workshop floor – strength question

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workshop floor – strength question

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  • #584285
    gerry madden
    Participant
      @gerrymadden53711

      With impending retirement I plan to build a small extension onto my garage to become a dedicated workshop. The structure will be well insulated and should need only a low level of heat input to keep it warm. To provide this I plan to embed a low-power electric heating element into the floor.

      The heating elements need to be embedded in 50mm of concrete screed which would sit on top of 100mm thick polystyrene blocks.

      My question is this: Is 50mm of concrete sitting on top of a relatively soft base material going to be strong enough to support machines weighing up to a ton ? Any thoughts or experience anybody?

      A crack in the concrete would be a bit of disaster for the heating elements as one might imagine

      Gerry

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      #28568
      gerry madden
      Participant
        @gerrymadden53711
        #584286
        Roger Best
        Participant
          @rogerbest89007

          No

          Mainly due to the polystyrene

          #584291
          Roger Best
          Participant
            @rogerbest89007

            All disturbed soil settles so you need to spread the load big time.

            It would be normal to use 100-150mm of concrete (not screed) with reinforcing mesh as the structural floor. This can be above the insulation. If below you need a similar thickness concrete top layer.

            Screed is not good for bending loads and would not be considered structural in this sense but its fine for making a smooth surface and wrapping around the pipes/wires of your heater.

            Good luck, just get a builder in. wink

            #584292
            Howard Lewis
            Participant
              @howardlewis46836

              Being a graduate of the "Brick mausoleum" school, my thought was to lay a 50 mm layer of concrete around a steel reinforcing mesh, to minimise the risk of deflection of the 50 mm of concrete containing the heating elements.

              But the increased weight, although a uniformly distributed load, might crush the cells in the polystyrene and so reduce its effectiveness as an insulator.

              Maybe the edges of the reinforcing mesh could be turned down to keep the weight off the polystyrene, at a slight expense of the insulation factor.

              Howard

              #584305
              Pete White
              Participant
                @petewhite15172

                I like underfloor heating, got in our Kitchen living area 40 m2, pipes off the combi boiler, its great, but for a workshop it would not be my choice. Don't forget there is a big lag time to get up to heat and if you are out there for a few hours IMO wouldn't work out well, especially with a thick chunk of concrete on top, to heat up first. I believe those electric heat meshes are 80 -120 watts per m2, not sure how long they would take to get the workshop up to working heat or how long to be on to keep it there?

                Insulation is the answer these days as you say, hardcore, 100 mm insulation slab, concrete slab on top, with "air" electic heating of some sort, would be my option.

                I like my workshop wood stove, but I am being woked out, should see me though yes smiley.

                Pete

                #584338
                Mark Rand
                Participant
                  @markrand96270
                  Posted by Howard Lewis on 06/02/2022 20:01:52:

                  But the increased weight, although a uniformly distributed load, might crush the cells in the polystyrene and so reduce its effectiveness as an insulator.

                  Hy shed has actually got 200mm of concrete on top of 100mm of EPS foam (one layer of badly positioned mesh). The specified strength of the foam is more than enough to support the concrete and the machines. Concrete's quite cheap in the grand scheme of things and a good thickness on top of the foam does a wonderful job at keeping the temperature stable.

                  #584377
                  Bazyle
                  Participant
                    @bazyle

                    Instead of the electric wires look at water pipe type of underfloor heating. You might find an offcut available cheap for a small shed area. Then you can have a variety of heat sources to warm the water tank. You can embed the pipe in/under the 4in reinforced concrete without wasting thickness on a low strength screed.

                    #584390
                    David George 1
                    Participant
                      @davidgeorge1

                      Would you be bolting down machinery? as a pillar drill or a pedestal grinder defiantly need bolting to the floor which possibly could damaged under floor heating. I would think at least 150mm steel reinforced and fiber mixed concrete would be my minimum. I have a wall mounted electric heater and a dehumidifier which makes it warm and dry in my workshop.

                      David

                      Edited By David George 1 on 07/02/2022 07:55:53

                      #584393
                      Martin Connelly
                      Participant
                        @martinconnelly55370

                        I have 100mm rigid insulating foam in all the walls and roof. The base is reinforced concrete then a thin underfloor insulating foam and chipboard flooring on top of that. I initially heat it with a small fan heater that takes the chill off then if I am using machinery for a few hours the heat from the machines maintains the temperature.

