Technology & Innovation

ECOFREEPLAN® System

The ultimate eco-responsible and sustainable flooring system

TWO TECHNOLOGIES IN ONE

Pioneering Industrial Flooring Solutions: Integrating Fiber Reinforcement and Post-Tensioning

At RCR, technological innovation drives our commitment to excellence in industrial flooring. Our unique approach combines fiber reinforcement and post-tensioning, maximizing joint-free areas for unrivaled durability and performance. By merging these technologies, we offer paving solutions exceeding expectations in longevity and functionality. With this groundbreaking technology, we redefine industry standards, setting new levels of performance in industrial flooring.

KEY FEATURES

ECOFREEPLAN® Advantages

With ECOFREEPLAN®, we introduce a revolutionary system that embodies the latest technological and environmental developments. This cutting-edge solution offers unparalleled advantages, including the execution of jointless large panel slabs, geometrical flexibility for concrete pours, controlled curling, true flatness regularity, and enhanced durability. By harnessing advanced additives like LINK EVR® and steel fibers, ECOFREEPLAN® redefines construction norms, delivering superior performance, sustainability, and cost-effectiveness. Join us as we revolutionize industrial flooring with ECOFREEPLAN®.

Execution of jointless large panel slabs

  • Eliminates the need for saw-cut joints, providing a smooth and uninterrupted surface.
  • Allows for the construction of monolithic slabs up to 2500 m2 without saw-cut joints.
  • Enhances flexibility in storage and traffic for various types of forklifts.
  • Ideal for automated warehouses and high-traffic logistics platforms.

Geometrical flexibility for the
planning of concrete pours

  • Accommodates irregular shapes and walkways without the requirement for saw-cut joints.
  • Optimizes slab panel distribution for each project, adapting to building geometry and obstacles.
  • Reduces construction joint costs and increases productivity.
  • Controls curling or warping at slab edges for improved performance.

Curling control

  • Minimizes "curling" or warping at slab edges for enhanced durability.
  • Counteracts lifting along construction joints, improving slab performance.
  • Enables efficient use of trucks and optimizes slab thickness during design.
  • Ensures consistent and stable performance of flooring over time.

True flatness regularity

  • Achieves accurate surface regularity with large panel pouring methods.
  • Maintains flatness characteristics over time, meeting industry standards.
  • Meets requirements for automated platforms (ASRS, AGV, AMR).
  • Reduces vibration, providing greater comfort and safety for operators.

Fewer joints, better performance

  • Reduces the opening of joints, limiting impact and premature wear of truck wheels.
  • Minimizes vibrations, ensuring greater comfort and safety for operators.
  • Provides triple function PERMABAN joints for precise slab lifting and controlled opening.
  • Enhances durability and extends the lifespan of the flooring system.

A more durable surface

  • Recommends ROCLAND QUALITOP VRS surface hardener for maximum abrasion resistance.
  • Reduces the appearance of microcracks, maintaining a smoother and more durable surface.
  • Thinner than cement, LINK EVR® creates a less porous and more impermeable surface.
  • Improves energy performance by using light-colored hardeners to increase reflectivity and reduce lighting requirements.
METHODS DEVELOPED BASED ON EXPERIENCE

How We Do It?

Preliminary study

The design and sizing phase is carried out by Monofloor consultants.

How to size?

The calculations established by Monofloor define, based on the essential data collected from the site (platform quality, loads, environment, etc.), the thickness of the pavement, the correct dosage of LINK EVR®, and the metallic fibers using contractually recognized and experimentally validated methods.

Concrete formulation

After analyzing and evaluating the materials available in each geographical area, Monofloor engineers optimize and validate the concrete formula for each project through testing, according to the necessary adjustments (cement type, composition, additives, particle size distribution curves).

Design and supervision

Monofloor also defines the specific reinforcement details, construction methods, concrete pouring phases, and control processes.

METHODS DEVELOPED BASED ON EXPERIENCE

ECOFREEPLAN® System better for

At RCR, technological innovation drives our commitment to excellence in industrial flooring. Our unique approach combines fiber reinforcement and post-tensioning, maximizing joint-free areas for unrivaled durability and performance. By merging these technologies, we offer paving solutions exceeding expectations in longevity and functionality. With this groundbreaking technology, we redefine industry standards, setting new levels of performance in industrial flooring.

Intensive logistics and heavy industry

Optimize large spaces with seamless, durable flooring solutions.

Automated or robotized warehouses

Enhance efficiency in automated warehouses with joint-free flooring.

Height storage systems VNA

Adapt to narrow spaces with high-performance, seamless flooring solutions.

Refrigerated and low temperature rooms

Maintain temperature control with durable, joint-free flooring options.

Agrifood

Ensure hygiene standards with seamless, easy-to-clean flooring solutions.

Recycling and waste treatment - Bulk storage

Support heavy loads and high traffic with robust, joint-free flooring.

ECOFREEPLAN a Green system

Optimized thickness and reinforcement will result in lower material consumption and production costs, leading to a significant reduction in the carbon footprint of the flooring. This balance is improved using high-performance steel fibres recovered from the metal reinforcement threads for tyre rubber, contributing to circular economy. These fibres allow a 95% reduction in carbon footprint compared to conventional reinforcement. In addition, the LINK EVR® used in the system is an excellent CO2 absorber (707g CO2 absorbed/Kg of LINK EVR® used). The Permaban joints are manufactured under the disciplines of ISO 14001.

Rocland's hardeners are also LEED v4 (Leadership in Energy and Environmental Design) certified. Following the recommendations for a clear and highly reflective hardener the result is even more spectacular. These properties make ECOFREEPLAN® the most environmentally friendly building system. The energy balance and the savings obtained are submitted on request to be included in a file of environmental excellence (BREEAM, LEED, HQE, ...).

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