Логотип Спидвея
Поделитесь оптимальными решениями, Профессиональные знания в области HVACR и новости отрасли

Полное решение напольного покрытия в холодной комнате

Оглавление

In the global cold chain logistics, холодная комната serves as core hubs, where the reliability of infrastructure directly determines the storage safety and operational efficiency of high-value goods such as food and pharmaceuticals.

Often overlooked, cold room flooring acts as aninvisible guardian,” bearing the critical role of preventing energy loss and resisting structural damage under extreme low-temperature conditions, heavy machinery impact, and prolonged thermal-humidity coupling effects.

As cold chain demand evolves toward ultra-low temperatures (-60℃) and automation, traditional flooring systems frequently suffer from issues such as frost heave cracking and insulation failure due to design defect. These failures result in global economic losses amounting to billions of dollars annually.

The challenge of constructing high-performance flooring systems through scientific material selection, precise construction, and rigorous quality control has become a key technical focus in the field of cold chain engineering.

What is Cold Room Flooring?

Холодная комната flooring is a multi-layer composite flooring system specifically designed for low-temperature storage environments. It consists of a moisture barrier, insulation layer, structural load-bearing layer, and surface functional layer, ensuring stable performance under extreme temperature fluctuations ranging from -40°C to regular ambient temperatures.

cold room flooring 01

Its primary functions are to prevent thermal loss, support heavy equipment operations, and resist structural damage caused by low-temperature conditions, making it a fundamental infrastructure component for the efficient and safe operation of cold room.

1) Core Functions

1.1 Thermal Insulation

Mechanism: Uses high-density insulation materials such as XPS extruded polystyrene panels and PU polyurethane foam to block heat transfer between the холодная комната interior and exterior, reduce the refrigeration energy consumption.

Practical Impact: Poor insulation panel can increase energy consumption by 20%-40%, directly affect operational costs.

1.2 Load-Bearing and Compression Resistance

Load Types:

Static LoadPressure from storage racks and stacked goods (heavy-duty холодная комната can reach up to 5 tons/m²).

Dynamic LoadImpact from electric forklifts and AGV handling equipment (dynamic load factor ≥1.5).

Требования материала:

Steel fiber-reinforced concrete (compressive strength ≥30MPa) or reinforced concrete (rebar diameter ≥12mm, spacing ≤200mm).

Failure Risks:

Insufficient load capacity may lead to floor cracking and sinking, potentially cause rack collapse accidents.

1.3 Moisture and Frost Heave Prevention

Low-Temperature Threats:

Groundwater vapor infiltrates the flooring and freezes, expanding by 9%, which leads to floor cracking.

Защитные меры:

Install double-layer moisture barrier (например, 0.5mm thick PE film + SBS modified bitumen membrane).

Embed the electric heating system (power ≥25W/m) in the foundation to prevent frost heave.

1.4 Safety and Durability

Anti-Slip Design:

Surface coated with epoxy resin and corundum (Коэффициент трения ≥0,6) or textured anti-slip patterns (depth ≥2mm).

Устойчивость к коррозии:

Resists chemical corrosion from saltwater, grease, and de-icing agents in cold chain environments (epoxy coating withstands pH range 1-14).

Lifetime Standards:

High-quality cold room flooring has a lifespan of ≥20 years, which can extend to 30 years with proper maintenance.

2) Важность

2.1 Economic Impact

Энергоэффективность:

Cold room flooring accounts for 15%~30% of total холодная комната energy consumption. Например, in a 5,000㎡ cold room, exceeding the thermal transmittance standard by 0.1W/(m²·K) can increase annual electricity costs by 30,000USD.

cold room flooring 02

High Repair Costs:

Partial repairs cost approx. US$50~70 per square meter, while full renovations require 2-3 months of downtime, leading to significant storage revenue losses.

2.2 Обеспечение безопасности

Risk of Structural Damage:

Floor cracking can cause refrigerant leaks, leading to explosion risks.

Poor anti-slip performance can result in forklift skidding and worker injuries, directly threaten operational safety.

2.3 Long-Term Operational Stability

Reduced Maintenance Downtime:

High-quality flooring reduces maintenance-related shutdowns. Например, a logistics company which upgraded its flooring reported a 70% reduction in failure rates over 5 годы.

