours after finishing (based on concrete temp)
Plano-Specific Slab Considerations
Climate & Curing
North Texas summer heat (95-105°F concrete temperatures) accelerates curing but increases plastic shrinkage cracking risk. We use fiber reinforcement, apply curing compound within 15 minutes of finishing, and sometimes install temporary misting systems on large pours. Winter pours (rare below-freezing nights) require insulated blankets to maintain minimum 50°F concrete temperature for 3-7 days.
Joint Layout Strategy
We coordinate joint layout with racking installers before pouring—racking posts should land mid-panel (not on joints) to prevent load transfer problems. Typical joint spacing in Plano warehouses is 15-20 feet for reinforced slabs, 30-50 feet for post-tension slabs. Sawcut joints within 4-12 hours of finishing (timing critical based on concrete temperature) to control where cracks occur.
Warehouse Slab Questions
Industrial Slab FAQ
What is the difference between FF and FL floor flatness numbers?
FF (Floor Flatness) and FL (Floor Levelness) are numerical ratings that quantify how flat and level an industrial concrete slab is—critical specs for warehouses with narrow-aisle racking and automated equipment. FF measures local variations (bumps and dips over short distances), while FL measures overall slope and levelness over longer distances. For Plano warehouses with Very Narrow Aisle (VNA) forklifts operating in 10-12 foot aisles, we typically target FF 50 / FL 40 minimum. Standard warehouse slabs for conventional forklifts need FF 35 / FL 25. Higher FF numbers mean flatter floors—FF 20 is basic screeded concrete, FF 50 requires laser-guided screeding, FF 100 is extremely flat (rare, very expensive). We measure floors using a Floor Pro or Dipstick device at 72 hours after placement and provide certified F-number reports to meet racking installer and warehouse operator requirements.
How thick should an industrial warehouse slab be in Plano?
Industrial warehouse slab thickness in Plano ranges from 5-8 inches depending on forklift wheel loads, racking post loads, and soil subgrade quality. For a typical distribution center with 4,000-6,000 lb forklifts and standard pallet racking, a 6-inch slab reinforced with structural fibers (1.5 lbs per cubic yard) or #4 rebar is standard. Heavier applications—multi-level mezzanine racking, very narrow aisle (VNA) systems with 8,000+ lb forklifts, or cold storage facilities with heavy-duty equipment—may require 8-inch slabs. Our structural engineers calculate required thickness using ACI 360 (Design of Slabs-on-Ground), considering subgrade modulus from your geotechnical report, wheel loads, post loads, and joint spacing. Under-sizing slab thickness to save $12,000-$20,000 upfront often results in premature cracking, joint deterioration, and $80,000+ repair costs within 5-10 years—penny wise, pound foolish.
Do you use rebar or fiber reinforcement in industrial slabs?
Both rebar and synthetic/steel fiber reinforcement have roles in Plano industrial slvanc, and we select based on slab use, load conditions, and joint layout. Welded wire fabric (WWF) or rebar grids are traditional reinforcement—6×6 W2.9×W2.9 WWF or #4 rebar at 18-24 inches on center provides crack control and post-cracking load capacity. However, modern practice increasingly uses structural fiber reinforcement (synthetic macro-fibers or steel fibers at 1.5-5 lbs per cubic yard) which eliminates the labor cost of placing rebar, prevents construction delays from rebar placement, and provides superior crack control. For heavy-load applications (8+ inch slabs, extreme point loads), we often use a hybrid: structural fibers for crack control plus rebar grid in high-stress areas like column bases or heavy equipment pads. Post-tension slabs (used on poor soils or for joint-free floors) use high-strength steel cables tensioned after concrete curing—expensive ($8-$12/SF) but eliminates most joints.
How do you achieve super-flat floors (FF 50+) for narrow-aisle racking?
Achieving FF 50+ flatness requires laser-guided screeding equipment, experienced finishing crews, and quality control at every step. Here's our Plano super-flat slab process: First, we ensure subgrade is properly compacted and smooth (no soft spots or bumps). Second, we use laser-guided screed machines (not manual screeding) that maintain elevation within +/- 1/8 inch across the entire slab. Third, we pour concrete in strategic sequences—typically 10,000-15,000 SF pours—to allow proper screeding time before initial set. Fourth, we use optimized concrete mixes (slump 4-5 inches, no excessive water) to minimize shrinkage. Fifth, our ACI-certified finishers power-trowel in multiple passes to achieve hard, dense surface. Finally, we measure with Floor Pro device at 72 hours and provide certified F-number reports. Super-flat finishing adds $1.50-$2.50 per square foot versus standard screeding, but it's non-negotiable for warehouses with VNA forklifts—racking installers won't warranty systems on non-compliant floors.
What is vapor barrier installation and when is it required?
Vapor barriers (also called vapor retarders) are plastic sheeting installed under concrete slabs to prevent ground moisture from migrating up through the slab—critical for Plano warehouses with moisture-sensitive goods, epoxy coatings, or polished floors. We typically install 10-15 mil polyethylene sheeting per ASTM E1745 Class A or B specifications, with all seams overlapped 6 inches and taped. The barrier sits on top of a compacted aggregate base (4-6 inches of crushed stone) to prevent punctures and provide a capillary break. Cost is minimal ($0.35-$0.60 per square foot including labor) but impact is massive—slabs without vapor barriers in Plano's humid climate often experience moisture-related flooring failures, mold growth on stored products, or epoxy coating delamination within 2-5 years. ACI 302 and most modern warehouse specs now require vapor barriers as standard practice, and we include them in all Plano industrial slab quotes unless specifically excluded.
How long does it take to pour an industrial slab in Plano?
For a typical 80,000-100,000 square foot warehouse slab in Plano, the installation process takes 2-3 weeks total: Week 1 includes subgrade prep, vapor barrier installation, and edge forming. Week 2 is concrete placement (we typically pour 15,000-25,000 SF per day with multiple trucks and finishing crews), initial curing, and sawcut joint installation. Week 3 is continued curing, joint sealing, and surface treatment if specified. The actual concrete placement happens in 3-5 days depending on slab size and logistics. We coordinate with local batch plants (multiple plants within 10 miles of Plano) to ensure continuous concrete supply—a 100,000 SF × 6-inch slab requires 1,850 cubic yards of concrete, typically delivered by 185 truck loads over 3-4 days. Night pours and weekend work can compress this timeline if your Plano project schedule requires accelerated placement.
Related Plano Industrial Concrete Services
Warehouse Floors
Super-flat floors with F-number compliance for narrow-aisle racking systems
Structural Foundations
Engineered pier and footing systems for Plano expansive soils
Slab Repairs
Joint repair, crack injection, and slab replacement for existing warehouses
Site Paving
Parking lots, loading docks, and truck court paving around warehouse buildings
Precision Concrete
Ready to break ground on your next Plano project?
Talk with our project managers about tilt-wall builds, structural foundations, and site paving. We mobilize fast and deliver commercial-grade concrete that holds up to the toughest specs.