Automated Equipment & Floor Construction Guide

6-2. AGV/AMR Floor Environments and Automated Warehouse Design

1. Floor Structure and Smoothness Requirements When Introducing Automated Guided Robots (AGV/AMR)

To operate AGVs (Automated Guided Vehicles) and AMRs (Autonomous Mobile Robots) smoothly, a highly precise floor environment—more so than general warehouses—is essential. The main requirements demanded to prevent meandering, tipping over of equipment, and sensor reading errors are as follows.

1.1 Floor Smoothness (Leveling and Flatness)

This is the element most directly linked to the traveling precision and stability of robots. Slopes and unevenness cause deviations in driving routes, load collapses, and travel incapacitation.

• Overall Slope (Gradient): Depending on the equipment specifications, 0.2% to 0.5% or less (a height difference of within 2cm over a 10m progression) is generally the guideline. High-stacking, high-rise rack-compatible AGVs require even stricter horizontal precision.
• Local Unevenness and Waves: Utilizing indices that express horizontality at 3m to 4m intervals (such as the US standard Ff/FL values or the UK TR34 standard), cases demanding a "super flat floor" level finish are increasing.
• Level Differences and Joints: Level differences in front of elevators and at area boundaries must be suppressed to 2mm to 3mm or less, and joints (expansion joints, etc.) must be filled smoothly by chamfering or resin filling.

1.2 Floor Surface Finish and Coating Characteristics

A surface finish that takes optical sensors and tire running characteristics into account is required.

• Wear Resistance and Dust Proofing: Because robots travel back and forth on the same routes at high speed, environments prone to generating dust from wear are unacceptable. Epoxy or polyurethane coatings that resist peeling, or hardener finishes, are used.
• Friction Coefficient (Slipperiness): To prevent slipping during sudden stops and turns, a floor finish with sufficient grip is required.
• Glossiness and Reflectance: For types (like AMRs) that recognize QR codes, markers, or self-position on the floor surface using cameras or LiDAR, extreme glossiness or reflection on the floor causes sensor malfunctions, so a matte finish is recommended.

1.3 Load-Bearing Capacity and Anti-Static Measures

Automated equipment is characterized by "strong concentrated loads placed on each wheel."

Furthermore, to prevent impacts on the precision machinery within the AGV/AMR main body and mounted IC boards, the installation of an "anti-static floor (conductive floor)" that releases static electricity is required.

2. Floor Flatness Standards (F-Number) and International Standards

When introducing AMRs (Autonomous Mobile Robots), VNA (Very Narrow Aisle) forklifts, or automated 3D warehouses, the floor's "flatness (lack of unevenness)" and "levelness (lack of tilt)" are the most critical specifications that dictate the system's availability.

2.1 Two Major International Standards Representing Floor Quality

Replacing the ambiguous traditional inspection method of "gap of 〇mm or less with a 3m straight edge," international standards managed by quantitative values (such as ASTM F-numbers) have become standard for automated warehouses.

2.2 Required Horizontal Precision Standards by Material Handling Robot

The required level is clearly divided according to the type of material handling equipment being introduced.

2.3 Construction Technology to Realize Super Flat Floors

Standard concrete placement cannot achieve a flatness in the $F_F\ 100$ class. The following special technologies are used.

• Laser Screed (Placing machine with automatic level adjustment): Computingly controls the screed (leveling board) while constantly receiving the reference height from a laser emitter, finishing to the utmost flatness during the concrete placement stage.
• Topping Construction (Self-leveling high-fluidity material): Forms a smooth surface by thinly applying an extremely fluid, high-strength cement-based self-leveling material on top of the concrete.
• Grinding Finish (Diamond Grinding): After construction of a new or existing warehouse, the travel track (aisle) portion of the VNA wheels is shaved in millimeter increments using dedicated grinding equipment to create a perfectly flat surface.

2.4 Precautions During Design and Construction

1. Level Differences at Joints (Concrete Expansion Joints): Drying shrinkage of concrete causes joint parts to spring up (curling phenomenon), creating minute level differences of 1 to 3mm. Because this causes AMR wheel shock and sensor malfunctions, "eliminating decorative joints" and "filling cutter joints with load-bearing epoxy" are essential.
2. Prevention of Age-Related Subsidence (Uneven Subsidence): If the entire floor tilts due to land subsidence, the $F_L$ value deteriorates significantly. The automated warehouse area requires a structural design where pile foundations (bearing piles), not direct foundations, are driven firmly directly under the floor slab.

3. Repair and Renovation Methods for Existing Warehouse Floors

When renovating an existing warehouse floor to make it AGV/AMR compatible, completely repouring the floor involves enormous costs and construction periods. Therefore, it is common to combine partial repairs and thin-layer renovations according to the "current state of the floor (level differences, slopes, scratches)."

