TENSIOPAV

Post-Tensioned
Industrial Floors

Joint-less
No Cracks
No waving
Engineered
Controlled

Guaranteed With a posthumous

10 Years Insurance
Policy covering
replacement of the job

Techinfloor ®
Innovative technologies for flooring
 Post-tension: from major buildings

P
ost-tension, applied to industrial floors represents a revolution
in the Market, a new concept of quality and professional
approach.
Techinfloor is the exclusive Distributor in Europe of the Post-
tension System, called TENSIOPAV, developed within an
International partnership with ORI Martin Group, with SLM
- Siderurgica Latina Martin -, manufacturing Company of steel
unbounded strands and cables, and with TTM, a leader Firm in
planning and application of the Post-tension System on major
building jobs such as bridges, aqueducts, Interports, etc.
TTM provides complete consultancy support, from the
planning phase to supply of the Post-tension Hard ware and designed, from the thickness of the plate, to the strand
(accessories, electronics, stressing jacks), to the final disposition and the additional armor, as well as the specific
tensioning phases. Such innovative Technology consists on characteristics of the concrete.
replacing the traditional armor (electro-sealed nest, metallic The concrete mix design, the pre-qualified recipe verifying
fibers, synthetic fibers, glass fibers, etc.) with unbounded, the characteristics of the mix in the concrete trucks, and the
greased and sheathed, drowned in the concrete steel strands, constant control techniques applied directly on the job site, will
then Post-tensioned with hydraulic stressing jacks. create a mapping of the constructive whole process.
TENSIOPAV System is guaranteed: from the initial engineered A floor finalized with the TENSIOPAV System will therefore
planning which influences the effects of all operation, to the result scientifically projected, punctually checked and guar-
typical techniques of the foundation, up to resistance against anteed with a 10 Years Posthumous Policy Insurance
the loads, both static and dynamic; everything is engineered covering replacement of partial or total work.

TTM tension technology

Post tension anchor system
s.r.l.

The advantages
• No more Joints
• No more cracks
• No more waving effects
• No more gradient differences among the edges of the plates
• Thickness reduction of the plate
• Flatness and improved link among the plates
• Maintenance costs dramatically reduced
• Better comfort of use
• Better image and aesthetical effect
• Control of the whole building process (from the steel strand
production to the final floor finalization)
• Posthumous 10 Years Insurance Policy
to concrete industrial surfaces

TENSIOPAV is the solution to the traditional problems of each

industrial floor: it is now possible to create floors without joints,
without cracks, without waving, wide monolithic surfaces, with
reduced thickness, which provide high flatness and drastic reduction
of maintenance costs.
TENSIOPAV proves to be perfect for all implants which are build
to have high shelves, highly concentrated and dynamic loads,
systematic circulation of vehicles with low wheels, floors with resin
coverings, and in general for all the highly functional and industrial
surfaces.

> Post-tensioning applied to radiant surfaces

TENSIOPAV System is the perfect solution where a heated floor

is planned: the post-compression of the concrete, in fact, creates
a resistance to revealed cracks created by the continuous cycle of
cooling and heating of the radiant floor.
The linear expansions inducted by the thermal variations are
limited, so a perfect efficiency of the whole structure in terms of
global resistance and performance is actually provided.
TENSIOPAV can provide absolute application flexibility versus any
traditional system: irregular geometric shapes (triangles, trapezes,
narrow rectangles, etc.) and/or outdoor floors with complex con-
structive parameters can be built at ease.
Techinfloor
The revolutionary TENSIOPAV System conjugates therefore
Special steel Technology with a total process control, when it
comes to realization of concrete floors.
To assure the overall coverage, a constant assistance, and a
State-of-the-Art execution of any job, Techinfloor has selected
some of the most important Companies of the industrial
floorings on the European market, gathering all of them in
the ”TENSIOPAV Group”: every member Company is active
since many years, with high skills and professionalism, in the
industrial floorings Market, and represents a valid partner
within the Group and a reference point for Engineers and Buyers
of their related area.
Techinfloor provides, after a following audit from one of the
most important Insurance Groups, a 10 Years Posthumous
Insurance Policy covering partial or total replacement
of the Post-Tensioned job; this being a formal result of the
punctual control of the whole productive process, that assures
the Customer for an exceptional State-of-the-Art realization.

