Case Study · Distribution Warehouse · Plano, TX
Assa Abloy Warehouse: Fixing Failed Line Striping, Damaged Concrete and a Battery Charging Room
Assa Abloy engaged Legacy to restore three areas of its distribution warehouse: a main racking aisle with failing line striping, a testing area with a delaminating concrete surface, and a forklift battery charging station that required protection from acid exposure.
“I was asked to secure bids for the refurbishment of a warehouse floor, and Legacy was ultimately awarded the project. From the outset, it was clear why Legacy is regarded as a leader in its field.
Evan, in particular, was extremely professional throughout the entire process. He handled delays and other challenges with patience, professionalism, and an unwavering commitment to the successful completion of the project. His responsiveness and focus on delivering excellent customer service were particularly impressive.
Legacy is an outstanding company with a clear commitment to quality, professionalism, and, most importantly, customer success. I would not hesitate to recommend Legacy to others.”
The Project
Project Overview
Assa Abloy operates a high-volume distribution warehouse with forklift and order-picker traffic running through narrow racking aisles on every shift. Legacy was brought in to address three areas of the floor, each with a different condition.
Main racking aisle: the existing line striping had been poorly applied. It was worn, patchy and delaminating unevenly, and the crosshatched walkways no longer read clearly. Rather than restripe, Assa Abloy chose to replace the aisle with a full coating system.
Testing area: the slab had been poorly placed, and the concrete cap was delaminating, leaving a rough, damaged surface.
Battery charging station: an approximately 450 SF area along the charger wall sat on bare concrete, with no protection from battery acid drips and spills.
Before
Existing Conditions
Failing line striping in the main aisle and an unprotected concrete slab at the battery charging station.
Preparation
Surface Preparation
Step one was removal of all existing line striping. Coating over old striping allows the lines to telegraph through the new floor and bonds the system to paint rather than concrete. The aisle was diamond ground until all striping was removed and the slab was clean and profiled.
In the testing area, the delaminating cap was ground down to sound concrete to provide a stable substrate for the new system.
The battery charging station was ground to clean, sound concrete to allow the chemical-resistant system to bond directly to the slab.
Work was phased by area, with each zone taped off during preparation and coating so warehouse operations could continue.
The Products
Products Installed
Main Racking Aisle
Neogard High-Traffic Urethane System
- Neogard moisture-mitigating primer, 25 mils
- Neogard high-traffic urethane, three-coat system
- Color: medium gray
Urethane resists wear from forklift tires and heavy foot traffic. The moisture-mitigating primer protects the bond on a slab on grade.
Warehouse flooringTesting Area
Same Neogard High-Traffic Urethane System
- Neogard moisture-mitigating primer, 25 mils
- Neogard high-traffic urethane, three-coat system
- Color: medium gray
Removing the delaminating cap first provides a sound substrate and prevents further surface deterioration.
Moisture mitigationForklift Battery Charging Station · About 450 SF
Neogard Urethane Cement + Novolac Topcoat
- Neogard urethane cement
- Novolac topcoat
Novolac epoxy is formulated for acid and chemical exposure, keeping battery acid on the surface and out of the concrete.
Battery room flooringResults
Completed Project
The main aisle is now a continuous medium gray floor with no striping visible beneath the surface, built for daily forklift and pedestrian traffic. The testing area has a sound, sealed surface, and the battery charging station has an acid-resistant floor that can be cleaned after a spill instead of absorbing it.
For warehouses with failing striping, deteriorating concrete or battery areas on bare concrete, Legacy can walk the facility and recommend the appropriate system for each area.
Finished photos
Facing similar warehouse floor conditions?
Send photos or a facility layout. Legacy will schedule a site walk and recommend the right system for each area.
Questions
Common Questions About This Project
Do you have to remove old line striping before coating a warehouse floor?
Yes. If old striping is coated over, its outline can show through the new floor and the coating ends up bonded to paint rather than concrete. On the Assa Abloy project, all existing striping was diamond ground off before coating.
What is the best floor coating for a forklift battery charging area?
Battery charging areas need a chemical-resistant system because battery acid attacks bare concrete and many standard coatings. For Assa Abloy's approximately 450 SF charging station, Legacy installed a urethane cement base with a novolac epoxy topcoat, which is built for acid and chemical exposure.
What does a moisture-mitigating primer do?
Concrete slabs can push moisture vapor up from below. Without mitigation, that vapor can cause bubbling and delamination in the coating. A moisture-mitigating primer, applied here at 25 mils, holds the vapor back so the floor system above it stays bonded.
Can you fix concrete that is flaking or scaling on the surface?
Yes. A delaminating surface is ground down to sound concrete, then a coating system is installed to seal and protect the slab.
Can a warehouse stay open while the floor is coated?
Yes. Work is phased by area, and each zone is taped off during preparation, coating and cure so the rest of the facility keeps operating.