Floor Requirements

for AutoStore
Installations

Revision: 1

Publishing date: 28.09.2021

AS-80997-STD-eng
Language: English Original
Imprint

AutoStore AS
Stokkastrandvegen 85
N-5578 Nedre Vats
Norway
Tel: +47 5276 3660
http://www.autostoresystem.com/
Copyright, Intellectual Property, and Disclaimer

All rights reserved. This manual is protected by applicable copyright law and international treaty provisions.
AutoStore Technologies AS is the sole proprietary owner of this manual, its contents and related intellectual
property, including, but not limited to, creative work, designs, patents and trademarks. No parts of this work,
including but not limited to, design, technical solutions, trademarks, graphic, electronic or mechanical, may be
reproduced in any form or by any means whether by photocopying, recording, taping, information storage and
retrieval systems or otherwise, without the written permission of AutoStore Technologies AS.

This manual and its contents and specifications are subject to change without notice. While every precaution
has been taken in the preparation of this document, neither AutoStore Technologies AS nor any other
company within the AutoStore Group (affiliates, subsidiaries or parent companies of AutoStore Technology
AS) assume any responsibility or liability for errors or omissions, or for any personal injury, loss or damages
resulting from the use of or reliance on the information contained in this document or from the use of programs
and source code that may accompany it.

AutoStore is a certified product. Modules and parts of the AutoStore system must not be modified, altered, or
installed, operated or used in a way not explicitly endorsed by the official documentation. To the fullest extent
permissible under applicable law, in no event shall AutoStore Technologies AS or any other company within
the AutoStore Group be liable for any claim, loss of profit or any other economic or physical damage caused
or alleged to have been caused directly or indirectly by this document.

All specifications provided in this manual follow European standards and may not reflect applicable local
standards. If applicable local standards deviate from the ones stated in this manual, then the strictest
specifications should be followed.

It is the responsibility of the distributor to ensure that local requirements are followed.
Contents

Imprint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Copyright, Intellectual Property, and Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. The Floor Surface Regularity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Floor Surface Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Floor Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Local sudden irregularities.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Joint openings over time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Special Consideration Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 United States Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Floor Surveying Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Checking Surface Regularity Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Floor Profiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Optical Laser Leveling Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Scanners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. Actions for non-compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. Floor Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1. Introduction

AutoStore requires a flat floor as a base for installation of an AutoStore system. The reason for this requirement is
tight tolerances for bin spacing and robot movement. The goal is to have a flat and level floor to allow the top grid
to also be flat and level. If the top grid is out of tolerance, the robots can succumb to errors. The bins sit directly
on the floor, and if the floor is out of level, it could impact the ability of the robot to retrieve bins in the stack.
The purpose of this document is to provide a specification that will result in a floor that meets the following
requirements needed for installation of the AutoStore grid:
▪ Flat and level top tracks for trouble-free robot driving.
▪ A stable grid without any loose connections, which can result in track deflection and wear on profiles.
▪ A proper bin footprint. Bins that are seated on an uneven surface, will overtime be deformed and out of spec.
This can cause robot error during bin handling.
AutoStore provides the floor flatness, level and datum Requirements. The partner or client is allowed to meet the
requirements anyway they see as acceptable. AutoStore does not provide construction means and methods, to
allow for local flexibility when doing construction. This manual is based on metric dimensions.
2. The Floor Surface Regularity

2.1 Floor Surface Definitions

Surface Regularity of the floor on which the AutoStore system is to be installed on must be controlled so that the
departures from a theoretically perfect plane are limited.
There are three properties of surface regularity that need to be controlled: Flatness, levelness and departure from
datum.
Diagram 1
a. Flatness: related to variations over
shorter distances. The short
wavelength profile of the floor.
Diagram 1(a) shows a floor that is
level but not flat.
b. Levelness: related to longer
distances. The long wavelength
profile of the floor. Diagram 1(b)
shows a floor that is flat but not level.

