Owner: HelloParks
Contractor: ASA Construction Ltd.
Designer: JKP Static Ltd.
In mid-2023, construction began on PT2 Big Box Warehouse, an innovative 42,000 m² warehouse with a jointless floor reinforced entirely with BarChip MQ58 macro synthetic fibres. PT2 is part of HelloParks Páty mega-park, spanning 87 hectares, located west of Budapest, Hungary, with a total development potential of 384,000 m².
The project used a standard C30/37 concrete mix, containing 320 kg/m³ CEM II/B or CEM III/A cement, with a water-cement ratio of 0.49. The slab thickness is 19 cm, with a rack load-bearing capacity of 76 kN. The joint spacing is 24 m x 24 m, and the crack width limitation is 0.3 mm.
Sustainable Construction by HelloParks
HelloParks is a fast-growing industrial real estate developer in Hungary, pioneering sustainable industrial facilities. They were the first industrial building developer in Hungary to achieve BREEAM New Construction Excellent and Outstanding certifications.
The decision to use synthetic fibres instead of steel reinforcement was driven by HelloParks' commitment to reducing carbon emissions. Anna Bencze, Head of Sustainability at HelloParks, explains:
“For the PT2 warehouse, the embodied carbon footprint of the concrete floor, calculated according to EN 15978 (A1-3, A4, B1-5, C1-4 life cycle stages), was around 3% lower with BarChip fibre compared to the previous technology (steel fibre) with the same floor size and technical data.”
This represents a significant reduction in carbon emissions simply by changing the reinforcement.
Design with TR34 and Finite Element Analysis (FEA)
The project was designed by JKP Static, a leading engineering design firm. The design was based on a complete static analysis following TR34, combined with advanced Finite Element Analysis (FEA) to evaluate the effects of expansion joint spacing, as well as shrinkage and friction modeling.
The modeling was influenced by JKP research, which shows that residual strength and friction work together to eliminate crack localization in macro synthetic fibre-reinforced slabs.
Dr. Juhasz from JKP explains:
“Our research showed that as residual strength increases, the maximum crack width decreases. Additionally, increasing friction also reduces the maximum crack width. This means that residual strength and friction work together to eliminate crack localization, even in strain-softening materials like macro synthetic fibre.”
Shrinkage Control and Early-Age Cracking
Controlling shrinkage in concrete is critical for the success of jointless floors. Research shows that BarChip MQ58 has the same effect as micro-PP fibre in reducing early-age shrinkage cracking.
Peter Schaul from JKP comments:
“Shrinkage ring tests showed that with 2 kg/m³ of BarChip MQ58, shrinkage cracks almost completely disappear.”
This is made possible by the unique design of BarChip MQ58, which provides a three-in-one functionality:
✅ Early-age shrinkage crack control
✅ Post-crack residual strength
✅ A fibre-free surface finish
Achieving a High-Quality Surface Finish
For industrial flooring, a smooth, durable surface is essential.
The benefits of a high-quality surface finish with BarChip MQ58 include:
✔️ Increased durability with improved resistance to abrasion and weathering
✔️ Easier cleaning and maintenance
✔️ Better aesthetics and improved indoor air quality
Recognizing BarChip MQ58’s reputation for exceptional finishing quality, construction company ASA conducted trials with 3, 3.5, and 4 kg/m³ of BarChip MQ58, with all trial slabs delivering flawless results.
Tibor Mihucz from ASA shares his experience:
“BarChip MQ58 is the only synthetic fibre that joins fibre strands along its length. They separate in the mix, have no memory, and do not show up on the surface. It is the easiest fibre to finish we have ever used.”
Execution Process
BarChip MQ58 fibres were added to the concrete at the batching plant and delivered ready-reinforced to the site.
Due to favorable site conditions, the fibre-reinforced concrete was placed directly from the truck, without the need for a boom pump. The floor was finished using standard processes and equipment, including:
- Laser screeding
- Helicopter finishing
- Hand tools
Successful Completion of the Project
The construction of PT2 Big Box, spanning 42,000 m², was completed in May 2024. Impressed with the results, HelloParks has since specified BarChip MQ58 in over 150,000 m² of industrial flooring.
To date, no fibres have been observed on the surface of the slabs.
