Why the Floor Is the Foundation of Your Industrial or Warehousing unit?

In industrial and warehousing facilities, the flooring takes the most abuse—yet it’s often the first place businesses try to cut costs. That initial saving? It rarely pays off in the long run.

The Hidden Price of a Cheap Floor

Poor surface preparation. Substandard materials. Rushed installation.

They might pass visual inspection at first, but problems begin to surface soon after, usually after "so called DLP period"

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While most of the time and attention of the warehouse supervisors is focused on making the men and the machinery work, no one pays attention to a supposedly less important aspect, the cleaning of the warehouse floor.A lot of energy and time goes into ensuring that forklifts work, deadlines are met, conveyors operate properly, and everything moves like clockwork.However, due to the extensive work involved and that too in a time bound manner, cleaning warehouse floors is no mean feat.

This is a tragedy because even though floors endure a lot of wear and tear on a daily basis, they aren’t maintained properly. They are subjected to spillage, tire scratches from MHE as well as debris, physical impact, chemical washes etc.

One needs to understand that keeping a warehouse floor clean not only keeps the products in good shape, it increases the lifespan of a product and saves it from getting exposed to dust and dirt.Lack of maintenance of floors is not only an unpleasant sight, it is also a safety and health hazard, especially in the case of food production companies and pharmaceutical companies & laboratories.

Thus, one must ensure regular and timely maintenance of floors by a first level cleaning of stains and debris to prevent slips and mishaps. And to take it a step further, a regular cleanup to remove stains and restore gloss can go a long way in increasing the longevity of the floor.This is where polished concrete floors have an advantage over regular floors. Their shine and sheen requires low maintenance and is easy to clean, which makes them a low maintenance option.

According to a report, the value of the Automated storage and retrieval systems  (ASRS) market in 2017 was 12.41 billion USD and is expected to nearly double by 2023.ASRS & Process Automation Systems is widely used in manufacturing facilities, distribution centers, and warehouses throughout the world.

The dynamic change in technological innovations has made modern day warehousing ahead of its times. And the concrete flooring which was once neglected and considered unimportant has become the soul of the warehouse.

Flat concrete flooring (FM2 type) has direct impact on the productivity and efficiency of the floor. If the floors are uneven or flawed, it will not only slow the speed of work but also cause mishaps and downtime, resulting in massive losses.Today, the concrete floors are designed and built with a provision to support artificial intelligence (AI) based robotic MHE and automations. This has taken the performance of distribution centres to a superlative level.

Being the pioneers in Concrete Flooring, BGSB leads in high performance floor construction of robotic warehousing solutions in their flooring designs. These ASRS & VNA type warehouses not only reduce labour costs and increase sorting capacity, but also minimise human error.Choose BGSB for state-of-the-art flat concrete floors that are designed to meet the technological demands of the warehouses in this dynamically changing era.

The Future of Flooring - Laser FM2 & FM3 Floors

With the dynamic growth of e-commerce and industrialisation, the demand for perfect Flooring is inevitable. Since Flooring is the edifice on which the warehouse and its productivity lies, this peaks the need for Faster Floors, Flatter Floors and High Performance Floors. This is the need of the hour in every warehouse and industrial facility that is striving to meet the ever growing consumer demand.

This puts the flooring contractors under a lot of pressure as the demand of the customer increases by the day. At BGSB, we bring together the finest amalgamation of machine and manpower, experience and expertise and cast Superflat Laser FM2, FM3 Floors, DM1 Floors, Jointless Floors, Steel Fibre Reinforced Concrete Floors to name a few.

To ensure optimum efficiency and smooth operations, BGSB has procured top-of-the-line laser screed machinery that helps in achieving the desired results. Laser technique helps in covering a wider area that reduces the time taken and enhances the efficiency. It reduces the dependency on manpower as it operates with technology and the end result is accurate, flawless and superflat.

The tolerances achieved with this machine in free movement slabs are FM2, and FM3 in accordance with the TR34.

Owing to space difficulties and storage issues, VNA storage has become the most obvious choice for warehouse facilities.

VNA storage warehouses have evolved to be one of the most efficient and productive way to stack stuff and meet the growing need for utilising every bit of space. One very important factor in the success of a VNA warehouse is its flooring which determines the speed, safety, smooth operations and productivity of the warehouse.

VNA Warehouse floors are meant to be flat and leveled in accordance with TR34. They are built and designed with meticulous planning and specifications and need to be in proportion with the height and width of the storage racks and the aisles. The higher the rack height, the flatter will the floor need to be.

