Warehouse Epoxy Floor
42,000 sq ft — South Atlanta

High-traffic industrial floor with a hard shutdown deadline.

A regional third-party logistics operator needed its South Atlanta distribution center floor restored before a peak receiving cycle. The 42,000 sq ft slab had absorbed years of forklift traffic: oil staining in dock bay approaches, hairline cracks at racking anchor points, and surface profile too smooth for standard epoxy adhesion. The window was fixed: 9 days of facility downtime, no extensions. The operator had a contractual obligation to be operational by day 10. Failure to deliver meant renting a satellite location — and billing us for the difference.

Shot-blast prep, 100% solids epoxy, urethane topcoat.

We mobilized a two-shift crew starting day one. Full-slab shot-blast using a Blastrac 2-10DPS to achieve CSP 3–4 profile across the entire 42,000 sq ft — critical for adhesion under rolling load. Oil contamination zones got two passes plus a degreasing etch. Hairline cracks were routed, filled with semi-rigid epoxy compound, and allowed to cure overnight before the base coat went down.

System: 100% solids epoxy base coat (15 mil DFT), broadcast anti-slip aggregate in dock lanes, polyaspartic urethane topcoat for UV stability and chemical resistance. Drive aisle delineation — yellow stripes and dock door approach marking — applied in the topcoat phase per the operator's rack layout drawing.

We split the floor into four zones and ran each zone sequentially with a 12-hour cure window between base and top coats. Day 6: all four zones coated. Day 7: topcoat complete, surface walk-tested. Two days early.

Opened to forklift traffic in 7 days. 5-year warranty.

The operator took possession on day 8 — one day before the deadline. Dock supervisors noted the improved traction in wet conditions (anti-slip aggregate broadcast per dock lane) and cleaner floor marking visibility for inbound drivers. FloorForge issued a 5-year warranty covering adhesion and wear layer integrity under continuous forklift and pallet jack traffic. Documentation package delivered at close: surface prep report, mil thickness readings per zone, system spec sheet, and warranty certificate.