Engineered planning, punctual control, no crack, no control and expansion

joint, dramatic maintenance costs reduction, reduced thickness, resistance and
durability are the major highlights of this new technology, that represents the top
of what the market of the Industrial floorings offers on a World Wide Base today.

TENSIOPAV Group is distinguished for:

• qualified technical support
• certified and Tested overall Quality
• specific and reliable Know-how
• consolidated business references
• constant assistance to the Customer
• serious and professional approach
• peculiar competences

In order to know details

of each different associated Company
member of Tensiopav Group,
please consult the site www.tensiopav.it
 The building process
Engineered Planning
The concrete Post-Tensioned plate is dimensioned with an
accurate engineered planning of each single detail, beginning from
Punctual control of the whole productive process

the position of the steel strands, the evaluation of the distance

between nest strands, the position of a low armor at the bottom
of the punctual and distributed loads, up to the organization and
the sequence of the concrete placements with respect to the
specific requirements.

Verification and preparation of the foundation

The careful and accurate preparation of the foundation is a fun-
damental must, when the use of the Post-tension System is
planned: it is mandatory to verify the carrying ability, the planarity,
the degree of compact resistance and homogeneity of the founda-
tion; a double layer of polyethylene is put on ground in order to
create a layer that isolates the concrete plate from the ground,
and to reduce attrition during Post-Tensioning operations.

Custom cut and position of the steel strands

Predisposition of the closing procedure with the easy-system,
position of the slow armors around the pillarsand to the fixed
points of the structure, carrying out strand distribution, cut of the
strands and their position according to the original planning.

Throw and punctual control of the building process

During the distribution on ground, the strand nest is set on distance
chairs to the appropriate level comparing to the thickness of
the plate. During the concrete placement, an integrated control
of the concrete and its technical characteristics is set in place
by collecting the samples on which a certified Laboratory will do
the proper tests, and from which it will extrapolate the minimum
tensioning values.
In order to enable the correct access of the stressing jacks for the
following tensioning phases, a free band is set up two sides of
the perimeter of the structure; this perimeter will be armed and
subsequently covered with concrete.

Partial and final Tensioning

The first stressing, or partial tension, will be applied usually after
24 hours with a special hydraulic stressing jack, in order to oppose
the plastic micro-cracks of the concrete.
As soon as the fit resistance of concrete will be reached (usually
after 72 hours), concrete will be finally post-tensioned, so that this
will confer the plate the carrying ability required by the project,
and the construction joints will be compressing one against the
other the linked lots.

Superficial finish and closing of the perimeter band

As soon as Post-tension System is applied, the free perimeter
band will be covered with concrete, and chemical surface
hardening finishes will be applied.
Engineered Planning

> Floor Engineering

The planning of the steel strand nest, with the evaluation

of the relative distance, is a mandatory step into the
realization of the work. It assures the correct evaluation
of all the constructive parameters and it guarantees that
the work is finalized according to the engineering criteria
related to the Post-tension Technology.
TTM always will guarantee an immediate answer to
the application requirements of the Customer, assuring
a flexible and reliable approach during calculation, sizing
and planning of the TENSIOPAV system.
Last generation software application, allows to develop
the calculations in perfect relationship to the loads that
the floor will have to bear, based on the use destination
of the property, and to where the structural loads may be
distributed in particular points of the structure.
The project comprehends constructive details, passive
armors location and slow armors placement along and
around the pillars.

“The State-of-the-Art engineering of industrial floorings”

 Preparation of the foundation

P
reparation of the foundation represents the first operational and fundamental step into the construction
of a Post-Tensioned surface using the TENSIOPAV System.
The interventions particularly to be taken care of, are the ones related to the followings essential
requirements:
• Compact pressure in order to avoid yeldings when the floor is in exercise phase;
• Leveling, in order to allow the free slide of the plate.
It results therefore fundamental, to perform technical surveys focusing on the Deformation Degree of
the foundation, applying tests on the plate, both static and dynamic.

