Newly formed CoGri Malaysia Sdn Bhd recently completed construction of a very special slab in Tesco's largest purpose built distribution centre in SE Asia. Sited North of Kuala Lumpur in Bukit Beruntung, the 416 metre long warehouse is a massive 50,000m2 on a 25 acre plot of land which includes another 24000m2 for future expansion. The main warehouse features 169 loading docks, 54,000 pallet spaces in 11 metre high selective racking.
Face Consultants prepared the design and specified the floor flatness as FM2 Special from the UK Concrete Society's Technical Report No. 34. This specification is for conventional wide aisle storage that may be converted to very narrow aisle in the future. The tolerances are designed to allow the conversion from conventional to narrow aisle racking storage with very little floor flatness upgrading required.
Face Consultants prepared the design and detailed specifications for the Malaysia DC which required:
To avoid casting during the heat, batching plant staff mobilised at 2:30 a.m. and the first truck arrived on site at 4 a.m. For this type of construction the metal fibre is integrated in the concrete truck. CoGri Malaysia chose to do the fibre integration at site with a conveyor. Usually fibres are introduced at the batching plant but doing it at site conserves fibres in the event that a load of concrete is rejected upon reaching the site.
- 2.4 x 2.6m pile grid
- 900 diameter pile heads
- 200mm thick sub base
- 210mm thick slab with 45kg/m3 HE+1/60 metal fibres
- AD10 armoured Joints
- 5 kg of fibre suppressant dry shake
- Masterkure 181 Acrylic Curing System