Location: Kandy Industrial Area, Sri Lanka
Client: Private Manufacturing Plant
Project Type: Concrete Polishing & Groove Cutting for Industrial Floors
Services Provided: Concrete Polishing, Floor Groove Cutting, Surface Preparation, Chemical Hardening

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Project Background

The client, a leading manufacturing company in Kandy Industrial Area, required a high-performance flooring solution for their factory premises. The plant’s operations involved heavy machinery, high-speed production lines, forklifts, and constant foot traffic, which demanded durable, smooth, and safe floors.

The key objectives were:

• Smooth and level surfaces for machinery installation and safe movement of forklifts
• Controlled expansion joints to prevent random cracking of concrete
• Dust-free and low-maintenance floors for operational efficiency
• Durability and resistance to wear, chemical spills, and mechanical stress

Thewnadee Engineering (Pvt) Ltd was commissioned to deliver a complete solution, including precision groove cutting and polished concrete flooring, ensuring structural integrity and long-term performance.

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Challenges Faced

During the preliminary assessment, several challenges were identified:

1. Random Cracking in Existing Slab
   • The concrete slab had minor cracks and weak joints, which could expand under machinery loads.
2. Uneven Surfaces
   • Parts of the slab were uneven due to initial pour inconsistencies, affecting machine leveling and forklift movement.
3. High Operational Load
   • The manufacturing facility operated 24/7, with heavy machinery that exerted high point loads on the floor.
4. Safety Concerns
   • Dust accumulation and uneven surfaces posed slip hazards for workers and potential damage to equipment.
5. Tight Timeline
   • The client required minimal downtime to avoid disruption to production schedules, necessitating efficient workflow and precise execution.

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Engineering Solution

To overcome these challenges, Thewnadee Engineering implemented a comprehensive workflow combining concrete polishing, groove cutting, and chemical hardening:

Step 1: Surface Assessment and Preparation

• The existing slab was thoroughly inspected for cracks, voids, and high spots.
• Minor repairs were conducted using high-strength patching compounds.
• The slab was cleaned and mechanically profiled to ensure proper adhesion and smoothness.

Step 2: Groove Cutting for Expansion Joints

• Controlled floor grooves were cut using high-precision diamond saws to accommodate expansion and contraction.
• Groove cutting prevented random cracking and directed stress along predefined lines, enhancing floor longevity.
• The groove layout was planned to support heavy machinery placement and optimize structural performance.

Step 3: Concrete Polishing

• Multi-stage grinding was carried out using industrial diamond abrasives.
• Initial grinding removed surface imperfections and leveled the slab.
• Successive polishing stages exposed aggregates, resulting in a smooth, reflective, and durable surface.
• Polishing improved floor density and wear resistance, reducing dusting and maintenance.

Step 4: Chemical Hardening

• A concrete densifier was applied to the polished surface to increase surface hardness, reduce dusting, and enhance durability.
• This step also prepared the floor for high-load and high-traffic operations without surface deterioration.

Step 5: Safety and Finishing Measures

• Anti-slip treatments were applied in forklift pathways and worker zones.
• Quality inspections ensured flatness, polish consistency, and joint alignment.

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Materials and Techniques Used

• Diamond Blade Saws: For precision groove cutting
• Industrial Diamond Abrasives: Multi-stage grinding and polishing
• Concrete Densifiers: Chemical hardening compounds for durability and dust control
• Anti-Slip Coatings: Applied in high-traffic zones
• Surface Profiling Tools: Mechanical grinders for substrate preparation

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Project Outcome

The project was completed successfully, delivering high-performance polished concrete floors suitable for heavy-duty manufacturing operations.

Key Achievements:

1. Controlled Cracking and Structural Integrity
   • Groove cutting prevented random cracking and improved structural longevity.
   • Expansion joints allowed safe movement of machinery without compromising floor integrity.
2. Smooth and Level Surface
   • Polished concrete provided a level, dust-free surface ideal for heavy machinery and forklifts.
   • Reduced vibration and wear on machines, improving production efficiency.
3. Durable and Low Maintenance
   • The combination of polishing and chemical hardening increased surface hardness.
   • Dusting and surface deterioration were minimized, reducing cleaning and maintenance costs.
4. Safety Enhancement
   • Anti-slip coatings in critical areas improved worker safety.
   • The reflective, polished surface enhanced visibility, reducing accidents.
5. Aesthetic and Professional Finish
   • Even in a purely industrial setting, the polished floor improved facility appearance and professionalism.
   • Client noted satisfaction with the consistent polish, smooth finish, and clean look.

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Client Feedback

The client praised the project for:

• The precision of groove cutting and joint alignment
• Smooth, reflective, and dust-free floors suitable for operational demands
• Durability and load-bearing performance for heavy machinery
• Professionalism and efficiency of Thewnadee Engineering’s team
• Timely completion without disrupting production schedules

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Conclusion

This manufacturing facility project highlights the importance of combining concrete polishing and groove cutting for industrial floors. By implementing:

• Precision groove cutting for stress management and expansion
• Multi-stage concrete polishing for smoothness, strength, and dust control
• Chemical hardening to enhance durability and longevity

Thewnadee Engineering delivered a flooring solution that balances durability, safety, and operational efficiency, providing a reliable foundation for industrial operations.

Professional concrete finishing and groove cutting are essential for industrial facilities, ensuring floors can withstand high loads, chemical exposure, and heavy traffic, while maintaining a dust-free, low-maintenance, and aesthetically clean environment.