Location: Colombo Industrial Zone, Sri Lanka
Client: Private Industrial Warehouse Facility
Project Type: Heavy-Duty Industrial Flooring
Services Provided: Power Troweling, Epoxy Coating, Floor Preparation, Chemical Hardening
Project Background
The client, a leading logistics and warehousing company in Colombo Industrial Zone, required a durable, high-performance flooring solution capable of supporting heavy machinery, forklifts, and pallet movement. The warehouse handles daily loading and unloading operations, with frequent use of forklifts, pallet jacks, and storage racks.
The existing concrete surface in the facility was uneven, dusty, and prone to wear, which affected operational efficiency and posed safety hazards. The client sought a solution that would provide:
- Long-lasting durability under heavy loads
- Smooth, flat, and dust-free surface
- Chemical and moisture resistance for maintenance and cleaning
- Low maintenance and cost-effective flooring
Thewnadee Engineering (Pvt) Ltd was contracted to deliver a complete industrial flooring solution, including professional power troweling and high-performance epoxy coating.
Challenges Faced
During the preliminary site inspection, several challenges were identified:
- Uneven Substrate
- The existing concrete slab had irregular surfaces, minor cracks, and settlement areas, which could compromise floor performance if not corrected.
- High Operational Load
- The warehouse operates with forklifts carrying up to 3 tons per trip, requiring a flooring system capable of withstanding high point loads without cracking or deformation.
- Moisture and Dusting Issues
- The concrete surface was prone to dusting, and high humidity in the Colombo Industrial Zone presented a risk of moisture penetration, which could affect epoxy adhesion.
- Time-Sensitive Installation
- The client required minimal disruption to ongoing operations, meaning the flooring work needed to be efficient and timely without compromising quality.
- Safety Considerations
- Ensuring a non-slip, safe surface for workers and forklifts was crucial.
Engineering Solution
To address these challenges, Thewnadee Engineering implemented a structured, multi-step flooring solution:
Step 1: Surface Preparation
- The floor was cleaned of dust, grease, and debris using industrial sweepers and pressure washers.
- Minor cracks and surface imperfections were repaired with concrete patching compounds.
- The substrate was mechanically profiled to improve epoxy adhesion and reduce the risk of delamination.
Step 2: Power Troweling
- A walk-behind and ride-on power trowel system was employed to smooth and compact the concrete slab.
- Multiple passes were carried out to achieve level surfaces and a high-density finish, ensuring that air pockets and voids were removed.
- Power troweling also enhanced the compressive strength of the floor, making it more suitable for heavy-duty industrial operations.
Step 3: Chemical Hardening
- A concrete densifier was applied to further increase surface hardness, reduce dusting, and improve durability.
- This step prepared the floor for the epoxy coating, ensuring a strong bond and long-lasting performance.
Step 4: Epoxy Coating Application
- A solvent-free, industrial-grade epoxy system was applied over the prepared floor.
- The epoxy provided:
- High chemical and abrasion resistance
- Seamless, dust-free surface
- Ease of cleaning and maintenance
- Multiple layers were applied to achieve uniform thickness and durability, with anti-slip additives incorporated in high-traffic areas.
Step 5: Curing and Quality Control
- The epoxy coating was allowed to cure for 48–72 hours, ensuring full adhesion and optimal hardness.
- Quality inspections were conducted to ensure flatness, smoothness, and coating integrity.
- Minor imperfections were corrected immediately to guarantee a professional-grade finish.
Materials and Techniques Used
- Power Troweling Equipment: Ride-on and walk-behind trowels with steel and float blades
- Concrete Densifier: Chemical hardening compound for surface densification
- Epoxy Coating: Solvent-free industrial epoxy with chemical and abrasion resistance
- Anti-Slip Additives: Incorporated in loading/unloading zones for enhanced safety
- Surface Profiling Tools: Mechanical grinders to prepare substrate for optimal epoxy adhesion
Project Outcome
The project was completed successfully within the scheduled timeframe, delivering a high-performance flooring solution that met all client requirements.
Key Achievements:
- Smooth, Level Surface
- The power-troweled concrete provided a flat, uniform base for warehouse operations, reducing wear on forklifts and pallet jacks.
- Dust-Free and Low Maintenance
- Chemical hardening and epoxy coating eliminated dusting, ensuring a clean and hygienic floor.
- Durability Under Heavy Loads
- The combination of troweling, densification, and epoxy coating allowed the floor to withstand heavy point loads without cracking or deformation.
- Chemical and Moisture Resistance
- Epoxy coating protected the surface from oil, lubricants, and cleaning chemicals, while reducing moisture penetration risks.
- Safety and Operational Efficiency
- Anti-slip epoxy zones improved worker safety, while smooth, uniform floors enhanced operational efficiency for forklifts and storage operations.
- Professional Finish and Aesthetic Appeal
- High-gloss epoxy finish enhanced the professional look of the warehouse, complementing the client’s operational environment.
Client Feedback
The client expressed high satisfaction with the project, highlighting:
- The durability and strength of the new flooring
- The smooth and dust-free surface that improved warehouse operations
- The professionalism and efficiency of Thewnadee Engineering team
- Overall cost-effectiveness, reducing maintenance and repair expenses
Conclusion
This industrial warehouse project demonstrates the importance of professional engineering and advanced flooring techniques in achieving long-lasting, high-performance industrial floors. By combining:
- Power troweling for surface smoothness and density
- Chemical hardening for dust prevention and strength
- Industrial-grade epoxy coating for chemical and abrasion resistance
Thewnadee Engineering delivered a solution that exceeds client expectations and ensures operational efficiency, safety, and durability for years to come.
Investing in professional flooring solutions is not only about aesthetics—it is a strategic decision to protect assets, ensure safety, and optimize industrial operations.
