85,000 Sq Ft Epoxy Floor
Weekend Install, Zero Downtime

Four active distribution zones. A USDA audit on the calendar. Two weekends to do the work.

A third-party logistics operator in Atlanta needed its 85,000 sq ft distribution floor system restored without interrupting fleet operations. The existing slab had been coated twice with standard epoxy and was failing in dock lane approaches — gouges, hot-tire tracking marks, and surface profile too smooth for adhesion. They had a USDA facility audit scheduled six weeks out and could not pass it on the existing surface.

The hard constraint: the facility runs inbound and outbound shifts Monday through Friday. The client could only afford two consecutive weekend windows for install. Anything beyond that meant rerouting trucks, hiring temporary swing space, or — worst case — losing an enterprise customer whose contract renewed in eight weeks.

Urethane mortar base. Food-grade polyaspartic topcoat. Four-zone phased weekends.

We broke the 85,000 sq ft slab into four zones (each approximately 21,000 sq ft) and phased the install across two consecutive weekends. Saturday morning mobilization, full coverage by Sunday afternoon — facility reopened to full forklift traffic at 6am Monday both weeks. Mechanical grind to CSP 3–4 profile was completed in each zone before any coating system was laid down. Oil-contamination zones got two passes plus a degreasing etch.

System: urethane mortar base coat (3/8" trowel-down at 1/4" finished thickness) for thermal-shock and impact resistance, food-grade polyaspartic topcoat for cleanability and chemical resistance. Anti-slip aggregate was broadcast into the wet base coat across all dock lane approaches. Drive aisle delineation — yellow stripes and dock door approach marking — was applied in the topcoat phase per the operator's rack layout. Mil-thickness logs were captured per zone, per coat (target 20 mils DFT minimum).

Cure schedule was tight: urethane mortar achieves 90% cure in 6 hours at 70°F; polyaspartic topcoat skins over in 2 hours and traffic-ready in 12. We ran the polyaspartic on Sunday morning so the floor was hand-traffic safe by Sunday evening and forklift-ready by Monday morning open. Two days early each weekend — comfortable finish.

Facility reopened Monday both weekends. USDA audit passed. No punch-list.

The facility opened to full forklift traffic Monday both weekends with zero production disruption. The 3PL operator reported zero product damage or delivery delays traced to floor condition through both weekends. Six weeks post-install, the USDA facility audit completed with no floor-related findings. The 5-year adhesion + wear layer warranty covers continuous forklift and pallet jack traffic through the warranty term.

Documentation package delivered at close: surface prep report with mil thickness readings per zone and per coat, system spec sheet, USDA audit reference, and warranty certificate. The 3PL has since flagged FloorForge as a preferred vendor on three subsequent facility upgrades across other metro Atlanta locations.