Diagram 2
Departure from datum: the deviation in
height of the surface of the whole floor -
from a single fixed level datum plane.
The datum plane could be the mean
floor level of all the readings taken on
the floor. The departure to datum is
usually written as + or – a specified
value from datum, an upper and lower
limit. As depicted in Diagram 2
Surface Regularity Properties:
Diagram 3
Property A: To Control Flatness.
The difference in millimetres between
the mid-point of a mean line between
two fixed points (Gauge) on the floor
and the floor itself at that mid-point of
the gauge (1/2 Gauge).

Diagram 4
Property B: To Control Levelness.
The elevational difference in millimetres
between two fixed points over a given
distance apart (Gauge).

Diagram 5
Property C: To Control Departure From
Datum.
Readings taken from a 3-metre square
pattern, over the whole of the floor area
where the AutoStore system will sit.
2.2 Floor Limits

The maximum permitted values for properties A, B and C are given below in Table 1. The floor is non-compliant if
any point on the floor exceeds any of these values.
Table 1:

Property Gauge (metres) Max Value (mm)

i 1.2 m 3.5 mm
A Flatness
ii 2.4 m 5.5 mm

i 1.2 m 4.0 mm
B Levelness
ii 2.4 m 6.0 mm

C Datum Entire Floor 3 m x 3 m grid + / - 20 mm

Diagram 6:

Local sudden irregularities such as steps (A), Joints (B), bolts (C) and Isolated Hollows (D) and Mounds (E),
should be identified as part the surface regularity floor survey. If they exceed the given limits, they should be
treated in the following manner:
▪ No step or mound should exceed 2mm in height.
▪ All bolts should be removed or cut flush with the floor surface.
▪ Isolated hollows (D) in the floor that have a width and length no greater than 30mm will be acceptable.
▪ Maximum limit for joint width (B) : 20mm
All joints are assumed to have adequate load transfer capacity in the form of dowels or nominal reinforcement
crossing the joint. Differential, vertical movement over a joint is not permitted.
2.4 Joint openings over time

Joints are generally categorized as restrained movement joints or free movement joints.
Joints are designed to accommodate drying shrinkage by relieving stresses. This is to ensure the tensile capacity
of the slab is not exceeded, and hereby prevent uncontrolled cracking.
Restrained movement joints are usually sawn induced and restrained by reinforcement crossing the joint, these
joints are intended to open slightly.
Free movement joints are generally construction joints that have little, if any, restraint to open and have dowels to
give load transfer capacity. These joints generally accommodate most of the drying shrinkage movement within a
single cast panel. The bigger the cast panel, the greater the joint opening. Free movement joints can open over
20mm over 12 months from the time of construction.
When designing a floor to accommodate an AutoStore system, the design should limit edge of slab curling, and
joint expansion during curing. Cracks not exceeding 2mm within the slab do not affect the operation of the
AutoStore and are therefore acceptable. Joints should be designed with a limit of 10mm after 90 days cure time.
75% of concrete shrinkage occurs over the first 90 days. AutoStore suggest allowing the slabs to cure for 30 days
before installing the grid over a construction joint to allow for the initial shrinkage and movement to occur. When
installing an AutoStore over construction joints, please refer to the installation manual for further information.
2.5 Special Consideration Structures

Suspended Floors
If the AutoStore system is to sit on a suspended slab, e.g. a piled slab, mezzanine or a structural upper floor,
flatness and levelness requirements listed in Table 1 above, must be achieved after all loads, dead and live, have
been considered. As it will be impractical to measure the surface regularity of the floor when it is fully loaded, the
floor designer must calculate the anticipated live load deflection of the AutoStore grid, and operational live loads,
and deduct this from the surface regularity Property Limits. This will form the basis of the construction tolerances
the contractor has to achieve. It is essential that the floor on which the Grid stands, is absolutely stable.
The AutoStore distributor will provide the load of the grid, robots, and bins.

Mezzanines
Length tolerances on short grid columns (b) that are seated on top of mezzanine and height of mezzanine (c)
must comply with standard column length (a) within a tolerance of ±3 mm.

