Taiping® Post-Tensioned Integrated Floor System: Low-Carbon Innovation for Sichuan Zhongyan Shifang Cigarette Factory Relocation Project

Traditional industrial floors have numerous control and construction joints, leading to edge spalling that disrupts forklift and AGV operations. Clean, heavy-load, high-traffic environments demand superior flatness, durability, and low maintenance. Floor solutions must be evaluated considering load, subgrade conditions, production workflow, and lifecycle costs.

The Taiping® post-tensioned integrated floor system reduces joint count by approximately 80%, minimizing edge damage, dust, step displacement, and production interruptions. The iBLM TaiShu Cloud AI-powered digital management platform enables multi-scheme comparison in about 60 seconds, generating 3D models, floor plans, material quantities, and preliminary cost estimates based on China's 34-province quota system. The platform supports client communication, project management, maintenance, and full-lifecycle digital twin archiving. The ST-NSM anchorage system, developed by Shente Materials, ensures reliable post-tensioning performance. Finite element analysis was used to design the foundation-floor interaction for safety and economy.

With the rapid development of modern construction, production environments in clean industrial facilities—such as pharmaceuticals, tobacco, and food processing—face common challenges: (1) numerous control joints due to concrete's low tensile strength, (2) floor cracking compromising cleanliness and product quality. The Taiping® post-tensioned integrated floor system offers a low-carbon, joint-reduced solution. This case study of the Sichuan Zhongyan Shifang Cigarette Factory relocation project illustrates how the system resolves these issues.

Project Overview: The post-tensioned floor covers approximately 25,000 m² with a design load of 3.0 t/m². The floor was divided into 9 construction zones based on functional areas, load distribution, soil conditions, and construction logistics. The largest single pour measured 120 m in length and 6,300 m² in area.

Key Features:

• Joint-Reduced Design: The post-tensioned floor slab acts as a fully compressed element, compensating for concrete's low tensile strength and enabling large-area, joint-reduced construction.
• Enhanced Cleanliness and Load Capacity: The joint-reduced design eliminates dead corners, inhibits bacterial growth, maintains design cleanliness, reduces maintenance frequency, eliminates differential settlement and step displacement, and provides overload recovery capability.
• Finite Element Analysis: Combined with geotechnical data, code requirements, and functional zoning, finite element analysis ensured safe, reliable, and economical design of the foundation-floor system.
• ST-NSM Anchorage System: Developed by Shente Materials specifically for post-tensioned integrated floors, this system guarantees reliable performance and high-quality delivery.
• BIM Visualization: 3D BIM technology was used for layout and construction detailing, ensuring quality compliance.

After one year of construction, the project is now ready for production. The Taiping® post-tensioned integrated floor system delivers joint-reduced design, long-term cleanliness, enhanced load capacity, and elimination of differential settlement, fundamentally addressing client concerns.

Comparison with conventional concrete floors shows significant advantages in joint reduction, cleanliness, load capacity, and maintenance. The system is increasingly adopted in clean production workshops.

Application Boundaries:

• The Taiping system includes three technology lines: post-tensioned integrated floor (for industrial facilities and underground garages), UHPC integrated floor, and UHPC long-life repair (for cold chain warehouses, industrial facilities, and underground garages). Post-tensioned floors are not used in cold storage.
• The iBLM TaiShu Cloud platform serves as an AI-assisted decision tool for scheme comparison and digital twin management; its outputs should be reviewed by professional engineers.
• Shente Materials should be selected based on specific structural system, floor type, and project conditions.

This case demonstrates how the Taiping® post-tensioned integrated floor system addresses common pain points in clean industrial facilities: reduced joints, enhanced cleanliness, higher load capacity, elimination of differential settlement, and lower maintenance frequency. The project achieved a maximum single-pour area of 6,300 m² with a length of 120 m, showcasing the system's capability for large-span, joint-reduced design.