Projects
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5/2/2024
PAC 2000A Conad Logistics Hub
In the logistic center of a giant of the Italian mass retail sector the concrete floors were created using the MAPECRETE SYSTEM for jointless industrial flooring
The new 90,000 m² logistics centre in Montalto Uffugo improves PAC 2000A Conad's distribution network in Italy and is part of a research project with the University of Calabria to optimise logistics. Collaboration with Mapei has enabled innovative fibre-reinforced concrete floorings to be created that are characterized by excellent durability and fewer joints.
A strategic hub for distribution in Southern Italy
A new, large logistics hub was recently completed in Montalto Uffugo, in the Province of Cosenza (southern Italy), close to the A2 Mediterranean motorway. The 90,000 m² platform, with a covered area of around 49,000 m² and 82 loading bays, is used to store goods for the retailer PAC 2000A Conad, the largest cooperative of the Conad consortium.
The PAC 2000A Conad sales network extends over 5 Italian regions (Umbria, Lazio, Campania, Calabria and Sicily) in Central and Southern Italy and, with 1,482 retail outlets, 79 concept stores and more than 25,000 employees, has a total turnover of 4,450 million euros.
Construction of the new logistics hub in Montalto Uffugo, the largest of its kind in the distribution sector in the whole of Calabria, will not only enable the various PAC 2000A Conad outlets to be supplied more efficiently, but will also promote a more advanced understanding of logistics and business management. The construction project, in fact, is part of an experimental industrial research and development project by the University of Calabria (UNICAL) aimed at creating methods and tools to manage internal logistics and distribution processes more efficiently and ensure this new logistics hub integrates into the existing network while being built.
MAPECRETE SYSTEM is a flexible system that allows to obtain concrete mixes with high dimensional stability and compensated shrinkage while reducing or eliminating the need for control joints .
Fiber-reinforced concrete floors with fewer joints
Mapei also contributed to the completion of such an important structure, in terms of sheer size and area of use, through the supply of a system (MAPECRETE SYSTEM) developed specifically for the creation of industrial floors in fiber-reinforced concrete with a lower number of contraction joints.
In fact, for a number of years Mapei has a dedicated team available for engineers, designers, construction companies and installers, along with a specific line of products and systems (Concrete Flooring Solutions) for this type of flooring. Fiber-reinforced concrete surfaces are becoming more widely used in industrial environments and require specific attention and expertise during both the design phase and the installation phase, and obviously to guarantee their high performance in service on a medium- and long-term basis.
Mapei contributed to create concrete floors by supplying the MAPECRETE SYSTEM
and technical support on site.
The Mapei offer is not limited to the actual products, but also includes technical support during the design phase: support that involves not only specialists in this particular Mapei line, but also, as in this case, the collaboration of highly experienced external professionals.
For the PAC 2000a Conad Logistics Hub in Montalto Uffugo, the consultation service provided by Livio Pascali enabled various design proposals to be formulated that would meet the requirements of the client, such as guaranteeing sufficient resistance to loads and creating durable flooring with fewer joints.
The solution chosen is called MAPECRETE SYSTEM: a flexible system that enables shrinkage-compensated concrete with high dimensional stability to be obtained that reduces or prevents having to include contract joints over pitch areas of up to 2000 m².
One system, so many advantages
The MAPECRETE system includes the use of a series of innovative products such as:
- DYNAMON FLOOR 25 acrylic-based super-plasticising admixture;
- EXPANCRETE expansive agent to promote compensated shrinkage;
- MAPECURE SRA 25 liquid admixture to reduce shrinkage;
- MAPEFIBRE ST 50 TWISTED structural polymer fibers for strengthening purposes.
By using a combination of these products, it was possible to compensate for hygrometric shrinkage, which concrete is normally subject to, and by using MAPEFIBRE ST 50 it was also possible to structurally strengthen the mix adopting an eco-sustainable approach. In fact, apart from improving the mechanical properties of concrete by increasing its durability, ductility and fatigue behaviour, these synthetic fibers also guarantee lower CO2 emissions. The result was the formulation of class C30/37 fibre-reinforced concrete, supplied by Calabria Calcestruzzi from Rende (Cosenza), applied using a vibro laser screed from BMB System, a company specialised in the installation of industrial flooring for large projects in the logistics sector, at a thickness of 30 cm internally and 20 cm externally.
The completed floors are made of class C30/37 fibre-reinforced concrete, supplied by Calabria Calcestruzzi from Rende (Cosenza) and applied using a vibro laser screed from BMB System.
A wear-resistant layer was created on the surface of the concrete by applying MAPETOP N AR 6, a product with very high mechanical characteristics and resistance to abrasion. MAPETOP N AR 6 was applied on both the internal and external flooring in order to exploit its excellent resistance to atmospheric agents, freeze/thaw cycles and attack from de-icing salts. MAPECRETE LITHIUM CURE was then applied after smoothing the surfaces, a lithium silicate-based consolidating treatment with anti-evaporation properties, which makes the surface of concrete more durable, easier to clean and resistant to abrasion.
The external concrete floors were also completed with solutions from the CFS (Concrete Flooring Solutions) by Mapei.
Project information
Thanks to MAPECRETE SYSTEM it was possible to create pitch areas of 20 x 20 m (400 m2), drastically reducing the number of distribution joints. The joints were sealed with MAPEFLEX PU 45 FT, a high-modulus polyurethane adhesive and sealant particularly suitable for use on industrial flooring, including those that have to withstand vehicles, and even heavy vehicles.
A wear-resistant layer was created on the surface of the concrete by applying MAPETOP N AR 6.
PAC 2000a Conad Logistics Hub, Montalto Uffugo (Cosenza, Italy)
Period of construction: 2021-ongoing
Period of Mapei intervention: 2022-ongoing
Mapei intervention: supplying a complete system for creating and treating cementitious flooring in an industrial setting
Client: PAC 2000A Conad
Works Director: EcoHouse engineering Srl
Concrete supplier: Calabria Calcestruzzi
Flooring contractor: BMB System
Mapei Coordinators: Gianluca Fiore (CFS, Mapei SpA), Marcello Pinto (CFS, Mapei SpA), GN Rappresentanze and Antonio Scarpino (Mapei SpA)
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