Diagram 7. Mezzanine
2.6 United States Reference

U.S. Concrete contractors use the FF/FL system. To help the US Contractors understand the requirements in
Table 1, we have provided the information below for consideration. The following guidelines shall apply to all
slabs being placed in a multiple slab installation for a single AutoStore installation. AutoStore recommends that
when contracting with the concrete floor contractor, the limits in Table 1 shall be used as the contract
requirement.
A. Overall Flatness and Levelness, FF/FL, 75/75
B. Minimum Local Flatness and Levelness, FF/FL, 50/50
C. Elevation Envelope ±20 mm
3. Floor Surveying Procedure

3.1 Checking Surface Regularity Properties

AutoStore does not determine the means and methods of construction / surveying the floor. It is up to the
individual partners to determine if the floor is within the tolerances set out in this manual. This section of the
manual provides basic guidance to those who require additional details.
AutoStore knows of three different methods that are used to survey floors:
1. Floor Profiler
2. Optical/laser leveling instrument
3. 3D Scanners
Note: The most critical factor when selecting a surveying method is that the accuracy of the equipment should be
at least +/- 0.5 mm.

3.2 Floor Profiler

A floor profiler is a special instrument designed specifically to survey the flatness and levelness of concrete floors
and can perform faster on larger floor areas than an optical/laser levelling instrument. A floor profiler cannot be
used to survey property C, Datum.
Floor Profilers that are known to meet the requirements for surveying floors within the tolerances described in the
manual are:
▪ F Speed Reader Floor Profiler - manufactured by CoGri Engineering Ltd
▪ AutoStore Profileograph - manufactured by CoGri Engineering Ltd
▪ Dipstick Floor Profiler - manufactured by Face Construction Technologies Inc
▪ Axiom Floor Profiler - manufactured by Somero Matson Group
To determine compliance with the maximum values of Properties A and B in Table 1 using a floor profiler, the
entire floor must be surveyed in the following manner:
▪ The area of the floor where the AutoStore system will be located shall be marked with a square pattern of
survey lines with 1.0 x 1.0 meter spacing. Where possible, the start and finish of each of the survey lines
should be taken at least 1.0 meter before and past the boundaries of the AutoStore system.
▪ Survey lines should be taken up to 0.3 meters off each column face or any floor penetrations. This may require
additional survey lines.
▪ All survey lines should be measured at maximum lengths of 300mm from center line to center line (Instrument
Gauge) along their entire length, including taking readings across joints. The data is to be collected and the
properties calculated to determine compliance with the maximum values of Properties A and B in Table 1.
▪ The data shall be collected in an electronic format that can be imported as a table in an Excel spreadsheet,
and the properties can be calculated to determine compliance with the maximum values of Properties A and B
in Table 1.
▪ To determine compliance with the maximum values of Property C in Table 1 using an optical/laser leveling
instrument, the entire floor must be surveyed in the following manner:
▪ Set a 3-meter square-pattern on the whole of the floor area covered by the AutoStore system plus at least
0.6m to the boundaries where possible - as shown in Diagram 5.
▪ Establish a set point as 0,0 then evaluate the data and identify the largest and smallest number from 0,0. The
difference shall not exceed the limit in Table 1.
3.3 Optical Laser Leveling Instrument

To determine compliance with the maximum values of Properties A and B in Table 1 using an optical/laser
leveling instrument, the entire floor must be surveyed in the following manner:
▪ The area of the floor where the AutoStore system will be located shall be marked with a square pattern of
survey lines with 0.6 x 0.6-meter spacing. Where possible, the start and finish of each of the survey lines
should be taken at least 1.0 meter before and past the boundaries of the AutoStore system.
▪ Survey lines should be taken up to 0.3 meters off each column face or any floor penetrations. This may require
additional survey lines.
▪ The data shall be collected in an electronic format that can be imported as a table in an Excel spreadsheet,
and the properties can be calculated to determine compliance with the maximum values of Properties A and B
in Table 1.
To determine compliance with the maximum values of Property C in Table 1 using an optical/laser leveling
instrument, the whole floor must be surveyed in the following manner:
▪ Set a 3-meter square-pattern on the entire floor area covered by the AutoStore system plus at least 0.6m to the
boundaries where possible - as shown in Diagram 5.
▪ Establish a set point as 0,0 then evaluate the data and identify the largest and smallest numbers from 0,0. The
difference shall not exceed the limit in Table 1.

