PROJECT: Warehouse Floor
SIZE: 1.6 million SF
STAKEHOLDER REALTY: 50 – year old facility’s concrete floors were never built for the load of modern forklifts in use today. Floors have been deteriorating for many years and were causing damage to forklift computer boards which were costly to fix. The only successful maintenance solution was to remove and replace. This proved to be very costly and very disruptive to a facility that was bulging at the seams with inventory. There were very limited options to move goods to another location while the remove and replace work was happening. Daily operations had to be maintained in all non-working areas making it challenging for safe egress and ingress for personnel, equipment and materials. To say the least, this was a very challenging environment for any maintenance solution.
SOLUTION: NEXT-GEN SURFACING SOLUTION’S Concrete Resurfacer was placed in multiple layers. The work started in January 2014 with outdoor temperatures typically in the 20’s to 30’s. An admixture was added to accelerate the cure and prevent shrinkage in a quick turnaround environment. As always, prior to application of the resurfacer material, all areas were properly prepared; shot blasted, grinded, chipped out and leveled. The project was contracted with a 5 year warranty on materials and labor.
RESULTS: The floor restoration project was completed with no business interruption and the facility remained in full operational mode. Even though the floor was turned over many times after only 12 hours of cure time, only minor flaws were caused by the 6000 lb. forklifts. Facility management was very happy with the results and the significant cost savings over their traditional remove and replace