PNL QUALITY EXAMINER

In recent years, the movement to reshore American manufacturing operations has gained significant momentum. This trend is driven by a combination of geopolitical tensions, global supply chain disruptions, and a growing demand for domestic job creation. Phoenix, Arizona, is rising to meet this moment and is emerging as one of the nation’s key hubs supporting and expanding U.S. manufacturing growth.

Phoenix offers a strategic location, access to infrastructure and available land, a skilled workforce, and a business-friendly environment. Its proximity to major markets in California, Texas, and Mexico supports robust import/export capabilities. Investments in the region’s highway system and the availability of affordable land have further enhanced its appeal. Local universities and community colleges are developing targeted programs to support the manufacturing industry, helping ensure a competitive local workforce.

Arizona’s low corporate taxes, streamlined permitting processes, and development incentives continue to attract a wide range of manufacturers. One of the most high-profile examples is construction of large- scale semi-conductor manufacturing plants in north Phoenix and Chandler by two major semi-conductor manufacturers. The facilities which are both operational and still under expansion puts Arizona on track to become one of the most advanced chipmaking locations in the world.

The Phoenix area has also drawn multiple electric vehicle (EV) manufacturers, aligning with broader trends in advanced manufacturing as well as large scale data centers that support recent artificial intelligent and cloud computing trends. Another area of growth has been large distribution centers that supply a myriad of products to local and regional consumers.

As all this large-scale industrial construction ramps up, meeting the precise specifications required by advanced manufacturing facilities becomes increasingly important. PNL provides critical construction inspection services for these types of facilities. In addition, one often overlooked but critical aspect is floor flatness testing. For facilities housing semiconductor, EV production lines, data and distribution centers, the performance of sensitive equipment and racking systems depends on stable, level surfaces. Proper floor flatness ensures the durability and accuracy of machinery operation, reduces installation delays, and supports long-term operational efficiency—making it a key component in delivering high-performance manufacturing environments. The remainder of this newsletter is focused on PNL’s technology and expertise in measuring floor flatness of concrete slabs for conformance to specifications.

In modern construction and quality control, ensuring the flatness and levelness of concrete floors is crucial, especially in environments like warehouses, data centers, and industrial plants where the performance of equipment and safety depend on precision. One standardized method for evaluating floor flatness (FF) and floor levelness (FL) is ASTM E1155. Advanced technologies like the Trimble TX6 3D laser scanner paired with Trimble RealWorks software are revolutionizing how this assessment is conducted.

ASTM E1155 – Standard Test Method for Determining FF Floor Flatness and FL Floor Levelness Numbers is a widely accepted protocol used in construction to quantify the flatness and levelness of a concrete surface. The test yields two numerical values:  

• FF (Floor Flatness): Measures short-distance waviness in the slab (local bumps or dips).
• FL (Floor Levelness): Evaluates how consistently the floor follows a specified slope or elevation over longer distances.

These values help determine whether a floor meets design and functional requirements, particularly in areas requiring strict tolerances, like those using forklifts, automated racking systems, or cleanroom equipment.

The Trimble TX6 is a high-speed, high-accuracy 3D laser scanner designed for detailed as-built capture of indoor and outdoor environments. It emits laser pulses and collects millions of points per second, generating dense 3D point clouds representing the scanned surface. This technology provides a non-invasive and highly accurate method to analyze surface profiles compared to traditional manual FF/FL testing methods.

Combining the Trimble TX6 3D laser scanner with Trimble RealWorks software offers a state-of-the-art solution for performing ASTM E1155 floor flatness and levelness assessments. This workflow enhances the precision, efficiency, and documentation capabilities compared to traditional methods, enabling project teams to deliver higher-quality flooring systems, reduce rework, and improve client satisfaction.

As the construction industry continues to embrace digital workflows, solutions like the TX6 and RealWorks exemplify how technology is transforming quality control into a fast, data-rich, and actionable process.

In this episode of Tech Talk, PNL Project Manager Zander Zuran sits down with technician Weston Ames to discuss our approach to floor flatness and levelness (FF/FL) testing. They’ll walk through the advanced equipment we use and explain why FF/FL testing plays a critical role in high-performance construction environments. You'll also get a behind-the-scenes look at a time-lapsed video of FF testing in action, showcasing the technology and precision that go into every scan. Whether you're new to FF/FL or looking to understand how we ensure top-tier floor quality, this is a great inside look at the process.

In warehouses, distribution centers, and industrial storage facilities the use of shelving systems, especially tall or high load racking, play a vital role in operations. However, improperly installed systems can pose serious risks to personnel, equipment, and inventory. Shelving collapses have resulted in serious injuries and fatalities across various industries. In multiple documented incidents, investigators identified unanchored racking, poor floor conditions, and improper bracing as contributing factors.

When it comes to warehouse safety and efficiency, the floor is the foundation of operations, and the flatness and smoothness of the floor are critical factors that impact the quality and longevity of the flooring system. 

Concrete anchoring systems are employed to prevent shelving units from tipping, shifting, or collapsing under dynamic loads such as forklift impact or uneven weight distribution and load shifts. OSHA and other safety standards require shelving over a certain height or load capacity to be securely anchored to the floor. Even in seismic zones or areas with heavy equipment traffic, anchoring is often the first—and most important—line of defense.

But no matter how strong the anchors are, their performance depends heavily on the quality of the surface they're attached to. That’s where floor flatness (FF) and floor levelness (FL) come in.

A flat, level floor ensures:

• Full contact between shelving baseplates and the floor for proper anchor engagement
• Accurate plumb alignment of vertical uprights to prevent leaning or instability
• Uniform load distribution, reducing stress points that can lead to structural failure
• Ease of installation, requiring fewer shims and adjustments
• Increased productivity by minimizing delays due to handling equipment downtime from wear caused by uneven floors or lost time from maneuvering around obstacles

If a floor is uneven or slopes beyond acceptable tolerances, anchors may not set correctly, baseplates may rock, stability of shelving units may be adversely affected, and the stability and smooth operation of material handling equipment such as forklifts, pallet jacks, and automated guided vehicles can be disrupted. This creates both a safety hazard and long-term maintenance and downtime problems.

In the high efficiency environments of distribution warehouses, floor flatness and levelness are the foundation of quality assurance. Before installing shelving or racking systems, it's good practice to conduct an ASTM E1155 FF/FL assessment, particularly in critical areas. At Phoenix National Labs, we use the Trimble TX6 3D laser scanner and Trimble RealWorks software to capture precise floor profiles and identify problem areas before installation begins. In addition to floor flatness and levelness testing, PNL also provides anchor installation special inspections to ensure shelving systems are securely and properly fastened. This added layer of quality control helps verify compliance with design specifications, improves long-term stability, and supports a safer work environment.