Floor Repair and Epoxy Coating for Manufacturing Plant

in Indiana

Services Performed

Commercial Flooring, Concrete Floor Repair and Resurfacing, Epoxy Flooring, Industrial Flooring

Location

Indiana

Wide, mostly empty warehouse interior with smooth gray concrete floors, overhead lighting, red support columns, and yellow safety railings in the foreground.

Client and Facility Overview

This project was for a large manufacturing plant in Indiana. The facility includes extensive office space and a large production floor that reflects the scale of its operations. Known for its substantial production capacity, the plant is a key player in the local industry.

Requested Maintenance

The client required a complete floor repair and application of a durable epoxy coating in their main manufacturing, shipping and receiving areas. The goal was to revitalize the heavily trafficked floor and ensure it could withstand future demands.

Decision Driver and Timing

The constant wear and tear typical of such a high-traffic environment were the driving factors behind this project. The client needed a flooring solution that would not only restore the integrity of the current floor, but also provide long-term durability to minimize future maintenance disruptions.

Scope of Work

Surface Preparation: Extensive prep work including removing floor bolts, repairing unusual cracks, filling holes, slurrying spalled areas and degreasing.
Diamond Grinding: Ensured the concrete surface was receptive to the new coating through thorough diamond grinding.
Epoxy Coating Application: Applied one coat of epoxy primer followed by two coats of 100% solid epoxy in safety orange.

Notable Details

The project was coordinated to minimize disruption to ongoing plant operations. By working systematically in phases, Painters USA ensured that a complete plant shutdown was not necessary.

The preparation phase was critical to the success of the project. This involved attention to every detail from bolt removal to degreasing to ensure the floor was in optimal condition for the epoxy coating. This attention to detail is similar to preparing a car's body before painting, and ensures a solid and durable end result.

The use of a highly durable 100% solid epoxy was essential to meet the client's need for a long-lasting floor. The safety orange color also improves visibility and contributes to a safer working environment.

Understanding that the client operates in a high-demand environment, Painters USA tailored the project timeline and execution strategy to fit seamlessly into the existing operational schedule, preventing any operational hiccups.

Client Satisfaction

Having addressed all structural and aesthetic requirements, Painters USA successfully delivered a revitalized and robust flooring solution. The client was very pleased with the outcome of the project, noting the professional execution and minimal disruption to their daily operations.