The evolution of floor flatness specifications reflects the increasing demands of modern warehousing operations. As someone who has spent years designing, constructing, and surveying industrial concrete floors, I want to share why TR34 4th Edition has emerged as the go-to specification for industrial concrete floor flatness, and what challenges still lie ahead in the context of robotics and automation.
From Straight Edge Testing to Sophistication
Historically, floor flatness relied on the straight edge method, which measured the maximum gap under a 3m straight edge.
This approach made sense when floors were constructed in small checkerboard patterns or long narrow strips. However, modern high-productivity, large-bay construction has rendered these measurement approaches outdated.
Key limitations of the straight edge method include:
- Not practical for measuring large floor areas
- Results are not very reproducible
- Difficulty producing a random sample
- Inability to effectively measure levelness
- Lack of consideration for the wavelength of floor undulations
These issues often meant floors were only tested when problems arose, leading to a false perception that specifications were being consistently met.
Some countries, like New Zealand, still include a straight-edge-based floor flatness requirement in their national standards (e.g., NZS3114:1987), but this is rarely used in industrial and warehouse settings.
Instead, a TR34-style floor flatness specification, which I helped produce, is now used. Concrete NZ Floor Guidance for Surface Regularity
Free Movement vs Defined Movement Areas
Before we move on we need to discuss the difference between Free Movement (FM) and Defined Movement (DM) floor requirements.
FM areas allow material handling equipment to move randomly in any direction, while DM areas, such as Very Narrow Aisles (VNAs), constrain movement to specific paths.
These different operational requirements call for different approaches to specification and measurement of the floor.
The F-Number System: A Step Forward
The American Concrete Institute’s F-number system is a significant improvement over the traditional straight edge specifications, measuring floor profiles at 300mm intervals for flatness (FF) and at 3m intervals for levelness (FL).
However, the F-number system still has a few clear drawbacks:
- Because these numbers lack a direct real-world reference, they can be difficult to interpret and or relate back to the floors real-world performance
- Although the way the floor is sampled is statistically sound, it doesn’t help you pinpoint the exact location of problems, making it harder to fix issues or trace them back to their source in the casting process
The F-number system is currently the predominant FM floor flatness system in the USA and in some other regions influenced by US standards.
Fmin for Defined Movement Applications
The most common Defined Movement floor flatness specification in the USA is “Fmin”. Fmin is the granddaddy of VNA floor flatness specifications – developed in the 1970’s.
This system, similar to TR34, utilizes a profileograph to assess flatness along the specific path a forklift will follow in a VNA aisle.
Fmin provides a dimensionless number to represent floor flatness in a similar manner to the F-number system and so it can have the same drawbacks.
In contrast:
The classification approach in TR34 allows for a direct connection between operational requirements, like racking heights and equipment types, and the required standard of floor flatness.
This makes TR34 more user-friendly and more easily applicable in a real-world setting.
Germany Goes its Own Way
Defined Movement Options: DIN 18202 and DIN 15185
Germany has developed its own standards for floor flatness – DIN 18202 and DIN 15185. These standards apply to different scenarios:
- DIN 18202: Covers of free movement area flatness requirements. This standard covers flatness tolerances of a variety of different building surfaces, including floors, ceilings, screeds, and walls. It categorizes surfaces into groups with allowable deviations over different distances. For instance:Group 3 applies to finished floors, and allows for maximum deviations over distances of 0.1m, 1m, 4m, 10m, and 15m. While DIN 18202 offers a structured approach to measuring flatness, it is primarily suited for general construction and doesn’t specifically address the specific needs of high-performance warehouse flooring.
- DIN 15185: Focuses on defined movement areas like VNA. It sets allowable differences in height between the outer forklift wheels as well as the maximum gaps allowed under straightedges of varying lengths. It lacks the comprehensiveness of the other common defined movement specifications that measure more specific properties of the floor surface along the VNA wheel path.
Why TR34 4th Edition Leads the Way
TR34 4th Edition merges the strengths of previous systems while addressing their weaknesses, and its approach to floor flatness specifications has several key benefits:
Practical Measurement Protocols
- Clear procedures for both FM and DM areas within the same document.
- Survey methodologies designed for modern construction techniques and suitable for large areas.
- Reproducible results.
