The Problem
A leading third-party logistics operator was commissioning a new 45,000 sqm distribution hub in Noida and needed industrial flooring suitable for sustained heavy forklift traffic, pallet drop loads, and chemical exposure from typical warehouse operations.
The base slab was newly laid by the general contractor and presented several surface preparation challenges including laitance, surface moisture, and minor cracking.
How We Approached It
We specified a four-coat epoxy system with anti-skid broadcast between primer and base coats. Surface preparation included mechanical grinding to remove laitance, moisture mitigation with a two-component epoxy primer, and crack injection on identified surface cracks prior to coating.
Installation was phased by zone to allow simultaneous racking installation in completed zones. A dedicated QA team performed pull-off adhesion testing on representative zones every 500 sqm.
Specification
- Substrate preparation: Mechanical diamond grinding to CSP-3 profile
- Moisture barrier: Two-component epoxy moisture-tolerant primer at 200 microns
- Base coat: High-build epoxy resin at 1.5mm thickness
- Anti-skid broadcast: 30–60 mesh silica sand, excess removed before top coat
- Top coat: Pigmented aliphatic polyurethane UV-stable topcoat at 200 microns
- Joint detailing: Polyurethane joint sealant at all perimeter and movement joints
The Result
The flooring was completed within the tight 11-week commissioning window. Post-completion inspection at 6 months shows negligible wear under continuous heavy forklift traffic, and the anti-skid surface has held up to all expected operational conditions.
The client has subsequently engaged us on two additional facilities under construction in 2026.
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