                        The most important thing in cold weather is warm socks to keep comfortable, the warm air tends to rise wink

                        Martin C

                        #584401
                        Samsaranda
                        Participant
                          @samsaranda

                          I found underfloor heating in a work area to be punishing on my feet and ankles, this was an aircraft hangar and we were in there for a full working day, every day, the underfloor heat makes your feet sweat and ache. I wasn’t alone in complaining about the problem almost everyone who worked in there felt the same. I wouldn’t by choice work again in an area with underfloor heating. With the problems already highlighted with bolting down machines I would go for heating above ground level, if the workshop is well insulated then a small oil filled radiator will work fine, that’s all I have in my workshop, which is well insulated, and I leave it on overnight on a low setting and it keeps the temperature to about 10 degrees, when I am working in there I crank up the thermostat to an acceptable level, this radiator is used in conjunction with a dehumidifier. Dave W

                          #584405
                          Journeyman
                          Participant
                            @journeyman

                            Current building regs go along the lines of this:-

                            concretefloor.jpg

                            Add reinforcing mesh to concrete slab for extra load bearing. Infill layer would be hardcore with a sand blinding on top. Heating if required in the top screed. If machines need fixing to floor heating element position needs careful planning.

                            John

                            #584406
                            not done it yet
                            Participant
                              @notdoneityet

                              Insulation is most important. Mine has at least 100mm on all sides and top – but not the floor. It would, if it was poured these days, but not 30 years ago as a base for a garage.

                              Electricity is the most expensive energy source for thermal energy – unless you can generate your own using PV or wind – or use a cheap night-time tariff. I have just installed a chinese diesel hot air heater and it is cheap to run. Ignoring the ridiculously hyped-up claims by the suppliers, they do the job.

                              We have no details of electrical loads, TOU, etc. My little “claimed” 5kW heater is far more than I need in my workshop, except, perhaps, heating it quickly from a close-to-zero Celsius start. Machines remain cold, lagging far behind air temperature, mind. Once up to workable temp my workshop needs , I would say, likely less than a kW to maintain a reasonable working environment under most conditions.

                              #584410
                              Pete White
                              Participant
                                @petewhite15172

                                What about those proper workshop mats, sited where you stand?

                                Those diesel heaters mentioned are good, got a couple of mates happy with those, thinking of getting one myself yes . There were problems when the exhaust was lengthened, so becareful there.

                                Pete

                                #584422
                                Sam Longley 1
                                Participant
                                  @samlongley1

                                  I have a chinese diesel heater in an insulated garage 20 ft * 12 ft * average 9 ft high & I find it next to useless. I have to use a calor gas radiant heater to suplement it & i find the gas heater far more effective & cheaper. The chinese thing uses lots of fuel ( cost seems to be running double calor gas) & I have tried different temp settings. Having to run it off 12 volts is an issue as well as I have to have a battery charger on the battery at the same time, otherwise the battery goes flat in a short time –

                                  When I had my Joinery works, one of the buildings had 15 electric radiant heaters aimed at each work station. They were very effective & the workforce had no complaints. However, electricity was cheaper then, so I am not sure how they would stack up now with one each aimed at the lathe, mill & work bench.

                                  The wife pays the bills so it might be a massive no no.

                                  As for under floor heating, one only needs to decide where one wants the machinery, Omit the insulation & fill that part in with concrete. There is no point in heating a machine so go round it. . No need to put it under side benches if you are going to stack boxes & tool chests there either. One needs to plan the layout first.

                                  Edited By Sam Longley 1 on 07/02/2022 11:19:32

                                  #584423
                                  Brian Rutherford
                                  Participant
                                    @brianrutherford79058

                                    I have electric element underfloor heating in a bathroom floor. The element is in the floor set in the adhesive. With a second layer of adhesive over the top for the tiles as per manufacturers instructions. It takes at least 8 hours to feel any heat in the tiles. God knows how long to heat through a 50mm screed. The floor is meant to be permanently on. If you use a programmer it will be full on when timed on and at 80% when off.

                                    If it fails then nothing you can do except change a thermostat. If electricity prices continue to rise I guarantee you will put another form of heating in there. Wet heating pipes differ in that they use a special conductive concrete screed which allows the heat through

                                    Brian

                                    #584446
                                    not done it yet
                                    Participant
                                      @notdoneityet
                                      Posted by Pete White on 07/02/2022 10:13:49:

                                      What about those proper workshop mats, sited where you stand?