> Verifications of the foundation material char-

acteristics and of ground conditions, through
plate tests

The Load Test on static plate with consequent calculation

of the Deformation Degree, is necessary to verify that the
foundation will support performance requirements imposed by
the specification of the engineered plan.
The resistance control Test on the job site, in correspondence
of the foundation, is in fact of fundamental importance in order
to be able to guarantee the minimum requirements of ground
mechanical resistance and stability against the loads that will
cover it. To verify then the homogeneity degree of the ground
foundation, the device LIGHT FALLING will be used, and then
the WEIGHT DEFLECTOMETER as below specified.
The 300 mms diameter and 20 mms thick galvanized steel plate,
can be considered stiff as per the calculation targets of the plan
submitted to the test: the load assumes form of a damped hit,
and the test is said to be dynamic.
The test LFWD is a functional beta methodology: efficient, rapid
and representative.
It will be necessary to compare results of the deformation form
versus the dynamic Evd values, and with the middle values Md
of the test of load statics.

> Barrier to Moist and double slide layer

The sheet of polyethylene, in double layer, is put above the

compacted foundation material, and it develops the double
function of barrier to the moist, and of layer of slide that
allows the Post-Tensioned plate to stir without rigid ties in
the tensioning phase or during longitudinal movements.
In fact, as quoted by the norm UNI 11146, the sheet of
polyethylene in double layer introduces the lowest attrition
coefficient among the plate and the foundation and it results
ideal for the post-tensioned applications.
Easy-system Closing Procedure

T
he closing procedure of the assembly plates
has been optimized with the definition of
the Easy-system Closing Procedure, that
guarantees rapidity and precision while in the
phase of concrete placement preparation: the
following phases result rapid and secure and
the construction joints are properly sealed
and proteceted.

> Assemblage of the perimetral closing bends

The easy-system is projected for this particular job, and is

constituted of two symmetrical metal stirrup and by one closing
wooden band.
The upper stirrup closes on the wooden band and fixes the
closing in a rigid way so that it is possible to regulate the plate
thickness determined by the project requirements.
On the wooden band are subsequently fixed the active heads, or
the heads from which the entrance stressing jacks are set up for
the following phases of partial and total tensioning.
 Strands
> Carrying out on the job site the strand
placement

The carrying out of the steel strands takes place on the job
site thanks to a system patented by TTM, our Partner in
Post-tensioning: the spool is loaded on a base with
a particular cone connected to a pushing system controlled
by an hydraulic device. The particular mechanism allows
to develop the spool in simple way and in full safety,
paying particular attention to the free end of the spool,
that can result dangerous even if engaged into the conic
base.
The spool is pushed out beginning from the cone, which
controls the carrying out process and allows the correct
placement of the long strands all over the floor.

> Cut of the strands

The strand goes out from the wheel along a metallic line, and once
fixed the desired length, the strand is cut to measure coherent
with the project.
The repeated operation creates the set of strand necessary to the
job in an easy, safe and fast way.
Strand nest Placement and Heads fixing

>  Installation of the wedges in the headings and binding

of the intersections of the strand nest

The heads anchorage is done fixing the wedges in the heads at the end of
the strand, through the following operations:
• cut of PVC cover, approximately for 5 cms, from the end of the strand;
• positioning of the heads on the strand and insertion of the wedge in
order to assure its fixing; this operation is necessary in order to fix, in
a total safe environment, the passive head which, drowned into the
concrete, will be highly solicited during the Post-tension action.
The consequent consists of putting to strands on a network design,
distancing them correctly in both directions, and sealing each single
intersection in a way that can guarantee the correct positioning after the
concrete trucks have delivered the cements.
 Additional passive armors

>  Installation of passive additional non pre-tensioned

armors

In order to better distribute loads along the perimeter dedicated to the

heads, additional metal bars are put along the closing ends, so active
heads will not mode while concrete will be stressed.
To absorb tensions in elevation and close to the pillars, additional armors
are positioned as per engineered planning.
The vertical structures englobed in the concrete placement throws
(pillars, grits, walls,etc) will become isolated with compressed but thick
materialproven to to guarantee the slide of the plates while in post-
tensioning phase.
Laser Screed-based concrete Placement