Comprehensive Assessment
- Properties E and F provide clear measurements of both flatness and levelness.
- Direct correlation between measurements and floor performance.
- Systematic grid-based sampling of levelness ensures a thorough floor assessment and makes it easy to identify and understand errors relative to how the floor was cast and how it will be racked and used.
Data-Driven Classifications
- Classifications derived from extensive operational data.
- Direct links between racking heights, MHE types, and required tolerances.
- Specifications that align with real-world warehouse performance needs.
Superior Sampling Methodology
- Ensures even coverage across the entire floor plate.
- Eliminates bias in measurement locations.
- Provides a clear picture of floor variability and performance.
Compatibility with Broader Logistics Industry Standards
One of the benefits of TR34 4th Edition is how it is fully compatible with material handling and racking requirements found in European Norm (EN) and FEM (Federation Europeenne de la Manutention) documents.
This means when you use TR34 as your floor specification you don’t have to be worried about a lack of cohesiveness between floor flatness, racking standards, forklift requirements and wire guidance installation.
This integration is particularly crucial to achieve a great outcome for VNA systems – if the floor flatness achieves the appropriate DM classification in TR34, and the racking and wire guidance are installed to tolerances in the appropriate EN and FEM documents we can be confident that the forklifts will operate to their full potential.
TR34 Real-World Benefits
Adopting TR34 4th Edition offers several distinct advantages:
- A clear connection between operational needs and floor specifications through a research-backed classification system that is based on racking height and has been validated on thousands of floors.
- A comprehensive and systematic sampling process.
- Clear guidelines based on racking heights and material handling equipment (MHE) requirements.
- Cohesive integration with other EN and FEM standards for DM areas.
What’s on the Horizon for Floor Flatness Specifications?
The future of warehousing is rapidly moving towards even greater automation and the deployment of robotics, such as AutoStore™ systems and Goods-to-Person (G2P) Autonomous Mobile Robots (AMRs). These systems introduce new requirements for floor flatness, which are not yet comprehensively covered in TR34 or any other standardized specification.
Challenges for Robotics and Automation
Robotic systems like AutoStore and G2P AMRs can demand different and even tighter tolerances than those typically found in existing industrial settings.
The performance of Robotic systems depends heavily on the floor conditions:
- AutoStore Systems: The grid structures used by AutoStore require exceptionally level floors to maintain consistent performance and allow accurate bin access.
- Goods-to-Person AMRs: These robots are highly sensitive to floor variations, as even minor unevenness can impact navigation and efficiency.
Face Consultants have worked with many of the leading robotics and automation vendors to help develop floor requirements guidelines, but the lack of industry standardisation can create challenges during the design and construction phases of a project.
Looking Forward: Adapting TR34 for Tomorrow’s Automated Warehousing Needs
As warehousing evolves with more automation and higher storage systems, a robust and practical floor specification becomes essential.
TR34 4th Edition provides the needed framework while remaining adaptable to future advancements. However, to fully support emerging technologies, industry stakeholders must work towards establishing new standards for robotic floor flatness.
For those still using alternative specifications, I strongly recommend considering the switch to TR34 4th Edition.
Its improved clarity, practical measurement protocols, and clear connection to operational requirements make it the logical choice for modern industrial flooring projects.
The next frontier will be developing standards to support the rise of automated solutions and the challenges they present.
By embracing TR34 now and preparing for future enhancements, warehouse developers can ensure their floors are ready for the next generation of intralogistics.
Don’t delay, Contact Face Consultants
Wherever your warehouse is located, TR34 4th Edition is your gateway to achieving world-class floor flatness for highly efficient and productive operations. At Face Consultants Ltd, we specialise in designing, surveying, and ensuring compliance with international standards including TR34. Our work with warehouses requiring robotics and automated systems is world-leading, some might even say ground-breaking.
Don’t let outdated specifications hold your facility back. Contact us today to ensure your floors are ready for the future of warehousing. We’ll help you build floors that elevate warehouse efficiency and drive operational excellence.
Tim Walker
Tim Walker is the Director of Face Consultants (NZ) and CoGri Limited (NZ). He has two decades of experience in the industry and provides the link between the Logistics Industry and Property and Construction; matching the requirements of one with the capabilities of the other.Contact Tim and his team today or follow us on LinkedIn:
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