Flooring – FlexDeck System
Flooring – FlexDeck System
STALWART GI Flooring System is a fully modular, bolt-type industrial flooring solution designed as an alternative to RCC slab construction inside factories and warehouses.
It provides strong load-bearing capacity, flexibility for future plant changes, and faster installation — without permanent civil work.
This system is ideal where plant expansion, layout changes, or temporary structures are expected.
Key Features
- Direct Access to Pallets: Allows individual pallet retrieval without moving other pallets, enabling easy stock rotation (FIFO).
- Adjustable Design: Beam levels can be easily repositioned at regular pitch intervals to accommodate changing pallet sizes.
- High Load Capacity: Engineered to support up to 4000 kg per level (Uniformly Distributed Load).
- Forklift Compatibility: Designed for efficient use with forklifts, reach trucks, and stackers.
- Modular Expansion: Can be expanded horizontally or vertically with ease to match future storage needs.
- Enhanced Safety: Includes locking pins, upright guards, and back stoppers to ensure secure pallet positioning and accident prevention.
Sizes Available
| Floor Height | 2000 mm – 12,000 mm total |
|---|---|
| Column Span | 3000 – 6000 mm depending on beam design |
| Deck Load Capacity | 300 – 1200 kg/m² |
| Load Capacity | 1000kg to 5000kg UDL |
Why Choose GI Flooring Instead of RCC Slab?
🔹 No Permanent Fixing
- RCC slab becomes permanently fixed for lifetime.
- If future plant expansion or layout change is required:
- RCC slab must be broken
- Production gets disturbed
- Civil demolition cost increases
- Time loss during removal
- Heavy material waste
- GI Flooring avoids all these problems.
🔹 Fully Modular & Flexible
- 100% removable and re-installable
- Can be relocated to another area
- Can be resized or modified
- Load capacity can be redesigned as per new requirement
- If not required in future:
- Material scrap value recovery approx. 60–70% possible
🔹 Cost Advantage
- Cost comparable to RCC construction
- Faster ROI due to quick installation
- No demolition loss
- Reusable structure
- Lower long-term modification cost
GI Modular Flooring vs RCC Slab – Comparison
| Parameter | GI Modular Flooring | RCC Slab Flooring |
|---|---|---|
| Structure Type | Fully modular, bolt-type steel system | Permanent civil concrete structure |
| Installation Time | Fast installation | Long construction time (shuttering, curing, etc.) |
| Future Modification | 100% removable & re-installable | Cannot be modified easily |
| Expansion Flexibility | Easily expandable or relocatable | Requires breaking and re-casting |
| Production Disturbance | Minimal | High during demolition or modification |
| Load Capacity | Customizable as per requirement | Fixed once constructed |
| Dismantling | Easy dismantling possible | Demolition required |
| Reusability | Can be reused at another location | Not reusable |
| Scrap Value | 60–70% material value recoverable | No recovery value |
| Civil Work Required | No heavy civil work | Full civil construction required |
| Cost Factor | Comparable to RCC | Comparable initial cost but high modification cost |
| Downtime During Changes | Very low | High downtime |
| Clean Installation | Dry installation (no curing time) | Wet work with curing time required |
| Long-Term Flexibility | High | Very Low |
Application Industry
Inside Industrial Plants
Machine Platforms
Storage Platforms
Temporary Expansion Areas
Production support areas
Equipment access flooring
IS Standards | Downloads | Safety Guidelines
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