Right arrow Traffic Behaviour in Distribution Centres

Traffic Effects on Distribution Centre Floors

Forklifts, reach trucks and VNA equipment load floors in very different ways, even when operating in the same building. Steering geometry, wheel type and guidance systems determine how forces are transferred into slabs and joints. This article supports our wider distribution centre flooring guidance by focusing on how traffic patterns drive floor response in day to day operation.

Contact us Right arrow

20 +

Years
Supporting Distribution Operations

Traffic-related floor issues rarely appear evenly across a site. They develop where equipment repeats the same movements, braking points and turning arcs shift load into narrow strips, and guidance systems restrict variation. Understanding these patterns is essential to keeping handling predictable and preventing avoidable deterioration.

Right arrow How Different Truck Types Load the Floor

Counterbalance forklifts distribute load through wider turns and variable routes, while reach trucks concentrate movement into defined aisles with repeat braking and mast loading at pick faces. VNA trucks apply the most repeatable loading of all, following fixed guidance lines that place wheel loads on the same strips every shift. Over time, these differences create distinct wear bands, joint stress points and handling changes that affect productivity.

On new builds, expected traffic behaviour can be considered during concrete slab installation. In existing centres, resurfacing is often used to correct local response in control strips. In inspection routes, polished concrete can help reveal early traffic-driven change.

Right arrow Traffic Characteristics That Matter Most

  • Repeated wheel paths created by guided or narrow aisle equipment.
  • Braking and acceleration loads at pick faces and aisle ends.
  • Steering correction forces during pallet alignment and placement.
  • Mixed truck types crossing joints at different angles and speeds.
  • Route constraints that limit variation and concentrate wear.

Right arrow Where Traffic Effects Become Floor Problems

Traffic-related deterioration usually starts where movement repeats and guidance restricts variation. These locations govern how trucks behave and how quickly issues spread into wider routes. Identifying them early helps prevent local change from escalating into handling disruption or access limits.

VNA travel lanes where wheel loads repeat on fixed guidance strips.

Pick faces where reach trucks brake, pause and realign pallets.

Aisle ends where trucks decelerate and turn under load.

Transfer lanes where different truck types cross joint lines.

Battery change and staging areas with slow manoeuvring and pivot loads.

Door approaches where traffic density and surface change combine.

Right arrow Our Approach

How We Assess Traffic Effects on Distribution Floors

Contact us Right arrow

STAGE 1

Mapping Equipment Types and Movement Patterns

We identify the truck types in use, their operating weights and how they move through the building. Routes, guidance systems, braking points and turning arcs are mapped to show where loads repeat and where movement is constrained. This establishes which strips govern daily handling behaviour.

Double arrowsSTAGE 2

Reviewing Surface, Joint and Wear Band Response

We assess how the surface and joints are responding within traffic bands, including edge stress, polishing and debris trapping. Differences between truck types are considered, especially where mixed traffic crosses the same joints. The focus is on behaviour under normal shifts rather than isolated defects.

Double arrowsSTAGE 3

Targeting Control Strips and Verifying Performance

Measures are focused on the strips that control handling accuracy and joint stability, such as guided lanes and aisle transitions. Works are phased so operations continue, then checked under live traffic to confirm predictable response across all truck types using the route.

Managing Fixed Wheel Paths

Guided equipment repeats loads in the same place, so small surface or joint changes can quickly affect handling. Keeping these strips consistent helps prevent vibration, steering correction and accelerated wear spreading into adjacent areas.

Reducing Stress at Braking Zones

Braking zones concentrate load transfer into short sections of floor. If these areas deteriorate, trucks adjust speed and path, increasing stress elsewhere. Treating braking strips early supports smoother operation across the wider route.

Handling Mixed Traffic at Crossings

Where forklifts, reach trucks and VNA equipment cross the same joints, load angles and frequencies differ. Managing these interfaces prevents uneven joint response that can disrupt one vehicle type more than another.

Using Wear Bands as Predictive Signals

Wear bands show where traffic is shaping the floor in practice. Changes in band width, texture or debris retention often appear before handling complaints. Treating them as indicators supports planned intervention rather than reactive repair.

Discuss Traffic Effects in Distribution Centres

If handling behaviour, vibration or joint wear is changing under forklift or VNA traffic, we can review how movement patterns are affecting your floor.

Contact us to discuss your distribution centre flooring requirements:

Right arrow FAQ

Traffic Effects Common Questions

Why do VNA lanes show wear sooner than open routes?
VNA trucks follow fixed guidance, so wheel loads repeat on the same narrow strips every shift. This concentration accelerates surface change and joint stress. Even small differences in response become noticeable because equipment tolerance is tight and variation is limited.
How does mixed traffic affect joint behaviour?
Different truck types cross joints at different angles, speeds and load levels. When these behaviours overlap, joints can respond unevenly and wear asymmetrically. This can affect one vehicle type more than another, leading to vibration or handling change that appears inconsistent unless traffic patterns are reviewed together.
What early signs indicate traffic-driven floor change?
Early signs include visible wear bands, debris collecting along wheel paths, subtle vibration at the same points, or operators adjusting speed and line. These indicators often appear before obvious damage and show where repeat movement is shaping the floor response.
Do braking zones need different attention than travel lanes?
Yes. Braking zones experience higher load transfer and edge stress than steady travel lanes. If they deteriorate, trucks compensate elsewhere, spreading the issue. Treating braking strips as control points helps stabilise behaviour across the wider route.
Can traffic-related issues be corrected without stopping operations?
In most centres, yes. By focusing on control strips such as guided lanes and aisle transitions, work can be phased while alternative routes remain available. Verifying behaviour after reopening ensures handling remains consistent under normal traffic conditions.