BICP Wins Post-Tensioned Floor Project for Luoyang Cigarette Factory

Traditional industrial floors with numerous saw-cut and construction joints are prone to edge spalling, dusting, and step formation under heavy loads and frequent traffic, affecting production continuity and maintenance costs. The client sought a durable, low-maintenance floor system with improved flatness and crack resistance.

BICP's Taiping integrated floor system was selected, specifically the post-tensioned integrated floor solution. This system incorporates horizontal prestressing tendons to introduce compressive stress into the floor slab, effectively controlling cracking from concrete shrinkage and temperature variations. By eliminating up to 80% of traditional joints, the system reduces joint-related damage, dust, and maintenance interruptions. The solution is tailored for industrial facilities and underground garages; for cold storage applications, UHPC-based alternatives are recommended.

BICP's Beijing Third Division, after a year of R&D, successfully won the bid for the post-tensioned floor engineering of the Luoyang Cigarette Factory relocation and upgrade project (Phase I, including the joint workshop and administration building). The project is invested by Henan China Tobacco Industry Co., Ltd. Luoyang Cigarette Factory, designed by SIPPR Engineering Group Co., Ltd., and constructed by China Construction Fifth Engineering Division Corp., Ltd. Located in Luoyang, Henan, the facility is scheduled to commence operations in 2019. It is a key municipal project and a strategic initiative for Henan China Tobacco's transformation and upgrade. Once completed, it will support the 'Golden Leaf' brand, producing 300,000 large cases of cigarettes annually with an estimated tax revenue of 2.5 billion RMB.

In industrial floor structures, heavy equipment loads, temperature variations, concrete shrinkage, and soil friction often lead to spalling, cracking, and deformation. Repairing such damage significantly impacts production and incurs high costs. The post-tensioned concrete floor system addresses these challenges by embedding horizontal prestressing tendons that create compressive stress in the slab, enhancing crack resistance and reducing joint spacing.

Key advantages of the post-tensioned integrated floor:

• Reduced joints: Traditional joints lose load transfer capacity under dynamic loads, causing deflection, cracking, and edge damage. Post-tensioning provides self-recovery after overload, allowing joint-free design, reducing maintenance costs, and improving production efficiency.
• Enhanced durability: Precompression effectively controls cracking from shrinkage and thermal stress.
• Greater stiffness and flatness: Post-tensioned floors exhibit higher rigidity, resisting deformation from soil moisture changes.

Project participants:

• Owner: Henan China Tobacco Industry Co., Ltd., formed through mergers of several provincial tobacco entities, with 8 cigarette factories and annual sales of over 3.1 million cases.
• Designer: SIPPR Engineering Group Co., Ltd., founded in 1951, a national comprehensive design institute with Class A engineering design qualification, under China National Machinery Industry Corporation.
• Contractor: China Construction Fifth Engineering Division Corp., Ltd., founded in 1965, a subsidiary of China State Construction Engineering Corporation, with triple-special-class qualifications in building, municipal, and highway construction.

Note: The Taiping system comprises three technology lines: post-tensioned integrated floor (for industrial facilities and underground garages), UHPC integrated floor, and UHPC long-lasting repair. For cold storage applications, only UHPC-based solutions are recommended.

This case demonstrates the application of BICP's post-tensioned floor technology in a large-scale industrial facility, highlighting key benefits such as reduced joint maintenance, enhanced durability, and improved operational efficiency. It serves as a reference for similar projects requiring high-performance floor systems.