Location: Katubedda, Sri Lanka
Client: Private Industrial Warehouse Operator
Project Type: Industrial Flooring – Epoxy Coating & Floor Groove Cutting
Services Provided: Epoxy Flooring, Floor Groove Cutting, Surface Preparation, Chemical Hardening
Project Background
The client, a large industrial warehouse operator in Katubedda, commissioned Thewnadee Engineering (Pvt) Ltd to install durable epoxy flooring combined with floor groove cutting for their warehouse facility. The warehouse required high-performance flooring to withstand heavy machinery, forklifts, storage racks, and chemical exposure.
The primary objectives were:
- Durable, seamless, and chemical-resistant flooring for warehouse operations
- Floor groove cutting to control expansion, prevent random cracking, and improve structural integrity
- Smooth, level surface suitable for forklifts and heavy storage racks
- Long-term durability and minimal maintenance
- Enhanced safety through anti-slip zones and controlled traffic areas
This project required a comprehensive industrial flooring solution, combining epoxy coating and precision groove cutting to optimize performance and longevity.
Challenges Faced
Several challenges were identified during site inspection:
- High Load-Bearing Requirements
- Floors needed to support heavy forklifts, pallet jacks, and stacked goods, requiring high compressive strength and abrasion resistance.
- Cracking and Expansion Control
- The large warehouse slab required controlled groove cutting to manage expansion and prevent random cracking over time.
- Chemical Exposure
- Frequent use of cleaning agents, lubricants, and spills necessitated chemical-resistant epoxy surfaces.
- Operational Continuity
- The warehouse had a tight schedule for operations, requiring efficient flooring installation without major downtime.
- Safety Considerations
- Anti-slip surfaces were required in loading/unloading zones and pedestrian pathways to ensure safety.
Engineering Solution
Thewnadee Engineering implemented a precision epoxy flooring and groove cutting workflow to meet warehouse operational requirements:
Step 1: Surface Preparation
- The concrete substrate was cleaned thoroughly to remove dust, debris, and contaminants.
- Cracks, voids, and uneven surfaces were repaired using high-strength patching compounds.
- Mechanical profiling ensured optimal adhesion for epoxy coating and accurate groove cutting.
Step 2: Floor Groove Cutting
- Controlled floor grooves were cut using diamond-tipped saws, creating predefined expansion joints to prevent random cracking.
- Groove layout was planned to support heavy machinery routes, storage rack areas, and high-traffic zones.
- Groove cutting improved structural performance and long-term durability of the warehouse floor.
Step 3: Epoxy Coating Application
- Industrial-grade, solvent-free epoxy coating was applied over the grooved and prepared substrate.
- The epoxy system provided:
- High abrasion resistance for heavy machinery and foot traffic
- Chemical resistance for spills and cleaning agents
- Seamless, dust-free surface for operational efficiency
- Multiple coats ensured uniform coverage and long-term performance.
Step 4: Chemical Hardening & Anti-Slip Measures
- A chemical hardening treatment was applied to increase surface density and durability.
- Anti-slip additives were incorporated in loading docks, walkways, and ramp areas to ensure worker safety.
Step 5: Curing & Quality Control
- Epoxy floors were cured under controlled conditions to maximize adhesion and longevity.
- Quality inspections verified levelness, adhesion, chemical resistance, and groove alignment.
Materials and Techniques Used
- Epoxy Coating: Industrial-grade, solvent-free, chemical and abrasion resistant
- Floor Groove Cutting Tools: Diamond-tipped saws for precise expansion joints
- Chemical Hardeners: To improve surface strength and reduce dusting
- Anti-Slip Additives: Applied selectively for safety
- Surface Profiling Equipment: Mechanical grinders for substrate preparation
- High-Strength Patching Compounds: For repair of cracks and uneven surfaces
Project Outcome
The project was completed successfully, delivering high-performance flooring suitable for heavy industrial use.
Key Achievements:
- Durable and Long-Lasting Floors
- Epoxy-coated floors withstand heavy forklifts, stacked goods, and constant traffic without damage.
- Controlled Cracking & Structural Integrity
- Precision groove cutting prevented random cracking and enhanced the structural performance of the warehouse slab.
- Chemical Resistance
- Floors resist cleaning agents, oils, and operational spills, reducing maintenance and repair needs.
- Smooth and Operational Surface
- Seamless epoxy coating provided a dust-free, smooth surface for forklifts, trolleys, and personnel movement.
- Safety Enhancement
- Anti-slip treatments in loading, unloading, and pedestrian zones improved overall workplace safety.
- Timely Completion
- Project was completed within the operational schedule, allowing the warehouse to commence operations without delay.
Client Feedback
The client expressed high satisfaction, noting:
- The durability and performance of the epoxy floors
- Controlled expansion and minimal cracking due to groove cutting
- Professionalism and efficiency of Thewnadee Engineering team
- Improved workflow, safety, and maintenance efficiency
- Confidence in long-term operational reliability
Conclusion
This industrial warehouse project highlights the importance of combining epoxy flooring with floor groove cutting to achieve high-performance, durable, and safe surfaces. By implementing:
- Surface preparation and crack repair for optimal substrate performance
- Precision floor groove cutting for controlled expansion and cracking prevention
- Industrial epoxy coating for durability, chemical resistance, and smoothness
- Chemical hardening and anti-slip treatments for safety and longevity
Thewnadee Engineering delivered a flooring solution that balances durability, safety, and operational efficiency, ensuring the warehouse can operate under heavy loads and chemical exposure for years.
Industrial epoxy floors with controlled groove cutting are essential for warehouses, factories, and industrial facilities, providing durable, low-maintenance, and safe operational surfaces.