3.1 Specific Renovation/Repair Procedures

• Repair of Joints, Cracks, and Level Differences (Partial Repair): Shave down level difference sections with a diamond cutter or polisher to make them flat. Fill expanding joints and cracks with an epoxy resin or urethane resin-based filler and polish flat.
• Correction of Floor Level (Unevenness Adjustment / Leveling): Pour a high-strength, highly wear-resistant self-leveling material capable of a thin coating of about 3mm to 10mm to create a horizontal surface by its own weight, or perform a polishing finish on the concrete surface.
• Surface Coating / Adding Functions (Floor Coating Method): Apply a finishing coat to prevent dust caused by wheel wear and to counteract sensor malfunctions.
  
  
• Marking for Alignment (Guidance Measures): Attach magnetic tape or install/print QR codes and position recognition markers on the floor surface, and apply a transparent protective coating for wear resistance over them.

4. Design Standards for Pedestrian-Vehicle Separation and Safe Aisles (ISO 3691-4 / JIS B 8431)

In "coexistence warehouses" where AGVs (Automated Guided Vehicles) or AMRs (Autonomous Mobile Robots) and workers move in the same area, pedestrian-vehicle separation and aisle design standards based on international safety standards (ISO 3691-4) and Japanese Industrial Standards (JIS B 8431) are required.

4.1 Aisle Width and Safety Clearance

Type of Travel Area	Required Clearance / Aisle Width	Points in Standards and Design
Dedicated Travel Path (Worker entry prohibited)	Vehicle width + 0.5m or more on each side	Block sudden entry of workers using physical fences or interlocked doors.
Coexistence Travel Path (Coexisting with people, low speed)	Vehicle width + 0.5m or more on each side (0.8m recommended)	Narrow areas where 0.5m clearance cannot be secured are deemed "danger zones," and deceleration/temporary stopping is mandatory.
Pedestrian-Vehicle Shared Aisle (Facing, passing each other)	Vehicle width (robot) + Personnel width (1.0m) + 1.0m or more	The main aisle where robots and workers pass each other must secure a width of at least 2.5m to 3.0m.

4.2 Differences in Design Philosophy Between AGV and AMR

Because AGVs and AMRs differ in their travel methods and evasion behaviors, their design philosophies for safe aisles must be distinguished.

4.3 Safety Area Zones (4 Zones) and On-site Safety Equipment

1. Exclusive Zone: For high-speed AGVs, etc. Enclosed with interlocked fences, emergency stop upon entry.
2. Operating Zone: For AMRs and low-speed AGVs (Guideline: 4km/h or less). LiDAR, safety scanners, and E-STOP are mandatory.
3. Working Zone: Areas where picking and transfer are performed. Implement sequence control confirming complete stop.
4. Pedestrian Zone: A worker-only area where robot entry is completely prohibited.

On-site Software and Equipment Countermeasures: Combine floor markings with low-reflection zone lines, "floor graphic projections" via projectors, and installation of emergency stop switches (E-STOP) along aisles.

5. "Construction While Operating" Procedures, Precautions, and Construction Cost Market Prices

When renovating AGV floors via "construction while operating (partial construction / night construction)" without stopping the operations of an existing warehouse, the biggest keys are maintaining operational lines and countermeasures against dust and odors accompanying the construction.

5.1 Standard Procedures and Precautions for Construction While Operating

• Odor Countermeasures: To prevent odor transfer to stored goods (food, cosmetics, etc.), the selection of low-odor, water-based paints and materials not containing VOCs is mandatory.
• Noise Countermeasures: Implement shutter shielding and notify neighbors regarding grinder noise during floor polishing.
• Joint Processing: Fine-polish the level difference at the boundary of split construction to 2mm or less to flatten it.
• Re-mapping: Since SLAM may shift due to the installation of curing sheets, etc., pay attention to landmark management.

5.2 Unit Price Market Values per Square Meter by Process and Specification (Cost Guideline)

These are the cost market prices for floor coating renovation work compatible with AGV/AMR travel.

Main Requirements Fluctuating the Unit Price (Added Factors):

• Scale of Construction Area: For small sections of 300㎡ or less or split construction, the unit price will be 1.3 to 1.5 times higher due to basic fee settings and surcharges.
• Night / Holiday Construction Surcharges: A labor cost surcharge of 20% to 30% on the construction unit price occurs.
• Degree of Damage to Existing Floor: Costs will rise if injection repair of cracks or full peeling of old paint is required.
• Marking Processing for AGV Guides: Additional processing (quoted separately) such as QR code installation, magnetic tape embedding, and clear protective coating for lines will occur.