Differences Between Cold Room Flooring and Regular Flooring

СравнениеCold Room FlooringRegular Flooring
Температура-40℃ to common ambient temperature, resistant to freeze-thaw cyclesSuitable for common ambient temperature (no low-temperature request)
Structural DesignMulti-layer composite (insulation layer and moisture-proof layer)Single-layer or simple layering
МатериалFreeze-resistant concrete, XPS or PU/PIR panelRegular cement, tiles/wood flooring
ГрузоподъемностьDynamic load (forklift) ≥3 tons/m²Static load (furniture) ≤0.5 tons/m²
Construction ProcessRequire embedded heating cables to prevent frost heaveRegular installation

Cold Room Flooring Classification

The classification of cold room flooring needs to combine with their use environment, functional requirements and engineering and technical features. They normally can be divided from four dimensions: материал, функция, load-bearing capacity and temperature:

1) Материалом

The material of холодная комната flooring directly affects their thermal insulation, durability and cost. Common types are as follows:

ТипMaterial CompositionФункцииПриложение
Concrete Flooring1. Regular freeze-resistant concrete (with anti-freeze additives)1. High compressive strength (≥30MPa)Общая холодная комната (-25℃ ~ 0℃)
2. Steel fiber concrete (with added steel fibers)2. Resistant to freeze-thaw cycles (≥F200 rating)
3. Экономически эффективным
Steel Structure Flooring1. Galvanized steel plate and PU polyurethane sandwich panel1. Легкий (self-weight ≤50kg/m²)Prefabricated cold storage, temporary cold chain facility
2. Aluminum-magnesium alloy panel and VIP (vacuum insulation panel)2. Quick installation (modular assembly)
3. Detachable and reusable
Composite Material Flooring1. Epoxy resin and quartz sand1. Seamless surface (anti-bacterial and moisture-proof)Фармацевтическая холодная комната, food processing workshops
2. Self-leveling PU polyurethane and fiberglass reinforcement layer2. Wear-resistant and corrosion-resistant (lifespan ≥15 years)
3. Easy to clean and maintain
Special Material Flooring1. Nano aerogel insulation layer and carbon fiber concrete1. Ultra-low thermal conductivity (≤0.018W/m•K)Ultra-low temperature cold room (-60℃), research cold room
2. Phase change energy storage flooring (PCM materials)2. Self-adaptive temperature regulation
3. Green and energy-efficient

1.1 Parameter comparison:

Thermal conductivity: ordinary concrete (1.5W/m•K) > steel fiber concrete (1.2W/m•K) > polyurethane sandwich panel (0.025W/m•K) > aerogel (0.018W/m•K).

1.2 Cost range:

concrete (US$ 30~60/㎡) < стальная конструкция (US$ 70~120/㎡) < composite materials (US$120~200/㎡) < special materials (≥US$200/㎡).

2) По функции

Based on the special requirements of cold room, must design flooring systems with targeted functional layers:

2.1 Thermal Insulation Type

Structural Features:

Thickened insulation layer (XPS/PU/PIR panel ≥150mm)

Thermal bridge interruption design (например, thermal break aluminum alloy keel)

Приложение:

Low-temperature freezing room (≤-25°C)

Blast freezer

2.2 Anti-Slip and Wear-Resistant Type

Technical Solutions:

Surface embossing treatment (pattern depth 1-2mm, Коэффициент трения ≥0,6)

With anti-slip steel sheets (galvanized steel sheet with diamond anti-slip texture)

cold room flooring 03

Приложение:

High-frequency forklift operation zones

Seafood cold chain cold room (wet environments)

2.3 Airtight and Leak-Proof Type (For Controlled Atmosphere Cold Room)

Core Requirements:

Integrated gas barrier membrane (oxygen permeability ≤5cm³/m²•day)

Seamless epoxy coating (thickness ≥3mm)

Приложение:

Контролируемая атмосфера (Калифорния) холодная комната for fruits

Seed preservation

2.4 Chemical Corrosion-Resistant Type

Материал:

Acid-alkali resistant epoxy resin (resistant to pH 1-14)

Polyurea elastic coating (resistant to saltwater corrosion)

Приложение:

Pickled food cold room

Chemical raw material low-temperature cold room

3) By Load-bearing

The cold room flooring load design needs to match the dynamic pressure of the storage equipment:

ТипLoad StandardStructural Design Key PointsTypical Application
Light Duty≤1 ton/m² (static load)1. Single-layer rebar mesh (Φ8@250mm)Small cold room, fruit and vegetable preservation cold room
2. Concrete grade C25
Medium Duty1-3 tons/m² (include forklift dynamic load)1. Double-layer rebar mesh (Φ12@200mm)Meat freezer room, logistics sorting centers
2. Steel fiber-reinforced concrete
Heavy Duty≥3 tons/m² (include intensive AGV operation)1. Prestressed concrete beams and steel sheet composite layerAutomation cold room, port cold chain hubs
2. Foundation reinforcement (pile depth ≥5m)

