BICP Wins Post-Tensioned Floor Project for Luoyang Cigarette Factory

Traditional industrial floors with numerous saw-cut and construction joints are prone to edge spalling, dusting, and step formation under heavy loads and frequent traffic, affecting production continuity and maintenance costs. The client sought a durable, low-maintenance floor system with improved flatness and crack resistance.

BICP's Taiping integrated floor system was selected, specifically the post-tensioned integrated floor solution. This system incorporates horizontal prestressing tendons to introduce compressive stress into the floor slab, effectively controlling cracking from concrete shrinkage and temperature variations. By eliminating up to 80% of traditional joints, the system reduces joint-related damage, dust, and maintenance interruptions.

BICP won the bid for the post-tensioned floor of the Luoyang Cigarette Factory relocation project (Phase I: joint workshop and administration building). The project is invested by Henan China Tobacco Industry Co., Ltd. Luoyang Cigarette Factory, designed by SIPPR Engineering Group Co., Ltd., and constructed by China Construction Fifth Engineering Division Corp., Ltd. Operations were scheduled to start in 2019. Once completed, it will support the 'Golden Leaf' brand, producing 300,000 large cases of cigarettes annually with an estimated tax revenue of 2.5 billion RMB.

In industrial floor structures, heavy equipment loads, temperature variations, concrete shrinkage, and soil friction often lead to spalling, cracking, and deformation. Repairing such damage significantly impacts production and incurs high costs. The post-tensioned concrete floor system addresses these challenges by embedding horizontal prestressing tendons that create compressive stress in the slab, enhancing crack resistance and reducing joint spacing.

Key advantages of the post-tensioned integrated floor:

• Reduced joints: Traditional joints lose load transfer capacity under dynamic loads, causing deflection, cracking, and edge damage. Post-tensioning provides self-recovery after overload, allowing joint-free design, reducing maintenance costs, and improving production efficiency.
• Enhanced durability: Precompression effectively controls cracking from shrinkage and thermal stress.
• Greater stiffness and flatness: Post-tensioned floors exhibit higher rigidity, resisting deformation from soil moisture changes.

Note: The Taiping system comprises three technology lines: post-tensioned integrated floor (for industrial facilities, underground garages and cold storage), UHPC integrated floor, and UHPC long-lasting repair.

This case demonstrates the application of BICP's post-tensioned floor technology in a large-scale industrial facility, highlighting key benefits such as reduced joint maintenance, enhanced durability, and improved operational efficiency. It serves as a reference for similar projects requiring high-performance floor systems.