Warehouse Floor Repair and Polish
In a busy warehouse setting, floor maintenance is critical. As a facility ages, control joints begin to fail and crack. Failing joints contribute to forklift tire wear, pallet jack hang-ups, and load instability. As the joints degrade, the concrete edges begin to spall. This breakage spreads quickly with every passing forklift, rapidly turning a small chip into a crumbling trench. This deterioration can lead to trip-and-fall hazards. Left unchecked, the condition can result in structural instability and OSHA compliance issues.
Polishing a warehouse floor offers several benefits that immediately upgrade your facility. The process seals the slab to completely eliminate concrete dust, keeping both your inventory and your workforce cleaner. A smoother surface drastically reduces wear on forklift tires, while the enhanced reflectivity boosts lighting efficiency. These floors deliver excellent slip resistance for foot traffic and vehicle stopping power, easily meeting or exceeding OSHA safety standards. Beyond simple dust mopping and occasional wet scrubbing, a polished and densified floor is highly stain-resistant and incredibly easy to maintain.
Our client operates a 300,000-square-foot warehouse facility that suffered from failing control joints, moderate-sized chipping, spalling, and cracking. The floor's finish was dull, dark, and difficult to maintain. They brought in the contractor, IA Solutions, and supplier, TSS Supply, to fix the problem correctly and permanently.
The plan set forth by the contractor involved dividing the warehouse into sections to be completed in stages, ensuring that the productivity of daily operations was not significantly impacted. The process began with several deep-cleaning passes using a riding floor scrubber.
All joints were ground out and filled with the industrial joint filler, HTS PE-85. PE-85 is a Polyurea Elastomer joint and crack filler engineered for industrial environments where it must support the weight of heavy forklifts. Filling the control joints with PE-85 prevents the edges from chipping under heavy traffic, protecting the floor from long-term structural damage.
Any larger voids, breaks, and chips were filled with HTS TX-3, a rapid-setting, high-strength urethane repair material. TX-3 holds up perfectly to heavy forklift traffic and was tinted Grizzle Gray to blend seamlessly into the existing floor.
Once all repair work was completed, the honing and polishing process began using propane concrete grinders and Polishing Pucks. The polishing process required five passes using 50-, 100-, 200-, 400-, and 800-grit resin polishing pucks.
After the second pass with the 100-grit pucks, the concrete was treated with Ameripolish 3D HS. This product hardens, or densifies, the slab—significantly improving abrasion resistance against heavy warehouse traffic. It enhances the clarity and gloss of the concrete to deliver a high-performance finish. It also limits concrete dusting, resulting in improved air quality and reduced ongoing maintenance.
To bring the concrete to a brilliant, high-gloss finish, a final pass was made using a propane burnisher equipped with a 3000-grit Twister Pad. Twister Pads feature microscopic diamonds embedded into a PET Pad, which pulls out a long-lasting, high-luster shine.
During the burnishing phase, Ameripolish’s 3D SPE was applied using Pump Up Sprayers. 3D SPE is a sealer that protects surfaces against oil- or water-based staining, acidic etching, and UV fading.
The result is a beautiful floor that is skid- and slip-resistant, protected from damage and wear, highly reflective for improved visibility, and sealed to dramatically reduce maintenance.
Achieve this level of durability and shine on your next project. Contractors can rely on TSS Supply for all the top-tier materials, tools, and equipment needed to get the job done right. For facility and building managers, IA Solutions is the premier flooring contractor that will execute the work flawlessly—delivering professional results on time and on budget.