Case:
A certain e-commerce cold chain холодная комната uses heavy-duty flooring (5 tons/m²), and the flooring structure is

Base layer: C35 concrete and Φ16@150mm steel mesh

Insulation layer: 200mm XPS panel (density ≥40kg/m³)

Surface layer: 4mm epoxy quartz mortar

Внимание: Can withstand multi-layer shelves and 10-ton forklifts 24 hours operation.

4) По температуре

Different temperature ranges have significantly different requirements for floor materials and processes:

Температура Технический запросFlooring Solution
High-Temperature Cold Room (0~10℃)1. Moisture-proof layer (single-layer PE film)Concrete, PU polyurethane spray coating and epoxy top layer
2. Insulation layer (100mm PU polyurethane)
Low-Temperature Cold Room (-25℃)1. Frost heave prevention trench (ventilation layer)Steel fiber concrete ,electric heating system and embossed steel sheet
2. Triple-layer XPS panel (150мм)
Ultra-Low Temperature Cold Room (-60℃)1. VIP vacuum insulation panel (thermal conductivity ≤0.007W/m•K)Nano aerogel composite flooring and intelligent temperature control system
2. Carbon fiber crack-resistant layer

5) Other Special Classifications

5.1 By construction process:

On-site cast floor: strong integrity, suitable for large fixed cold room.

Prefabricated assembled floor: modular steel sheet / concrete sheet, construction time saved by 50%.

5.2 By environmental protection level:

Traditional floor: contain VOC coatings (such as solvent-based epoxy).

Green floor: water-based epoxy, solvent-free polyurethane (compliant with LEED certification).

Cold Room flooring Construction Process

1) Subgrade Preparation

OPERATIONAL STEPS

1.1 Subgrade Cleaning

Remove organic matter such as humus and tree roots to a depth of ≥300mm.

Measure subgrade moisture content using a nuclear density gauge (ASTM D6938), with a requirement of ≤12%.

1.2 Crack Repair

Cracks <3мм: Inject epoxy resin grout (ASTM C881).

Cracks ≥3mm: Cut a V-shaped groove and fill with polymer repair mortar (В 1504-3).

1.3 Gravel Layer Installation

Материал: Graded crushed stone (particle size 5-40mm, mud content ≤3%, ASTM D2940).

Compaction: Layer thickness ≤150mm, compacted with a 12-ton or heavier vibratory roller for 6-8 passes.

Density Test: Sand cone method (ASTM D1556) or nuclear density gauge (error ≤1%).

1.4 Technical Parameters

Final Leveling Accuracy: ≤5mm/3m (measured with a laser level, ИСО 8512).

Load-Bearing Capacity: CBR value ≥8% (tested by ASTM D1883).

cold room flooring 04

2) Vapor Barrier Installation

OPERATIONAL STEPS

2.1 Выбор материала

PE Film: Thickness 0.3mm, compliant with ASTM D4397, permeability ≤0.1g/m²•24h.

SBS Membrane: Thickness ≥4mm, flexible at -25°C without cracking (В 13707).

2.2 Installation Process

Overlap Width: Long side ≥100mm, short side ≥150mm.

Уплотнение: PE film sealed using a double-track welding gun (400-450°С), SBS membrane heated with a torch (flame distance 300-500mm).

2.3 Seam Test

Vacuum Box Test (ASTM D7877): Negative pressure -54kPa, bubble observation with soapy water.

Destructive Test: Randomly cut seams; peel strength ≥4N/mm (В 12316-1).

2.4 Key Control Points

Corner Treatment: Inner corner radius ≥50mm, outer corners reinforced with an additional layer (width ≥200mm).

3) Insulation Layer Installation

OPERATIONAL STEPS

3.1 XPS Panel Selection

Плотность: ≥35kg/m³

Compressive Strength: ≥300kPa (В 13164).

Flame Retardant Rating: Б1 (GB 8624) or Class 1 (ASTM E84).

3.2 Installation Process

Staggered Layout: Offset adjacent panel seams by ≥300mm, seam gap ≤2mm.

Filling Material: Single-component PU polyurethane foam adhesive (expansion rate ≥80%, ASTM C591).

