Construction of the Garage Floor in a ZAPF Precast Concrete Garage

This construction method differs significantly from a brick garage, where a floor slab is often poured on-site and construction continues on top of it.

Basic principle of construction

The construction process can be divided into three stages:

1. Site preparation: The subgrade must be load-bearing. Depending on the property, earthwork, compaction, leveling, and drainage preparation may be necessary.
2. Foundation: The garage stands on point or strip foundations. ZAPF creates a special foundation plan for this purpose that matches the specific garage model.
3. Prefab garage with integrated floor: The precast concrete garage is delivered with the floor and placed on the prepared foundations. The garage floor is therefore not a separately cast site slab, but rather part of the delivered prefabricated unit.

How is the garage floor created?

ZAPF describes the creation of a prefabricated garage as an industrial manufacturing process that ranges from the steel structure through casting to delivery and installation. (ZAPF Garages) The garage floor is not considered in isolation, but as a functional component of the entire concrete structure.

The integrated floor must meet several requirements:

• Supporting the vehicle’s weight,
• sufficient suitability for vehicle traffic,
• a durable surface,
• connection to the door area and driveway,
• suitability for future coating or renovation,
• coordination with drainage and the foundation.

Structure in Relation to the Foundation

The foundation permanently supports the garage and prevents subsidence or tilting. ZAPF emphasizes that the construction of the foundation is crucial for the garage’s long-term stability. The foundations are not considered part of the garage floor. They are either provided by the client or pre-fabricated and placed beneath the garage. The integrated garage floor, on the other hand, is part of the delivered prefabricated garage.

Installation of the Garage

Installation takes place after the site and foundations have been prepared. The prefabricated garage is delivered and placed on the designated foundations. ZAPF describes the process for a prefabricated garage from planning, permits, and foundation preparation through delivery, assembly, and handover.

For homeowners, this means: The main concrete area inside the garage does not need to be poured, reinforced, stripped, and dried on-site. The garage floor arrives at the construction site along with the garage structure.

Surface and protection of the garage floor

The concrete floor of a garage is exposed to heavy wear and tear in everyday use. This includes moisture, dirt, road salt residue, oil stains, tire abrasion, mechanical impacts, and temperature fluctuations. A floor coating can protect the surface and make cleaning easier.

ZAPF offers floor coatings based on epoxy-hardened materials for precast concrete garages. These are designed to permanently protect the floor from moisture, impacts, and wear.

Entrance threshold and transition area

A particularly stressed area is the threshold at the garage door. There, vehicle loads, water, dirt, and mechanical stress from entering and exiting the garage all combine. When renovating floors, ZAPF points out that the entry threshold is often affected as well and can be renovated at the same time.

Therefore, planning should consider not only the interior surface but also the transition between the driveway, the door area, and the garage floor.

Drainage and Moisture

Garage floors are regularly exposed to moisture, for example from wet vehicles, snow, rainwater, or cleaning water. Drainage and proper connection details are therefore important. The ZAPF data sheet on drainage describes, among other things, that drainage pipes can be laid underground starting from the foundation and that foundations should be set on stable ground to a frost-free depth.

Whether and which drainage solution is required depends on the project, location, and garage type.

Step-by-step: Understanding the construction process

1. Plan the garage: Size, model, and features are determined.
2. Receive the foundation plan: ZAPF creates a suitable plan for the foundation.
3. Prepare the construction site: Subgrade, earthwork, utilities, and drainage are taken into account.
4. Constructing the foundations: Point or strip foundations are built according to the plan.
5. Have the garage delivered: The prefabricated garage is delivered with an integrated floor.
6. Erecting the garage: The garage is positioned on the prepared foundations.
7. Optional floor protection: A coating can make the usable area more durable and easier to maintain.

Common Misconceptions

A common misconception is to equate the garage floor with a site-prepared floor slab. With ZAPF precast concrete garages, the floor is already part of the delivered garage. An additional full-surface concrete slab is normally not required. (ZAPF Garages)

A second misunderstanding concerns the foundation. Even if no site-prepared floor slab is required, a professionally constructed foundation is essential. The garage requires load-bearing point or strip foundations.

FAQ

Is the garage floor poured on-site by ZAPF?

No. The precast concrete garage is delivered with the floor. The garage floor is an integral part of the industrially manufactured garage.

What does the garage stand on if no floor slab is poured?

The garage stands on suitable point or strip foundations. ZAPF creates a special foundation plan for this. (ZAPF Garages)

Can the integrated garage floor be coated?

Yes. A coating can protect the floor and make it easier to maintain. ZAPF offers epoxy-hard floor coatings for precast concrete garages for this purpose. (ZAPF Garages)

Is the transition to the driveway important?

Yes. The threshold area is subjected to particular stress from driving in and out. In older garages, this area can be renovated along with the floor. (ZAPF Garages)

What needs to be completed before the garage is delivered?

Before delivery, the planned foundations and the agreed-upon preparations on the property must be completed. This may include earthwork, utilities, drainage, and access.