Joint Free Flooring (JFF)

Level Best Concrete Flooring cast a completely seamless floor in one day. A
single panel of 42 × 18m wide – beyond Technical Report 34’s(1) aspect ratio
guidance for standard jointless slabs.

Level Best Concrete Flooring has constructed the first warehouse concrete floor slab in the UK using a system created using both steel fibre reinforcement in conjunction with steel post tensioned bars. The flooring system is not only joint free, but also crack free as the shrinkage is controlled using the hybrid reinforcement. This joint free floor slab was cast in one day with the industrial concrete flooring contractors utilising one of their light remote controlled laser screeds to reduce weight on the membrane during trafficking and concrete install. Although technically more complicated to construct than a more traditional warehouse concrete floor, Level Best managed to overcome any potential design and install problems using out of the box thinking and vast experience in floor slab technology. The joint free floor has many benefits to end users such as extremely low maintenance, easy to clean and keep hygienic, high surface abrasion resistance, high impact resistance and cost effective for the right uses. Not only has the floor slab no joints, but it also has no shrinkage related cracking, a unique scenario for concrete poured in mass during the summer months.

Ideal Applications

To find out more about our services please get in touch with us today

Compared with conventional reinforcement solutions, Joint Free Flooring reduced steel use in the building significantly; it was estimated that the overall carbon footprint of the seamless floor was reduced by 30% compared with a like-for-like conventional reinforcement system.

By creating joint-free distances up to 150m in some cases, Joint Free Flooring reduces the number of joints and associated weaknesses. Over time, this will diminish the maintenance and repair costs and increase floor durability.

The end result for Level Best Concrete Flooring was a floor with a low total cost of ownership, no joints and no reinforcement detailing, more spacious interiors, greater flexibility of layout and better aesthetics.

Tension pockets for joint free concrete floor system

Steel strands left loose during concreting process of this joint free floor slab.

Level Best Concrete Flooring ensured all subbase levelling was completed prior to the installation day. Prefabricated posttensioning tendons (pre-cut strands with anchors already fixed), which
allowed the post-tensioning to be installed in less than a day.

Due to restricted slab edge access and to avoid infill strips of floor area designated for the post-tensioning tendon stressing operation, pockets (similar to column isolation joints) were located at one end of the building, to allow future access of a stressing jack.

Due to the width of the building and the pour occurring in one single day, only longitudinal strands were required.

Step 2 - Concreting

Steel fibres were added to the concrete on site. The fibres are glued in bundles that are gradually released during mixing to disperse evenly through the concrete without balling. The steel fibre concrete was poured onto the ground by direct discharge from concrete trucks. The process for finishing the surface of the concrete slab to the required flatness and levelness was identical to typical flooring construction. Level Best also applied a dry shake topping to the surface of the concrete to increase toughness and abrasion resistance.

Steel fibre reinforced concrete being poured in conjunction with laser screed

Powerfloated and polished joint free warehouse floor slab

Steel bars tensioned once concrete gained sufficient strength

Joint free warehouse floor following completion

Step 3 - Stressing

Prior to the stressing operation, the post tensioning tendons were checked, and wedges were firmly installed into the anchors. As soon as the concrete achieved a compressive strength of 10MPa, 25% of the ultimate stress was applied. Once the compressive strength reached 25MPa, the final design stress was applied to the tendons. Initial stressing was done on day two after casting, final stressing a day later. The protruding strands were cut, and the stressing pockets then filled with steel fibre reinforced concrete. Depending on the concrete strength maturity in the first days from casting, initial and final stressing can be done faster.

Why you should consider Level Best

You can find out more about Joint Free Flooring in the latest edition of Concrete

Independent Verification & Expert Partnerships

Where independent verification is required, Level Best Concrete Flooring works in partnership with The Concrete Society. This collaboration ensures all assessments are supported by third-party technical documentation and align with industry best practice.

Book a Concrete Floor Survey or Consultation

If you require a concrete floor inspection, TR34 flatness test, or structural floor assessment, contact Level Best Concrete Flooring today. Our team will arrange a professional site survey and provide expert guidance tailored to your facility. Get in touch now to request a quotation or book your floor testing service. Level Best Concrete Flooring, serving industrial and commercial clients nationwide across the UK.

