Advancements in High Tolerance Flooring (Lantai Super Flat) for Logistics Facilities in Indonesia

March 11, 2024

High Tolerance Flooring Construction - IndonesiaIn the dynamic landscape of Indonesia logistics and warehousing, the demand for high tolerance flooring is more critical than ever, especially with the rise of e-commerce, automation, and robotics. This article explores the key aspects of high tolerance flooring in logistics facilities in Indonesia, focusing on flat floors, super flat floors, relevant standards, and the evolving trends in warehouse automation.

High Tolerance Concrete Floor Standards

The foundation of an efficient logistics facility begins with high-tolerance concrete floors. In the logistics realm, precision matters, and as these high tolerance floors adhere to stringent flatness and levelness criteria, this ensures the smooth navigation of machinery, reducing equipment wear and tear, damage, and safety risks. Therefore, ultimately improving productivity for superior operational efficiency.

In some American-standard-influenced countries, including Indonesia, the terminology for these floor specifications is popularly represented as a “Super flat floor” or “Flat floor”, often measured using ASTM/FF-FL numbers (F numbers) and ACI/F-Min. Despite being influenced by ASTM standards, we have seen an increase in demand for British Standards, especially in Indonesia for the UK Concrete Society’s Technical Report 34 (TR34).

The term “Super Flat” was also used in TR34 3rd Edition as a floor classification representing the highest tolerance classification within Defined Movement for Very Narrow Aisle (VNA) fork trucks operating at heights greater than 13m.

With tightening competition in the logistics market, warehouse owners are striving to leverage their operational efficiencies. Hence, it is critical to find the right flooring standard, such as TR34, which encompasses detail defining parameters to accurately meet Material Handling Equipment (MHE) requirements.

Free Movement vs. Defined Movement: Striking the Right Balance

High tolerance flooring specifications often include distinctions between ‘Free Movement’ and ‘Defined Movement.’ While free movement allows flexibility for general traffic, defined movement zones are strategically designated for specific activities, such as Very Narrow Aisle (VNA). Both FM & DM specifications are used as a basis design for robotic operations or automated material handling systems particularly newer automation versions that are picking at heights in excess of 13m.

The following table summarizes the common international flooring standards that are used worldwide:

Standards Origin Free Movement Defined Movement
German/European DIN 18202 DIN 15185
American ASTM 1155 ACI F-min
British UK Concrete Society, TR34 4th Edition UK Concrete Society, TR34 4th Edition

Balancing these specifications is crucial for creating a versatile logistics environment that caters to both conventional and automated processes. This adaptability is particularly relevant in the context of the evolving trends in the Indonesian logistics sector.

Technical Report 34 (TR34) by UK Concrete Society

In the context of logistics storage facilities, Technical Report 34 (TR34) by The Concrete Society stands out as a benchmark. This standard, unlike generic flatness and levelness criteria, specifically considers comprehensive and defining parameters such as reach truck operating height and racking height in relevance to the Material Handling Equipment (MHE) or system used, aligning with the unique demands of logistics operations.

1. Table 3.1: Permissible 95 pecentile values on Properties E and F.
1. Table 3.1.
2. Table 3.2: Permissible limits on Properties dZ, dX, d2Z and d2X in defined-movement areas.
2. Table 3.2.

Warehouse Trends 2024 – E-Commerce, Automation, and Robotics

Latest reports indicate that Indonesia remains the largest e-commerce market in the SEA region, accounting for USD 59 Billion in 2022, making it one of the top 10 countries with the largest e-commerce industry.

Some of the leading e-commerce platforms in Indonesia are Shopee, Tokopedia, Blibli, and Lazada, which cater to the diverse needs and preferences of Indonesian online shoppers. With the rise of this industry sector, Indonesia expects to see an increased demand for automation and robotic systems in warehouses, to meet customer expectations for faster, more efficient, and more accurate delivery.

Adoption of Advanced Warehouse Automation in Indonesia

Warehouse Automation in Indonesia
3. Warehouse Automation

Looking ahead to 2024, the trend in warehouse logistics is leaning heavily towards increased automation and robotics systems.

As the industry evolves, logistics facilities in Indonesia are expected to adopt advanced technologies to enhance efficiency and competitiveness.

High tolerance flooring is set to be a cornerstone of this transformation, ensuring that warehouses can seamlessly integrate automation solutions for a more streamlined and agile operation.

Why High Tolerance Floors are so Important for Automated Systems

Concrete floor flatness and levelness are just some of the many critical parameters required for the successful implementation of warehouse automation. Uneven floors can lead to operational challenges, increased maintenance costs, reduced equipment lifespan and safety concerns. The precision demanded by automation and robotic systems necessitates flooring that meets advanced stringent flatness and levelness criteria, as well as other parameters (i.e. abrasion, gloss, friction etc.) which are not specified in general flooring standards. Thus, bespoke flooring specifications are essential for different equipment, such as Automated Guided Vehicles (AGVs), Autonomous Mobile Robots (AMRs), and Automated Case-handling Mobile Robots (ACRs). CoGri and Face Consultants are one of the few experts in the industry who can provide comprehensive and specialised flooring expertise for these industry players.

Strategic Investment in High Tolerance Flooring

In the competitive landscape of logistics, the role of high tolerance flooring cannot be overstated. As Indonesia positions itself as a logistical hub, investing in flooring solutions that adhere to global standards is imperative. Whether it’s the American Standards, TR34 from The Concrete Society, or other international benchmarks, the emphasis on precision and adaptability is clear.

As we look towards 2024 and beyond, the integration of automation and robotics in warehouses is set to redefine the logistics landscape. High tolerance flooring is not merely a foundation for logistical operations, it is a strategic investment in the future of efficient and technologically advanced supply chains in Indonesia. Investing in high tolerance flooring is the right investment when preparing for the future readiness of automated logistics facilities.

Contact CoGri Asia today to see how we can help. You can also view the flooring services we offer for automated systems and our high tolerance floor construction solutions.

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