Another very important factor in the efficient operations of VNA Warehouse is the flawless movement of Heavy Equipments that need to be carefully manoeuvred between the aisles and depends on the floor flatness and levelness. VNA storage warehouse must have jointless and durable floors in order to ensure safety, productivity and speed.

In order to build and design world class VNA storage warehouse, BGSB has state of the art machinery, futuristic technology, highly skilled manpower. BGSB casts high performance VNA storage floors in a way that requires less maintenance ensures optimum productivity. We study the usage, the height, the weight and then create a roadmap of design and build that is carried out by our team of specialists.

Why Your Warehouse Floors Are More Important than Ever in 2025

As warehouses embrace the future of automation, robotics, and AI, their floors must keep up. Today’s warehouse floors aren’t just for holding inventory—they are key to ensuring smooth operations. From robots moving goods to forklifts gliding seamlessly across the floor, warehouse flooring technology plays a huge role in making modern logistics efficient and safe.In this guide, we’ll explore the top trends in warehouse flooring for 2025 and how BGSB Concrete is paving the way for smarter, more durable floors.

1. Super Flat Floors: A Must-Have for Robots and Automated Systems

Why It Matters:

Robots and automated delivery systems require smooth, perfectly levelled floors to operate at peak performance. Even a slight bump or uneven surface can cause automation to malfunction, reducing efficiency and increasing downtime.Our Solution:
We use laser robotic system and highly skilled operators to ensure ultra-flat casting of floors that are optimised for automation. The result? Smooth, levelled and flat surfaces that support even the most advanced and sensitive robotic systems and ASRS racking.Benefits:* Increased efficiency in automation
* Reduced maintenance costs for equipment
* Enhanced safety for workers and machines

2. Fewer Joints, Fewer Problems: Jointless & seamless Floors for Maximum Durability

Why It Matters? Traditional warehouse floors are often riddled with joints. Over time, the edges of construction joints tend to crack resulting in damaged joints, especially under heavy loads or constant MHE traffic. These imperfections can disrupt or slow down automated workflows and increase the need for repairs. In addition it also leads to damage of jerk sensitive PU wheels of MHE and the replacement cost of such wheels goes north of $1500 approx. 

Our Solution: At BGSB Concrete, we specialise in jointless & seamless floors, with large pour - hybrid design using weld mesh, steel fibres and Shrinkage Reducing Admixtures (SRA) to eliminate the common issue of shrinkage cracking. This means less or NO cracks, smoother movement, and longer-lasting floors. BGSB uses and promotes use of "Glide Armour Joint” due its design versatility which ensures super smooth load transfer over the joints. 

Benefits:* NO downtime for repairing joints

Why the Floor Is the Foundation of Your Industrial or Warehousing unit?

In industrial and warehousing facilities, the flooring takes the most abuse—yet it’s often the first place businesses try to cut costs. That initial saving? It rarely pays off in the long run.

The Hidden Price of a Cheap Floor

Poor surface preparation. Substandard materials. Rushed installation.

They might pass visual inspection at first, but problems begin to surface soon after, usually after "so called DLP period"

A warehouse or an industrial facility is the hub of all action. That makes it prone to many issues and challenges. One of the biggest hazards that a warehouse faces is the safety hazard.

One of the key factors responsible for contributing to the safety of a warehouse is its flooring. Many structural issues are caused by weak or unlevelled surface. Floor undulation is the primary cause of mishaps such as tripping incidents as they affect the stability of the floor thereby endangering the safety of the workers.Poor floor flatness also have negative impact on the performance of machinery and the tools in the warehouse. If the floors are flat enough, it will be disastrous to the stability of the racking system and the smooth running of the forklifts (MHE) and delivery trucks. In order to avoid accidents it’s usually seen that operators of MHE’s will run the equipment at lower speeds, thereby slowing down the efficiency of the warehouse hence, lowering the productivity.

Thus it is crucial to have flat floors to ensure safety, productivity and longevity of the warehouse. At BGSB, we cast superflat concrete floors for all your warehouse and industrial facility needs that will give your warehouse floors a longer life and a better output. Think flooring, think BGSB.

While Epoxy is a chemical compound, Polished Concrete is a composite material that is composed and bonded.First, let’s talk about what sets them apart. There are many differences between epoxy and concrete polishing.We all know a warehouse is subject to wear and tear, heavy loads, chemical stains etc. Polished concrete gives a satin smooth and clean surface that does not peel or scratch as compared to epoxy flooring which can scratch.

A warehouse also incurs a lot of expenditure and the costs involved are astronomical. Polished Concrete flooring enhances light reflectivity by 100% and reduces the electricity costs by leaps and bounds.Also, Polished Concrete Flooring are low maintenance floors that remain presentable and clean if maintained properly as compared to an epoxy floor which requires various cleaning procedures to remove dust and debris build up.