                                      Those diesel heaters mentioned are good, got a couple of mates happy with those, thinking of getting one myself yes . There were problems when the exhaust was lengthened, so becareful there.

                                      Pete

                                      When installing, one is advised to follow the Webasto or Eberspacher installation details as pipe/duct sizes are important. The chinese instructions often leave a great deal to be desired – either factually, or language problems.

                                      The Eberspacher manual can be found at:

                                      **LINK**

                                      132 pages, of which few are relevant to a simple installation but, nevertheless, useful for those that want to be sure they install the heater correctly.

                                      The advantages of these heaters are: No water vapour is produced, or introduced, within the area heated. They do not need draughts to be sure of proper combustion (ie they are can be completely draught-proofed – my workshop is such, with no windows. Minimum fuel delivery (152ml/h) soon gets my workshop to a reasonable temperature for working, even if the machine temperatures lag behind. Full-chat would soon have been simply too hot in a short time.

                                      I suspect that Sam’s garage is neither fully insulated nor draught-proofed. Also he may be procuring his fuel at inflated cost. He might be drawing in cold air from outside, for all we know.

                                      Gross energy cost for gas oil is currently about 7p/kWh tops? (mine is currently a lot lower than that🙂 ) – unless bought in inappropriate volumes from convenience sources.

                                      I run mine from the mains (practically). The 12 volt battery (needed as the power supply in case there is a power cut) is simply float charged from a lidl battery charger. My battery returns to ‘float’ charge only a few minutes after the heater is turned off, even though the controller is a permanent draw. Electricity draw is, I believe, 36-40W at full output but only around 12-15W at minimum fuelling.

                                      #584448
                                      duncan webster 1
                                      Participant
                                        @duncanwebster1

                                        I have 75mm insulation in walls, a lot in the roof, and 25mm under the floor. A 2kw gas balanced flue heater is more than adequate, warms up quickly then turn it down to 1kw.

                                        #584453
                                        Nigel McBurney 1
                                        Participant
                                          @nigelmcburney1

                                          my workshop has 3 to 4 inch concrete floor (no reinforcing) laid on a foot of rubble, with a membrane in between,then 18mm shuttering ply with top layer of 18 mm chipboard,ordinary diy quality. No problems with cold feet and the floor supports a 6 inch Colchester,and in the past has supported a 35 cwt turret mill. In cases with large long bed lathes ie 7.5 ch eg colchester triumph I would use in future 6 to 8 ins of reinforced concrete,and the lathe directly mounted on the concrete,as over a year the concrete will move depending on ground conditions ,my triumph was mounted on 4 ins on concrete over a 9 inches of crushed concrete and the movement in the ground conditions did affect the accuracy,it has now departed as I have got to old as a big lathe can be hard work.If I want my workshop warm I use a 3 kw fan heater,the walls and ceiling are insulated and windows are old double glazing

                                          #584462
                                          not done it yet
                                          Participant
                                            @notdoneityet
                                            Posted by duncan webster on 07/02/2022 14:02:16:

                                            I have 75mm insulation in walls, a lot in the roof, and 25mm under the floor. A 2kw gas balanced flue heater is more than adequate, warms up quickly then turn it down to 1kw.

                                            That is about as cheap, per kWh, as one can get at the moment, short of home renewable generation. Combustion air from outside and inlet air to the combustion chamber preheated by the exhaust gases. No water vapour from a fuel burning in the heated area.

                                            That would cost me 5p/h at 1kW (assuming 80% efficiency) whereas an electric fan heater would cost me over 25p/h during the day. No contest!

                                            #584465
                                            Pete White
                                            Participant
                                              @petewhite15172
                                              Posted by not done it yet on 07/02/2022 13:52:12:

                                              Posted by Pete White on 07/02/2022 10:13:49:

                                              What about those proper workshop mats, sited where you stand?

                                              Those diesel heaters mentioned are good, got a couple of mates happy with those, thinking of getting one myself yes . There were problems when the exhaust was lengthened, so becareful there.

                                              Pete

                                              When installing, one is advised to follow the Webasto or Eberspacher installation details as pipe/duct sizes are important. The chinese instructions often leave a great deal to be desired – either factually, or language problems.