Frequently Asked Questions

What is a TR34 floor survey?

A TR34 survey assesses the flatness and surface regularity of industrial concrete floors in line with The Concrete Society’s TR34 standards. These standards are widely used in warehouse and logistics environments where precise flatness is crucial for materials handling and safety.

Why is concrete floor testing important?

Regular testing identifies structural weaknesses, uneven surfaces, and load-bearing limitations before they cause operational issues. It helps ensure compliance, improve safety, and reduce costly future repairs or downtime.

How often should industrial floors be tested or surveyed?

It’s recommended to test or assess industrial concrete floors every few years, particularly in high-traffic or heavy-load areas. However, frequency may vary depending on usage, age, and any visible signs of damage or wear.

What does a concrete floor testing report include?

Our reports include detailed findings on strength, flatness, cracks, reinforcement, and structural performance, along with clear, actionable recommendations for maintenance or refurbishment.

Do you provide independent verification?

Yes. Level Best works with The Concrete Society and FMK (Floor Maintenance & Knowledge) to deliver independent verification and supporting technical documentation, ensuring every project meets the highest industry standards.

Where does Level Best Concrete Flooring operate?

We provide industrial concrete floor testing, assessment, and appraisal services nationwide across the UK, including manufacturing facilities, warehouses, logistics centres, and commercial sites.

How can I arrange a floor testing survey?

Simply contact our team via phone or email to book a site assessment or consultation. We’ll discuss your requirements, schedule a survey, and provide a detailed proposal based on your facility’s needs.

On the Level

A word from Jon Wilcox

One of the more important components of managing and maintaining a concrete floor is to have a full assessment and survey conducted at certain intervals during long term leasing or when a lease is about to end. We always ensure the assessment includes a TR34 compliant flatness test as well as the associated tests for levelness and strength. This is crucial in ensuring that the new tenant will be able to use the floor for their intended purpose and in the case of the floor needing any adjustment or dilapidation works, its much better to do this now rather than find out later. We do ensure the assessments and surveys are conducted by independent and trusted suppliers which gives our clients confidence that the results of any surveys are objective and as accurate as technology allows. Forewarned is forearmed as they say so should the floor be suitable for some applications and not others it allows the client to better specify and select the type of business that may lease the property.

Latest Projects

Industrial concrete flooring in Worcester by Level Best

Posted by Level Best on 7th February 2023 | Featured

This old and dilapidated concrete floor slab has been re- laid and newly installed by the innovative concrete flooring contractors Level Best Concrete Flooring in Worcester on behalf of Hollis Global. The original floor was damaged with broken down joints … Read More

Industrial concrete flooring overlay in Long Eaton, Derbyshire

Posted by Level Best on 17th October 2022 | Featured

Level Best Concrete Flooring have been involved in a complex project in Long Eaton near Nottingham in Derbyshire involving the construction of 5,500 square metres of industrial concrete flooring as part of a major dilapidation project. Works commenced with the … Read More

Bespoke commercial concrete flooring in Leamington Spa, Warwickshire

Posted by Level Best on 6th September 2022 | Featured

Industrial concrete flooring specialists, Level Best Concrete Flooring, have completed another medium-sized retro-fit bespoke industrial/commercial project on behalf of a private client and industrial landlord in the heart of central England in Leamington Spa, Warwickshire. Level Best worked closely with … Read More

Level Best Concrete Flooring has recently completed an overlay concrete floor slab in Didcot, Oxfordshire

Posted by Level Best on 5th November 2018 | Featured

Level Best Concrete Flooring has recently completed an overlay concrete floor slab in Didcot, Oxfordshire. The new floor slab was bonded to the old floor using a high strength bonding agent with extra strong capabilities to ensure the client doesn’t … Read More

We appointed Level Best Concrete Flooring Limited to carry out the design and construction of the internal warehouse concrete floor slabs for our contract at CePac, Goole, East Yorkshire. It was the first time we have worked with Level Best and the standard of work carried out was to the highest quality and our client was extremely impressed. We have since used Level Best on three other successful concrete flooring projects.

Britcon

Project Manager

Joint Free Flooring (JFF)