Location: Katunayake, Sri Lanka
Client: Private Cold Storage & Logistics Company
Project Type: Industrial Epoxy Flooring with Chemical Resistance
Services Provided: Epoxy Flooring, Surface Preparation, Chemical Hardening, Anti-Slip Treatment
Project Background
The client, a leading cold storage and logistics provider in Katunayake, commissioned Thewnadee Engineering (Pvt) Ltd to install durable epoxy flooring capable of withstanding the unique demands of cold storage environments.
Cold storage floors must endure heavy foot and equipment traffic, low temperatures, and potential chemical spills from cleaning agents and refrigerants. The primary objectives were:
- Durable, seamless flooring resistant to wear and heavy loads
- Chemical-resistant surfaces for cleaning agents and refrigerants
- Hygienic, dust-free, and easy-to-clean floors
- Anti-slip surfaces to ensure safety in cold and wet conditions
- Long-term performance with minimal maintenance
The project required a high-performance epoxy flooring system tailored for cold storage applications.
Challenges Faced
Several challenges were identified during the initial site inspection:
- Low Temperature Environment
- Cold storage floors experience extreme temperature fluctuations, requiring an epoxy system that maintains adhesion and durability in sub-zero conditions.
- Heavy Traffic
- Forklifts, pallet jacks, and trolleys impose high point loads on floors. Flooring needed high abrasion resistance and load-bearing capacity.
- Chemical Exposure
- Frequent cleaning and sanitizing with chemical agents required floors resistant to corrosion and surface damage.
- Safety Concerns
- Floors must remain non-slip even in cold and wet conditions to protect workers.
- Tight Timeline
- The facility was operational on a strict schedule, requiring efficient installation without disrupting cold storage operations.
Engineering Solution
Thewnadee Engineering implemented a custom epoxy flooring solution suitable for cold storage operations:
Step 1: Surface Preparation
- Concrete substrate was cleaned using industrial methods to remove dust, grease, and contaminants.
- Cracks and surface irregularities were repaired using high-strength patching compounds.
- Mechanical profiling ensured optimal adhesion of the epoxy system.
Step 2: Epoxy Flooring System
- A solvent-free, industrial-grade epoxy system was applied, designed for low-temperature environments.
- The epoxy provided:
- High abrasion resistance for heavy equipment and foot traffic
- Seamless and dust-free surfaces for hygiene and cleaning efficiency
- Chemical resistance to cleaning agents and refrigerants
Step 3: Anti-Slip Treatment
- Anti-slip additives were incorporated in walkways and high-traffic zones.
- The treatment ensured worker safety in cold and wet conditions, reducing the risk of slips and accidents.
Step 4: Chemical Hardening & Finishing
- A chemical hardening treatment was applied to enhance surface durability and reduce dusting.
- Multiple epoxy layers ensured uniform thickness and long-term performance.
Step 5: Curing & Quality Control
- Floors were cured under controlled conditions to ensure adhesion and durability.
- Quality checks included levelness, adhesion, chemical resistance, and surface smoothness.
Materials and Techniques Used
- Epoxy Flooring: Industrial-grade, solvent-free, low-temperature resistant
- Chemical Hardeners: For enhanced durability and surface strength
- Anti-Slip Additives: Applied in wet zones and walkways
- Surface Profiling Tools: Mechanical grinders to prepare concrete substrate
- High-Strength Patching Compounds: For crack repair and surface leveling
- Quality Control Tools: Adhesion testers, level meters, and chemical resistance testing
Project Outcome
The cold storage flooring project was completed successfully, delivering high-performance epoxy floors that met all operational and safety requirements.
Key Achievements:
- Durable and High-Performance Flooring
- Epoxy floors withstand heavy loads, foot traffic, and equipment movement, ensuring long-term functionality.
- Chemical Resistance
- Floors resist cleaning agents, refrigerants, and other chemicals, reducing surface degradation and maintenance needs.
- Seamless and Hygienic Surfaces
- Epoxy coating provides dust-free, easy-to-clean floors, essential for cold storage hygiene standards.
- Safety Enhancement
- Anti-slip zones in critical areas reduce the risk of slips and accidents, even under cold and wet conditions.
- Low Maintenance and Long-Term Efficiency
- Epoxy floors require minimal maintenance, providing cost-effective long-term performance.
- Timely Completion
- The project was completed on schedule, allowing the cold storage facility to operate without delays.
Client Feedback
The client expressed high satisfaction, highlighting:
- Durability and chemical resistance suitable for cold storage operations
- Smooth, hygienic, and dust-free floors for operational efficiency
- Professional execution and timely project completion
- Safety improvements through anti-slip treatments
- Overall confidence in long-term flooring performance
Conclusion
This cold storage facility project demonstrates the importance of specialized epoxy flooring in temperature-sensitive and chemical-exposed environments. By implementing:
- Surface preparation and repair for optimal adhesion
- Industrial-grade epoxy coating for durability and chemical resistance
- Anti-slip treatments for worker safety
- Chemical hardening and multi-layer finishing for long-term performance
Thewnadee Engineering delivered a flooring solution that balances durability, safety, hygiene, and operational efficiency, ensuring the facility operates reliably for years to come.
Industrial epoxy floors designed for cold storage environments are essential for safety, operational efficiency, and long-term cost-effectiveness.