                                              The Eberspacher manual can be found at:

                                              **LINK**

                                              132 pages, of which few are relevant to a simple installation but, nevertheless, ………

                                              Thankyou for the link, these heaters are getting some good reports, will be getting one fitted and runner for next winter. Apparently there is quite alot of information on Utube, as usual.

                                              #584468
                                              SillyOldDuffer
                                              Moderator
                                                @sillyoldduffer
                                                Posted by gerry madden on 06/02/2022 19:38:24:

                                                The heating elements need to be embedded in 50mm of concrete screed which would sit on top of 100mm thick polystyrene blocks.

                                                My question is this: Is 50mm of concrete sitting on top of a relatively soft base material going to be strong enough to support machines weighing up to a ton ? Any thoughts or experience anybody?

                                                Gerry

                                                Relatively soft materials aren't a problem provided the weight is spread over a wide enough area. Tanks rarely get stuck in mud because caterpillar tracks massively reduce the pressure on the ground.

                                                Looking up polystyrene insulation I found 3 pressure resistant grades made specifically for insulating floors, able to take 100kPa, 150kPa and 300kPa for 10% compression. Polystyrene made to insulate walls is no good.

                                                300kPa is a bit over 40 pounds per square inch so my flat-bottomed sheet-metal lathe stand with two 13×13" plinths would support 13520 lbs (over 6 tons). As my lathe actually weighs about 600lbs, say 800lbs with the stand, the pressure would be only 2.4 psi, and I'd expect polystyrene under the plinth to deflect by about 0.06mm.

                                                Although concrete screed isn't as good at distributing pressure as chipboard or floorboards, I think it would be safe to support heavy machines provided a stiff board were placed underneath to guarantee load spreading. For example, a length of kitchen worktop 52" x 24" under my 800lb lathe and stand would reduce the floor loading to about 0.7psi, which is trivial.

                                                I'd be nervous of doing anything that increased pressure on a polystyrene insulated floor such as putting a heavy machine on wheels. But this is mainly because I don't know how 50mm of concrete screed behaves laid on top of polystyrene. I suspect the combination is much stronger than I give it credit for because floors are generously specified to take loads. Is there a builder or architect on the forum?

                                                Dave

                                                #584480
                                                Neil Lickfold
                                                Participant
                                                  @neillickfold44316

                                                  With my new house build, the concrete floor minimum thickness was increased from 50mm for the rest of the house to 100mm for the workshop. I also increased the concrete to 30mpa instead of the std 25mpa, as the higher cement content makes for a slightly nicer finish on the floor as well. The poly styrene under the floor areas that goes down to the base, so makes a concrete rib that is 200mm deep in the workshop and 150mm deep for the rest of the house. The foam is specific for house construction, but I don't know what compressive strength was used. My driveway is cracking and is placed on sand and they did not reinforce it. Not happy about that. The cracks are now happening 2 years latter. It is also only around 75mm thick. Which I think is too thin for an un reinforced structure.

                                                  #584482
                                                  Bazyle
                                                  Participant
                                                    @bazyle
                                                    Posted by Sam Longley 1 on 07/02/2022 11:15:13:

                                                    . There is no point in heating a machine so go round it. .

                                                    Edited By Sam Longley 1 on 07/02/2022 11:19:32

                                                    How about the opposite. Just heat the machine say to 22C with sheet and blanket over it when not in use. Avoids rust. Then stand on a duckboard which has a small heater panel if your feet get cold and a radiant heater aimed at your back if your body gets cold.

                                                    #585105
                                                    gerry madden
                                                    Participant
                                                      @gerrymadden53711

                                                      Thanks all for your input.

                                                      I think its clear now 50mm of concrete on a compliant base is quite risky, and especially so with electrical elements embedded in it. I will have to consider something substantially thicker, probably 100mm min. In a house this wouldn't be helpful as it just slows the warm-up time. But in the workshop it would only be a background heat just to keep the room a little above ambient, so perhaps 100mm is not a problem.

                                                      I had planned plenty of insulation and the calculations suggest it wouldn't take much energy to maintain a reasonable differential with the outside ambient. I already have solar panels on the house and they generate far more than I can use, so this would heat the workshop most days, and for free.

                                                      The real problem now is that the planning people want to reject the whole concept due to 'green belt' concerns. So all workshop design activities are on hold until this is sorted, ….if it can be sorted.

                                                      Gerry

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