> Concrete Placement on the job site

The Concrete Placement is usually done with Laser Screed

technology, the laser controlled Machine with vibrating control
that guarantees highly compact pressure of the concrete, together
with a flatness degree: the vibro-placement of the upper part of
the concrete allows air molecules to evaporate, so the floor will
be free of micro-cracks and nests.
Besides that, the Laser-Screed sensitively reduces execution
times, allows to compact surfaces much better than with the
traditional manual placement.
Contextually to the concrete placement, the needle vibrating
operations take place, while the distance chairs are set up on the
crossing, following project specifications.
Punctual control of the concrete

> Punctual control of the concrete

The technological building process of the TENSIOPAV System includes

also a pre-qualification of the concrete implant, in order to make sure
that the optimal prescriptions of the mix-design and the punctual control
of the mixture of furnished concrete are guaranteed: on the job site
specific tests are performed according to normative, and according to
the Pavical requirements to comply to the project applications in terms
of resistance and composition that the concrete must guarantee for a
proper application of the Post-tension System.
The samples collected in square dice are submitted to crushing in
certified laboratories so that the resistance matured from the concrete
after 24 and 72 hours are defined and inspected and therefore, once
extrapolated, the relative pressure levels will be applied from the
stressing jacks during post-tensioning operations, both partial and final.
Partial and final Tensioning operations
> First partial tensioning

The wooden band is removed the following day after the

concrete placement, only if concrete has reached the correct
strength in order not to be damaged.
Cleaning of the anchorage hollow takes place, then it is
important that the stressing jack does not have any obstacle,
and that the wedges are perfectly installed in the headings.
Integrity of the concrete is checked, both along vertical and
the longitudinal parts of the surface, and that there are not
cracks, or nest effects, or micro-caves.
A deep check is dedicated that strands are perpendicular to
the anchorages and that the anchorages parallel to the face of
concrete, then the stressing jack is set for operation.
The stressing jack has a designed device that exactly covers
the taking of the strand in the exact end point of the concrete
placement.
Introducing a small pressure on the jack, it is able to com-
pensate, partially or totally, the traction stress nduced by the
spontaneous withdrawal of the concrete.

Piston excursion

> Final Tensioning

Fixing wedges are perfectly positioned to avoid their separation
during the positioning of the stressing jack.
A specialized operator of TTM is there to properly apply the
Post-tension procedures, coherent with the recommendations
on safety operations defined by the same TTM.
After the Tensioning operations, actual extensions of the
strands are noticed, comparing them with the theorical ones
expected by the project requirements, and verifying the
perfect equipment efficiency.

Strand Extension
Post-tensioned Floor

> The Concrete Industrial Flooring revolution

Having a monolithic continuous Post-Tensioned surface is of

paramount importance for a Logistics and Great Distribution
Company, with electronic management systems of automated
carts, which won’t suffer anymore the problems caused by
waving floor plates or by broken joints.
TENSIOPAV System is the absolutely best solution for Firms
that need extremely high cleaning standard, because by
eliminating the joints, the primary cause of dust and degrade
of any kind is simply eliminated.
TENSIOPAV System satisfies, therefore, the most demanding
requirements, proving to be the ideal investment for sensitive
Buyers who focus on high qualitative standard.
TENSIOPAV System offers ideal support for potential super-
ficial treatments, chemical hardeners, polishings, resin finish-
es based on the specific techniques might come out from the
Customers’ requirements.

TENSIOPAV: the beginning of a new Era.

Techinfloor ®
Innovative technologies for flooring

Head Office
Strada Paolo VI nr. 15
91022 Castelvetrano (TP)

Contacts
Trapani
Tel xx39 - 0924 92 20 66
Fax xx39 - 0924 92 25 52
Bergamo
Tel xx39 - 035 44 90 412
Milano
Tel xx39 - 02 97 48 02 17

www.techinfloor.com The new Era

info@techinfloor.com of Industrial floorings

Exclusive Distributors for floor Systems

TTM tension technology

Post tension anchor system
s.r.l.

Members of
The ideal solution for

• Logistics and Great Distribution Companies

• Highly moving Hard ware Centers
• Automated Wharehouses
• Deposits
• Industrial Sites of any kind
• Malls
• Multi floor parking lots
• Electronics Centers
• Food Centers
• Frozen Food Centers
• Pharmaceutical and Medical Centers
• Airport Runways and Taxiways
• Airport Terminal
• Heated Floors