3.3 Double-Layer Insulation Reinforcement

Fiberglass Mesh: Weight ≥160g/m², alkali resistance (В 13496).

Interlayer Treatment: Apply polyurethane primer (adhesion strength ≥0.2MPa).

cold room flooring 05

3.4 Special Handling

Equipment Foundation Perimeter: Leave a 20mm expansion joint, filled with closed-cell PE foam rod (ASTM D1056).

4) Reinforced Concrete Pouring

OPERATIONAL STEPS

4.1 Rebar Installation

Specifications: HRB400-grade deformed steel bars (ASTM A615 Gr.60 equivalent).

Tying Standards: Tie wire density ≥3 ties/m², concrete cover thickness ≥40mm.

4.2 Concrete Mix Preparation

Mix Ratio: Water-cement ratio ≤0.45, fly ash content ≤15% (В 206-1).

Antifreeze Agent: Calcium nitrite-based (3%-5%, ASTM C494 Type C).

4.3 Pouring and Curing

Pouring Temperature: 5-30°С (pre-cool aggregates to ≤25°C in hot conditions).

Vibration Technique: Internal vibrator (frequency ≥12,000rpm), spacing ≤500mm.

Curing: High-polymer curing membrane (ASTM C171), water spraying to maintain moisture.

4.4 Strength Testing

7-Day Strength: ≥70% of design strength (cured per ASTM C31).

5) Surface Finishing

я. Epoxy Self-Leveling (Food-Grade)

5.1 Base Preparation

Blasting Treatment: Cleanliness level Sa2.5 (ИСО 8501-1).

Moisture Content: ≤4% (CM test, ASTM F1869).

cold room flooring 06

5.2 Coating Application

Primer: Solvent-free epoxy (thickness 0.2mm, surface resistance ≥1×10⁸Ω).

Intermediate Coat: Quartz sand epoxy mortar (aggregate size 0.3-0.8mm, thickness 1.5mm).

Top Coat: Self-leveling epoxy (thickness 2mm, wear resistance ≤50mg/1000r, ИСО 5470).

II. Anti-Slip Stamped Finish (Industrial-Grade)

5.3 Stamping Process

Embossing Timing: 1-2 hours before final concrete setting (penetration resistance 3.5MPa).

Texture Depth: 1.5-2мм (triangular wave pattern, friction coefficient ≥0.65, ОТ 51130).

5.4 Sealing Treatment

Penetrating Sealant: Silane-based (absorption rate ≤5%, В 1504-2).

Cold Room Flooring Quality Control

The quality control of холодная комната flooring must run through the entire cycle of material selection, construction process and final acceptance, combining international standards and engineering practices to ensure the floor performance meets the requirements of strict working conditions. The following is a detailed quality control plan:

1) Material Test

The material properties of cold room flooring directly affect the lifetime of the floor and energy efficiency, so must be strictly tested according to international standards:

Тест Test StandardQualified CriteriaInternational Reference Standards
Изоляционная панель
ПлотностьASTM C303 (measurement of dimensions and mass by cutting method)≥35kg/m³В 13164 (Евросоюз)
Thermal ConductivityASTM C518 (heat flow meter method, temperature difference of 20℃)≤0.028W/(m·K)ИСО 8301 (Международный)
Moisture ContentASTM C208 (oven-drying at 105℃ until constant weight)≤1%BS EN 12087 (UK)
Compressive StrengthASTM D1621 (compression rate of 5mm/min)≥300kPa (for heavy-duty cold room)В 826 (Евросоюз)
Concrete
Compressive StrengthASTM C39 (28 day standard curing test block)≥30MPaВ 12390-3 (Евросоюз)
Freeze-Thaw ResistanceASTM C666 (50 freeze-thaw cycles, temperature range -18℃ ~ 4℃)Mass loss ≤5%ИСО 4848 (Международный)
Chloride Ion ContentASTM C1218 (titration method)≤0.06% (to prevent steel reinforcement corrosion)В 206-1 (Евросоюз)

International certification requirements:

Изоляционные панели must provide CE certification (Евросоюз) or UL certification (Северная Америка).

Concrete admixtures must comply with REACH regulations (Евросоюз) or EPA standards (США).

