The existing concrete floor across this 46,000 sft production area had developed extensive surface delamination and cracking from years of trolley and forklift traffic, with several low spots holding water after washdown. The client needed a seamless, durable floor that could handle continuous wheeled traffic — without shutting the factory down for an extended period.
Our engineers surveyed the slab section by section, mapping delaminated areas, cracks, and level deviations before specifying the repair scope. Deteriorated concrete was cut back to sound substrate and rebuilt with a polymer-modified repair mortar, and construction joints were treated to prevent reflective cracking through the new floor.
A self-levelling epoxy screed system was applied in sequenced sections, coordinated with the client's production schedule so only one zone was out of service at a time. The finished floor is seamless, chemical-resistant, and rated for continuous forklift and trolley traffic, with a satin finish for easier housekeeping across the production floor.
The project was completed in phases over several weeks with zero unplanned production downtime, and the floor has been in continuous industrial service since handover.
