Innovative Floor Refurbishment in a Utility Company Warehouse

Innovative Floor Refurbishment in a Utility Company Warehouse

The Problem

A utility company faced a significant challenge with the deteriorating condition of their main warehouse floor, which was nearing the end of its lifecycle, it was in need of  a warehouse floor refurbishment. The warehouse operates 24/7, making it impossible to shut down for extensive repairs or replacement. Aware that delaying the refurbishment could lead to the need for a complete floor demolition and replacement – a costly and disruptive process – the company sought a repair solution. Based on previous successful projects, Unconventional Solutions was chosen for their expertise and quality of service.

The Substrate

The warehouse floor was made of concrete, a durable material suited for heavy industrial use. However, even concrete can wear down over time, especially under constant use in a high-traffic warehouse.

The Solution

warehouse floor refurbishing process

Unconventional Solutions devised a strategic approach to refurbish the floor without requiring a complete shutdown of the warehouse operations:

  • Floor Preparation: A scarifier with a dust collector was used to prepare the floors. This equipment not only ensured efficient removal of the damaged surface layer but also maintained a clean working environment.
  • Patching and Crack Filling: The USI Epoxy Mortar Patch Kit was used to patch larger holes. A variant of the mixture with less aggregate was used to fill smaller cracks, ensuring a smooth and even surface.
  • Priming: The entire area was then primed with USI Flexible Broadcast Primer. This primer is designed to enhance the adhesion of the topcoat, a critical step for a lasting repair.
  • Applying Epoxy Floor Coating: Two coats of USI High Build Epoxy Floor Coating were applied. This high-performance coating provides durability and a fresh look to the old concrete floor.
  • Adding Slip Resistance: USI Granular Aggregate LD was backrolled into the top coat to provide slip resistance, enhancing the safety of the warehouse environment.
  • Staged Implementation: To minimize disruption to warehouse operations, the project was executed in stages over several weekends.

The warehouse floor refurbishment was a resounding success. The strategic approach allowed the warehouse to continue operating while the floor was progressively restored to a like-new condition. The client was particularly pleased with the improved lighting in the warehouse due to the light gray coloring of the new floor, which made the environment more LED-friendly. The project not only saved the company from the high costs and disruptions of floor replacement but also enhanced the overall safety and aesthetics of the warehouse.

refurbished floor

Products Used


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