2) Construction Monitor

The construction process requires real-time monitoring of key parameters to ensure the process meets the design requirements:

Monitor ItemTest Tool and MethodControl StandardRecording Frequency
FlatnessLaser level (Germany Leica Rugby 610, accuracy ±1.5mm/50m)Permissible deviation ≤3mm/2m1 point per 10㎡
Joint SealingHelium leak detector (USA INFICON Whisper, sensitivity 1×10⁻⁶ Pa·m³/s)Leakage rate ≤1×10⁻⁶ Pa·m³/s1 random check per 20m of joints
Rebar SpacingSteel ruler measurement and image recordingΦ12@200mm, deviation ≤±10mm5 random checks per 100㎡
Concrete SlumpSlump cone test (ASTM C143)120±20mm (for pumped concrete)1 test per truckload
Curing Temperature & ВлажностьTemperature and humidity logger (HOBO MX2301, accuracy ±0.5℃)Temperature 10-25℃, humidity ≥90%Continuous monitor, recorded every hour

Key control points:

After the insulation layer is laid, require infrared thermal imaging scanning (FLIR T1030sc) to detect the hollowing rate ≤1%.

When pouring concrete, the temperature entering the mold is at 5-30℃ (ASHRAE 90.1 requirement).

3) Acceptance Criteria

The final acceptance of холодная комната flooring requires the integration of international standards and project technical specifications, mainly included the following contents:

Acceptance ItemTest MethodStandard RequestInternational Reference Standard
Thermal Insulation PerformanceHeat flow meter method (ИСО 8301)Heat transfer coefficient ≤0.4W/(m²·K)IIR (International Institute of Refrigeration) Standard
Compressive StrengthRebound hammer (Switzerland Proceq SilverSchmidt, error ±3%) and Core sampling test (ASTM C42)≥30MPa (28 дни)ACI 318 (США)
Moisture Barrier IntegrityVacuum negative pressure test (ASTM D7877, -54кПа)No leakage or bulgingВ 13859-2 (Евросоюз)
Surface Slip ResistancePendulum friction tester (UK Portable Skid Tester, В 13036-4)Friction coefficient ≥0.6 (сухой) / ≥0.4 (wet)OSHA 1910 (США)
Environmental ComplianceVOC detection (Gas Chromatography, ИСО 16000-6)Epoxy surface VOC ≤50g/LLEED v4.1 (Международный)

Acceptance document requirements:

3rd-party inspection report (such as SGS, TÜV, BV).

Material CE/UL/FDA certificate.

Construction process video record and hidden engineering certification sheet.

4) Special Requirements for International Projects

4.1 EU market

Require EPD environmental declaration (В 15804).

Concrete carbon footprint ≤300kg CO₂/m³ (В 16757).

4.2 North American market

Fire rating Class 1 (ASTM E84).

Anti-slip coefficient ≥0.5 (OSHA 1910.22).

4.3 Middle East/Southeast Asia

Salt spray resistance test (ASTM B117, 500 hours without corrosion).

Anti-ultraviolet aging (QUV 2000 часы, color difference ΔE≤3).

cold room flooring 07

5) Quality Problem Handling Process

5.1 Defect Identification: Locate the problem area through infrared thermal imaging and ground penetrating radar (GPR).

5.2 Cause Analysis: Laboratory retests material properties and reviews construction records.

5.3 Repair Plan:

Hollow insulation layer: Drill holes and inject PU polyurethane foam (ASTM C1620).

Crack repair: V-groove cleaned and filled with epoxy mortar (ASTM C881).

5.4 Re-test: After repair, re-test according to the original standard and issue a supplementary acceptance report.

Заключение

Холодная комната flooring is far more than just aconcrete surface—it is a sophisticated system integrating material science, structural mechanics, and thermal engineering.

Its performance directly impacts the cold room’s energy costs, cargo preservation quality, and personnel safety. As cold chain logistics evolve toward ultra-low temperatures (-60°С) and automation, which will place a higher demands on flooring for extreme cold resistance and high-frequency impact durability.

Companies must involve professional teams in the design and construction phases to prevent the risks associated with the short-sighted approach of prioritizing heavy equipment while neglecting flooring quality.

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Об авторе

Картинка Вик Чунг
Вик Чунг

Привет, я Вик! Начать работу в сфере HVACR с 2008, наши основные продукты включены: кондиционер, система охлаждения холодильной камеры, охладитель воды, Генератор льда, коммерческий дегидратор, осушитель, Тепловой насос, электрический двигатель, и все аксессуары. С тех пор как присоединился к China Speedway Group в 2012, Я работал здесь больше, чем 10 годы, в качестве генерального менеджера экспортного отдела, мы установили 50+ Агент в разных странах и регионах.
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