3.4 Scanners

Tremendous progress has been made with 3D scanners in the industry, however AutoStore is not aware of any
scanner that meets the +/- 0.5mm tolerance limits. In addition, the accuracy of the equipment declines as the
distance from the laser to the point on the floor being surveyed increases.
4. Actions for non-compliance

Where the required property limits are exceeded, it is recommended that individual measurements are examined
in detail to determine the cause, and extent of the failure. The cause and extent of the failure will determine the
type of remedial action required. Property failure could be due to curled joints, in which case simply grinding the
joints may resolve the non-compliant issues.
If Property C limits are exceeded, please discuss this with AutoStore before starting any planned remedial works.
Control to datum has the least influence on the performance of the AutoStore system and any remedial action to
achieve compliance with this property may not be necessary. Compliance with Properties A and B are necessary.
Options for remedial action could be one of the following:
▪ Controlled grinding
▪ An industrial grade screed
▪ Cut out and replace the slab
▪ Concrete topping slap
5. Floor Loading

The expected weight for each m² of floor space covered by an AutoStore installation can be calculated using the
following formula:

Variable Description Value Note

B2 Weight of 330 Bin 4.6 kg Material: PP-ESD (antistatic; the heaviest material)

B3 Weight of 425 Bin 5.8 kg

Z1 Number of Bins in height 220 Bin 25 nmax for 220 mm Bin = 25 (Including TopBin on Level
0)

Z2 Number of Bins in height 330 Bin 17 nmax for 330 mm Bin = 17 (Including TopBin on Level
0)

Z3 Number of Bins in height 425 Bin 14 nmax for 425 mm Bin = 14 (No TopBin allowed)

N1 Number of Bins for each m² SDG 2.955 1 / (0.480*0.705) = 2.955

N2 Number of Bins for each m² DDG 2.809 1 / (0.505*0.705) = 2.809

M Max. weight in each Bin 30 kg

G Grid weight 310 kg Includes loaded Robots on Grid

W Total weight for each m² Weight in kg, see calculations below

Bin Size Formula Max weight

Single Double Grid (SDG) Full stack

330 mm Bins W=((Z2*(B2+M))*N1)+G 2049 kg/m²

425 mm Bins W=((Z3*(B3+M))*N1)+G 1792 kg/m²

Double Double Grid (DDG) Full stack

330 mm Bins W=((Z2*(B2+M))*N2)+G 1963 kg/m²

425 mm Bins W=((Z3*(B3+M))*N2)+G 1718 kg/m²

WARNING
Small and large Bins have the same maximum weight. Therefore a system using small Bins can have a higher
weight per m2 because it supports more Bins per column.

WARNING
Make sure that all surface areas support the calculated maximum weight, especially when installing a multi-
level system!
6. Index

A
Actions for non-compliance 18

C
Checking Surface Regularity Properties 16
Copyright, Intellectual Property, and
Disclaimer 4

F
Floor Limits 11
Floor Loading 19
Floor Profiler 16
Floor Surface Definitions 9
Floor Surveying Procedure 16

I
Imprint 3
Introduction 7

J
Joint openings over time 13

L
Local sudden irregularities. 12

O
Optical Laser Leveling Instrument 17

S
Scanners 17
Special Consideration Structures 14

T
The Floor Surface Regularity 9

U
United States Reference 15
 AutoStore AS AutoStore System Inc.
Stokkastrandvegen 85 3 Corporate Park Drive
5578 Nedre Vats, NO 03038 Derry NH USA
Tel: +47 52 76 35 00 Tel. +1 (603) 404-3479

autostoresystem.com