Replace Existing Concrete Surface with Industrial Epoxy Flooring Permanent Aisle Lines & Signage

Restoration of concrete flooring in a 35+ year old manufacturing plant. When Hyster/Yale forklift manufacturers told us they were upgrading there manufacturing plant and needed a new floor system for their new automated NexGen assembly line we tailored a hybrid 3 coat system to serve their specific application. Considering the amount and degree of decline in this facility, we decided that a standard "off the shelf" system was not going to serve this customer best. Our first order of business, as with every job we perform, was a close look at the existing floor and evaluation of surface preparation. Years of accumulation of old coatings, contamination, oxidized and worn concrete surface required a combination of diamond grinding and shot blasting as one method was inadequate for this order to even get to the concrete surface we started with aggressive diamond tooling on our grinding equipment to remove all the old coatings. Once all the coatings were removed we ultimately used a shot blasted profile as our working surface in which to apply the new floor system for greatest adhesion.

With surface preparation completed, we then routed all expansion joints and cracks and filled them with an epoxy filler designed to allow movement within the slabs but also capable of carrying heavy loads without breakdown at either slab shoulder. The next step was the application of an epoxy primer specifically designed to provide adhesion on oil contaminated concrete surfaces...with years of experience and successful projects under our belt with this particular product we were confident in our choice to cure the various areas of contamination which would ordinarily threaten disbondment otherwise. The next step was patching of heavily worn areas and in some cases where the concrete matrix was nonexistent even to the aggregate...this was accomplished by a slurry application of epoxy filler to bring these areas back to flush. An intermediate application of 100% solids epoxy was then applied as the working layer of this floor system.

In a movement to embrace the 5s philosophy of lean manufacturing practices, this facility requested aislelines and markings throughout the plant to distinguish between forklift traffic, pedestrian traffic and designated work areas and product/parts placement. So our next step was the installation of the various aisleway markings and stop signs. This was accomplished with the use of a moisture cured urethane system designed for excellent adhesion values, abrasion resistance and colorfast properties. Once all markings were completed we then applied a final clear application of Hi Solids 2 component aliphatic urethane with the addition of aluminum oxide to extend the surface wear of the system as well as provide a subtle degree of non skid properties. By "embedding" these lines into the floor system, periodic line stripping and maintenance is virtually eliminated.

Important to note that after installing numerous samples for this customer, their final choice was a "clear" epoxy system. The clear system is less telling of traffic patterns and wear that you would be experienced in a manufacturing setting such as this. The normal thought process tends to be "Solid Color" however since beginning this project in 2008 we can attest to the advantages of the clear system over the solid, opaque system as it does in fact show less wear and tear.

Industrial Epoxy Flooring, Permanent Aisle Lines & Signage
Industrial Epoxy Flooring, Permanent Aisle Lines & Signage

Replacing Existing Concrete Surface Highlights

Product Description
Installation of Clear Epoxy/Urethane flooring system.
This is an older manufacturing plant where Hyster and Yale forklifts are manufactured. After 35+ years of use, this plant decided to upgrade both their automated assembly line as well as the facility itself Since 2008 McCord Contractors has been onsite and involved in the process of refurbishing the floors throughout the 300000 + square foot facility one area at a time. As well as refurbishing the plant floors with a clear coating system they also desired to move their facility toward compliance with the 5S processes of lean manufacturing which meant "Safety" and designating the pedestrian areas from forklift areas. This was accomplished by embedding the aisle way lines, pedestrian crossings and STOP signs into the coating system thereby eliminating the need for periodic "line stripping" by plant personnel.
Capabilities Applied/Processes
Diamond Grinding and Steel Shot blasting
  • The first step was the removal of all existing coating that remained by means of both diamond grinding and steel shot blasting. Once the old coating was removed we chose steel shot blasting as our concrete preparation tool for 2 reasons…1) This will provide the best profile for the best adhesion for the new epoxy floor system…2) shot blasting would remove more of the old, oxidized and in many instances, oil contaminated concrete prior to the coating application.
  • Once all surface preparation was completed, we routed the existing expansion joints as well as dynamic, random cracking that had occurred and filled with semi-rigid epoxy filler. General Polymers product 3580. Additionally, we had areas of exposed aggregate and areas of severe spalling in which case we trowel applied a slurry mixture of 100% solids epoxy to bring theses surfaces up flush with the surrounding existing concrete floor.
Floor Coating Installation
  • Prime the prepared concrete with General Polymers product 3504 oil tolerant epoxy primer to prevent contamination from causing disbonding issues on the newly applied coating system.
  • Application of the intermediate coat of 100% solids epoxy Squeegie apply using notched squeegee and allow the slurry mixture to self level.
  • Apply the various pedestrian and forklift aisle lines as well as STOP signs, Pedestrian Crossings and foot prints using Corothane I single component moisture cured urethane from Sherwin Williams Industrial and Marine.
  • Finish with wearcourse of SIKA 315 high solids urethane with aluminum oxide added for wear and non slip.
  • Once flooring portion of the job is completed, we would fill the large crack between the floor and concrete wall transition with Polysulfide sealant in a 45 degree cant.
Equipment Used to Manufacture Part
Blastrac 1-10 D electric shot blasting machine.
HTC 800 HDX Planetary Diamond Grinder
SawTec JS 110 gas powered diamond saw with catalytic converter for scrubbing emissions.
Factory Cat walk behind floor scrubber.
Overall Laboratory Dimensions
Varies 2500 sq. feet to 20000 sq. feet
This clear floor system is very forgiving of wear patterns and general wear and tear that takes place in such a facility as opposed to an opaque, solid color floor which tends to be more telling of wear and tear.
Floor Material
Failed coating over concrete removed and underlying concrete prepared by steel shot blasting.
Flooring Finish
Very subtle nonskid finish using aluminum oxide
Turn Around Time
Work has been performed over numerous scenarios from working a more relaxed schedule, regular time during the week to 2nd and third shift work to around the clock crews in order to complete in a very compressed time frame.
Industry for Use
Manufacturing (Gas and Electric) Fork Trucks Facility
Installation Location
Greenville, North Carolina
Standards Met
Customer supplied specifications
Profile Name
Manufacturing/Industrial Epoxy Flooring System with permanent aisle lines and signage

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