The Problem

The primary warehouse of a Michigan Power Plant faced a significant challenge due to years of heavy use. The concrete floor had been subjected to constant forklift traffic, exposure to water, cleaning chemicals, and salts, leading to severe damage. In need of a long-term solution, the plant required a repair process that could be completed over a weekend during a unit outage for this industrial floor restoration. This approach was essential to minimize inconvenience and downtime, as well as to avoid the high costs associated with a complete floor replacement.

The Substrate

The damaged floor in question was made of concrete, a durable material typically used in industrial settings for its strength and longevity. However, even concrete can succumb to wear and tear under constant heavy use and exposure to harsh substances.

The Solution

The USI Team developed a comprehensive plan for this industrial floor restoration using a combination of specialized products to repair, protect, and upgrade the damaged floor:

• Surface Preparation: Following the products’ Technical Data Sheets, the floor was thoroughly prepared for the repair process.
• Deep Damage Repair: For areas with concrete damage ranging from 3 to 6 inches deep, USI Epoxy Mortar Concrete Patch was used. This product is designed for repairing significant damage and ensuring a stable and durable base.
• Priming: Next, the USI Flexible Broadcast Primer was applied. This primer is crucial for ensuring optimal adhesion of subsequent layers and enhancing the overall durability of the repair.
• Protective Coating: The team then applied USI HB Epoxy Color Coat, a high-build epoxy coating known for its excellent abrasion, impact, and chemical resistance. This layer not only restored the floor’s appearance but also provided a robust protective barrier.
• Safety Enhancement: Lastly, XD Grip was applied to the floor. This addition was crucial for improving safety by increasing the floor’s traction, thereby reducing the risk of slips and falls in the workplace.

Products Used:

• USI Epoxy Mortar Concrete Patch: For repairing deep concrete damage.
• USI Flexible Broadcast Primer: To prepare and prime the concrete surface.
• USI HB Epoxy Color Coat: A high-build epoxy coating for durability and resistance.
• XD Grip: Applied for enhanced safety and traction.