Thus, it is no guessing game that when it comes to Warehouse Flooring, Polished Concrete flooring certainly has an edge over Epoxy flooring and is a much smarter decision. But choose only the best for extraordinary results. Opt for BGSB, the market leader in Polished Concrete Flooring for your commercial space.

 Sinus-shaped armour joints allow smooth & jerk-free movement of MHE and forklifts over the construction joints and allow proper load transfer between floor slabs. It is because if it’s special shape which is not straight like conventional it classic shaped joints. They not only help in proper load transfer between slabs but also ensure longevity of the floor.

At BGSB, we use the best quality Sinus-shaped armour joints essentially required for constructing sturdy and seamless concrete floors.

Now Introducing superflat Concrete floors in India which will facilitate smooth and quick VNA (very narrow isle) movement within your warehouses and factories.

From ordinary concrete floors, you can make a very interesting, inexpensive and durable flooring that holds permanently by concrete polishing. Even when renovating the floor, sanding and polishing can be a way of repairing a concrete floor in need of renovation.

Polish Concrete Floor

In commercial buildings, exposed concrete is often planned from the outset as a very durable and durable floor covering. Another floor covering is not necessary.During production, care is also taken to ensure that the surface is a bit smoother.

An ordinary concrete floor can also be used as a floor covering, if you grind it first, and then polished to shine. Of fair-faced concrete then distinguishes him only the "ordinary" optics.

Ground concrete floor as a stylistic device

When it comes to obtaining the most discreet and deliberately sober-looking floor covering, a sanded concrete floor is very suitable. In the interior, this can also be a ground screed.The floor is then very resistant to abrasion, has an interesting, but very subtle look due to the not quite uniform surface, and does not require baseboards.

Concrete flooring is a massive growing trend and its roots are spreading in the flooring market in warehouse, retail, and decorative facilities across India & the globe.Concrete flooring has transformed more than any other concrete trade in the last decade. From conquering the industrial flooring type into the architectural and retail world.

It’s myriad features such as durability, strength, value for money, sustainability make it the new acceptable standard in commercial and industrial flooring

Concrete flooring has graced the space in high-visibility and high-traffic commercial spaces, such as retail stores, restaurants and salons. The better substitute for wood, vinyl tile, and carpet.

Concrete’s ability to take pressure and wear and tear is much more than most flooring materials. Add to it, versatility that allows it to be customized to suit any spectrum, is what sets it apart.

Concrete Floors are best suited for high-traffic retail facilities because of their durability and design versatility. Concrete flooring stands for durability, abrasion resistance and low maintenance.

Crazing, a network pattern of fine cracks that do not penetrate much below the surface, is caused by minor surface shrinkage.

Crazing cracks are very fine and barely visible except when the concrete is drying after the surface has been wet. The cracks encompass small concrete areas less than 50 mm (2 in.) in dimension, forming a chicken-wire pattern. The term “map cracking” is often used to refer to cracks that are similar to crazing cracks only more visible and surrounding larger areas of concrete. Although crazing cracks may be unsightly and can collect dirt, crazing is not structurally serious and does not ordinarily indicate the start of future deterioration.

When concrete is just beginning to gain strength, the climatic conditions, particularly the relative humidity during the drying period in a wetting and drying cycle, are an important cause of crazing. Low humidity, high air temperature, hot sun, or drying wind, either separately or in any combination, can cause rapid surface drying that encourages crazing. A surface into which dry cement has been cast to hasten drying and finishing will be more subject to crazing. The conditions that contribute to dusting, as described below, also will increase the tendency to craze.

To prevent crazing, curing procedures should begin early, within minutes after final finishing when weather conditions warrant. When the temperature is high and the sun is out, some method of curing with water should be used, since this will stop rapid drying and lower the surface temperature. The concrete should be protected against rapid changes in temperature and moisture wherever feasible.

Hearing a hollow sound in your concrete floor? Or while tapping your floor, you discover more such empty, loud rings?Well, your concrete floor could be facing the common yet serious problem of delamination. A problem that’s audible even before it becomes visible.

Delamination is the detachment of a surface layer (top wear layer) due to the various technical reasons, including but not limited the ill-timing of hardener broadcasting, mix design issues or final trowel finishing process, which must only be started at an appropriate stage while the concrete is still green.

It is troweling that compresses and lessens the penetration of the surface layer of the concrete floor. If it’s done ahead of time, bleed water or air can be trapped below the cemented surface layer forming blisters that delaminate the surface.From our pouring experience of over a decade, we suggest to tackle such problem with a few noteworthy points that helped us overcome this situation and counter it successfully: