Taiping System: 120m Ultra-Long Joint-Reduced Integrated Floor for Shifang Cigarette Factory Relocation Project

Traditional industrial floors have numerous saw-cut and construction joints, leading to edge spalling, dust, unevenness, and production disruptions for forklifts and AGVs. High demands for cleanliness, heavy loads, frequent traffic, and long-term durability require a robust floor solution.

The Taiping system, a post-tensioned integrated floor solution, was applied across workshops including tobacco processing, temporary storage, blending, leaf storage, packaging, and high-bay warehouse. Key measures: single-pour bay length up to 120m, area up to 6,300 m² per bay, total area ~40,000 m². Eliminated surface saw-cut joints, reduced structural joints by 80%, and controlled cracking through optimized concrete mix, post-tensioning, and construction monitoring. Finite element analysis coupled floor-slab and subgrade models to determine slab thickness and tendon layout. Collaborated with floor finishing contractor to optimize materials and methods for flatness.

Project Overview

The Shifang Cigarette Factory Relocation Project of China Tobacco Sichuan Industrial Co., Ltd. is located in the Shifang Economic Development Zone (South), covering approximately 370 mu (24.7 hectares) with a total floor area of about 117,000 m². The project adopted the Taiping system—a low-carbon integrated floor solution—for the joint workshop's tobacco processing, temporary storage, blending, leaf storage, packaging, and high-bay warehouse areas. The system achieved a maximum single-pour bay length of 120 m, a maximum single-pour area of approximately 6,300 m², and a total post-tensioned integrated floor area of about 40,000 m².

Challenges and Solutions

Challenge 1: Large-volume concrete placement and crack control

With single bays up to 120 m long and 6,300 m² in area, all concrete had to be placed within one day, posing significant challenges for construction organization, concrete quality, crack control, and flatness. The Taiping system provided full-process technical consultation, including concrete mix design, workability optimization, and key construction and curing instructions, resulting in a defect-free floor.

Challenge 2: Heavy loading requirements

Production floor live load: 20 kN/m²; high-bay warehouse live load: 100 kN/m². A coupled floor-soil finite element model was used to optimize slab thickness and tendon layout, ensuring structural adequacy.

Challenge 3: High flatness requirements

Tobacco processing lines up to 100 m long demand exceptional floor flatness. The Taiping system collaborated with the floor finishing contractor to optimize surface materials, construction methods, and machinery, achieving the required tolerances through self-inspection.

Advantages of the Taiping System

• Eliminates construction joints, retaining only minimal structural joints
• Reduces shrinkage and flexural cracking, enhancing durability
• Minimizes joint maintenance, lowering lifecycle costs
• Improves flatness by eliminating joint curling
• Allows reduced slab thickness while improving overload capacity and recovery

Application Boundaries

• Post-tensioned integrated floors (Taiping) are suitable for industrial plants and underground garages, not for cold storage.
• For cold storage, use UHPC integrated floor or UHPC repair system.
• Shente New Materials products (Tai'an anchors, Tairen armored joints, Taiqing anti-leak anchors, Taiheng UHPC) should be selected based on specific structural and floor system requirements.

Achieved 120m joint-reduced monolithic floor bays, reducing maintenance and improving production continuity. Suitable for tobacco, logistics, lithium battery, and biomedical manufacturing facilities. Post-tensioned integrated floors applicable to industrial plants and underground garages; for cold storage, use UHPC integrated floor or UHPC repair system. Shente New Materials provides in-house prestressing anchors (Tai'an), armored joints (Tairen), anti-leak anchors (Taiqing), and UHPC materials (Taiheng) for quality assurance.