On April 27th, we participated in the "RZD Innovation Day" event held at the Lomonosov Innovation Cluster in Moscow. We showcased our "Betonium" technology – a solution for modernizing existing concrete surfaces without slab demolition, new floor installation, or operational downtime. RZD representatives learned about our technology and expressed interest in its application at their facilities. Following the meeting, we are already planning joint projects.
Floor as part of the infrastructure
The effect of coating on the object's performance
On large infrastructure facilities, the floor is subjected to high loads daily. Vehicles move across it, cargo is transported, employees and passengers walk on it, and cleaning machines, warehouse systems, and production equipment operate.
If the coating is dusty, has cracks, potholes, deteriorated seams, or unevenness, the property incurs permanent hidden costs.
Cleaning is becoming more difficult.
Equipment gets dirty and damaged.
Increased wear on wheels and equipment components
There is a need for regular local repairs
Simple non-usable areas
For companies the size of Russian Railways, such problems are particularly critical. The large area of facilities, constant load, high cost of downtime, and long service life of infrastructure require solutions that don't just eliminate defects but change the quality of the coating for years to come. More details about the "Betonium" technology at presentations.
Why is this relevant to Russian Railways?
Distributed infrastructure solution
For a system like Russian Railways, it's important that the technology is not a point-solution repair but a scalable modernization tool.
On warehouses and terminals, evenness, wear resistance, and stable equipment movement are important. In depots and production facilities, strength and repairability are key. At stations and passenger areas – durability, ease of cleaning, and the appearance of the flooring.
Modernization using our technology meets all these requirements. That is precisely why we consider "Betonium" to be a relevant solution not only for commercial warehouses and manufacturing facilities but also for large infrastructure organizations.
What is "Betonium"
Comprehensive modernization of existing pavement
"Betonium" is a deep processing technology for existing concrete floors. We do not cover the old base with a new layer, nor do we turn repairs into construction. We are working with an existing concrete foundation: repairing, leveling, strengthening, and polishing the surface without stopping operational processes.
As a result, the concrete becomes denser, stronger, smoother, and more resistant to loads.
Stop dusting
Easy to clean
More resistant to wear
Maintains operational characteristics for decades
Does not absorb moisture
Reflects light better
Visually enlarges the space
Proven technology
Experience in implementing and the economics of large-scale projects
During the event, questions about savings, return on investment, and operational cost reduction generated particular interest. This is natural for large organizations: not only the cost of performing the work is important, but also how the coating will perform over the following years.
The "Betonium" technology is already being used at major facilities of federal and international companies. Among tConcrete's partners and customers are X5 Retail Group, ETM, Lemana Pro, Samsung, LG Electronics, Elfplast, MixTrade, and other companies. The average payback period for projects ranged from 0.45 to 1 year.
At one of ETM's warehouse facilities, their specialists calculated the economic efficiency of a coating upgrade using the "Betonium" technology. The calculation model was prepared for a warehouse with an area of 20,000 m² after 5 years of operation.
With a project cost of 80 million ₽, the total economic effect over this period was approximately 1.108 billion ₽.
The main effect was formed by several factors:
Increase in warehouse turnover (~1.08 billion ₽)
Reduction of equipment repair costs by approximately (23.4 million ₽)
Reduction in cleaning expenses by approximately (~4.5 million ₽)
Reduction in the number of accidents caused by uneven floors (~99%)
This calculation shows that modernizing the concrete coating affects not only the condition of the floor but also the economics of the entire facility's operation: speed of operations, maintenance costs, equipment stability, and reduction of operational losses.
An additional factor is light reflection. After polishing, the surface acquires a mirror effect, which helps to fill the space with light at a lower energy cost. For large-area objects, this significantly increases lighting efficiency and reduces the load on lighting systems. In warehouses, terminals, depots, and station premises, where lighting operates for extended periods, this effect can become a noticeable part of operational savings.
Application in Russian Railways Infrastructure
Solution for JSC "Russian Railways" facilities
The RZD Innovation Day was aimed at finding universal infrastructure solutions.
The event brought together representatives of the logistics and transport infrastructure, functional branches of Russian Railways OJSC, and external companies.
We see broad potential for applying the technology at Russian Railways (OAO RZD) facilities. Primarily, these are areas where the concrete floor is constantly subjected to mechanical stress: locomotive and carriage depots, warehouses, freight terminals, sorting stations, container platforms, and technical and production facilities.
Durability, dustlessness, and surface smoothness are important for these types of facilities. The more stable the coating, the fewer local repairs, downtimes, and other operational costs arise during the facility's operation.
A separate area is stations and passenger infrastructure. For stations and public spaces, the covering must simultaneously solve several problems. It must withstand:
A constant flow of people
Regular cleaning
Equipment relocation
Long-term operation
At the same time, the appearance of the floor is also of great importance: passenger infrastructure is perceived not only as a technical object, but also as a public space. Here, the floor must be not only durable, but also visually aesthetic.
Polished concrete fully meets these requirements. At a high degree of polishing, concrete acquires a distinct sheen, up to a mirror effect. This allows "Betonium" to be used as a decorative and functional solution: the coating retains the strength and monolithic nature of concrete, while having a modern appearance.
Automation Readiness
Concrete floors as the foundation for technological development of infrastructure
Modern warehouse, production, and infrastructure facilities are gradually transitioning to automation. This applies to logistics, cargo handling, the operation of warehouse equipment, cleaning equipment, and automated systems.
For such equipment, surface quality is important. Unevenness, dust, and local defects hinder the equipment's movement, increase wear and tear on the machinery, and reduce process predictability, causing malfunctions.
Universal solution
Technology years ahead
At the "RZD Innovation Day," it was important for us to showcase not a narrowly focused floor repair technology, but our capabilities for large-scale infrastructure modernization.
"Betonium" can be used on various types of facilities where the coating is subjected to high daily loads: in warehouses, depots, terminals, technical rooms, production areas, stations, and passenger areas.
This technology combines operational reliability, cost-effective maintenance, and the ability to maintain a modern appearance. This is why we consider it a solution for organizations that prioritize not just repairing a floor, but increasing the economic efficiency and durability of their existing infrastructure.
Key takeaways
The relevance of "Betonium" technology for large infrastructure organizations:
"Betonium" allows for the modernization of an existing concrete foundation without demolition and without halting operations at the facility.
After processing, the coating menghasilkan less dust, is easier to clean, reflects light better, requires less frequent repairs, and reduces the load on equipment.
Concrete hardening and polishing make the surface more resistant to wear, mechanical stress, and prolonged intensive use.
The technology can be applied in technical and production areas, as well as in passenger spaces.
A flat, stable, and dust-free surface increases the predictability of equipment movement and creates more suitable conditions for process automation.
If you are looking for ways to reduce costs in the construction and operation of your facilities, contact the tConcrete team
We look forward to receiving your application. You can share your resume, portfolio and cover letter at hr@tconcrete.ru or send your project to hello@tconcrete.ru
