Case Study: Transforming Industrial Spaces with High-Durability Epoxy Flooring Solutions

In this case study, we focus on one of our projects for a large-scale industrial project where CCE successfully transformed a worn-out warehouse floor into a high-durability, easy-to-maintain epoxy floor.

industrial manufacturer facility

Our Client's Challenge:

Our client, a leading manufacturing company, was grappling with frequent damage to their warehouse flooring due to heavy machinery and high foot traffic. Cleaning the floor was cumbersome due to its porous nature, and there were safety hazards from uneven areas. The client sought to overhaul the existing flooring to boost durability, improve safety, and enhance the warehouse's overall aesthetic.

Our Solution

To tackle the client's challenges, we recommended a high-solid epoxy flooring solution. This type of epoxy is distinctively formulated with a higher percentage of solid components, making it significantly more durable than its counterparts (water-based epoxy and solvent based epoxy). Its exceptional toughness and hard-wearing characteristics made it an ideal match for the client's industrial environment that constantly grapples with heavy machinery usage and high foot traffic. Solid epoxy also does not contain any amounts of volatile organic compounds (VOCs). VOCs are chemicals which release gas and can cause injury from prolonged inhalation, so eliminating them increased the safety of the work environment.


One of the most persistent issues our client faced was that their environment has rapid wear and tear. High-solid epoxy combats this problem effectively due to its superior resistance to abrasion and impact. It also withstands chemical spills and stains, a common occurrence in industrial warehouses, ensuring the floor maintains its integrity and appearance over time. We offered to create a 3 coat system made up of a primer, basecoat and a topcoat that would be a total of 14mm thick to secure the longevity of the flooring system.


Furthermore, a high-solid epoxy floor is seamless and offers a glossy finish, which does more than just enhancing the aesthetic appeal of the warehouse. The absence of seams and cracks eliminates the accumulation of dirt, dust, and bacteria, making cleaning and maintenance significantly easier. This was a critical aspect for this specific industrial space, where cleanliness was impactful to the functionality and safety of operations.


Moreover, the high-gloss finish of the epoxy floor improves the brightness of the area, helping to create a safer and more energized working environment. The ability to incorporate non-slip additives also augments safety, preventing slips and falls in areas prone to spills or where machinery might leave residual fluids.


In essence, the high-solid epoxy flooring solution provided a comprehensive answer to the client's issues, delivering not just durability and easy maintenance, but also safety enhancements and aesthetic improvement.

The Process:

The first step of the project was a comprehensive assessment of the existing floor, which involved conducting several tests. We tested for the presence of moisture using a moisture meter as too much humidity can affect the bond between the epoxy coating and the concrete floor. We also performed a concrete hardness test using a rebound hammer to determine the concrete's compressive strength, vital information for choosing the correct preparation method and epoxy type.

Once we established the floor's condition, we proceeded with the surface preparation, arguably the most crucial part of the process. In this project, we utilized shot blasting, an effective method for preparing industrial concrete floors. Shot blasting involves propelling steel shot at high velocity onto the floor to remove contaminants and to roughen the surface, which aids in the better adhesion of the epoxy coating. For this process, we used a ride-on shot blaster, which allowed for efficient and uniform blasting over the large warehouse area.

After shot blasting, we performed diamond grinding using industrial diamond grinders. This process further smoothed the surface and removed any remaining impurities or weak layers of concrete, ensuring a pristine surface for the epoxy to bond with.

We then repaired any cracks or damaged areas using a high-strength epoxy mortar. Once the repairs had cured, we thoroughly cleaned the floor again to ensure it was free from dust or debris that might hinder the application of the epoxy.

Next came the application of the 100% solids epoxy. We used a professional-grade, two-component mixing and dispensing machine to mix the epoxy resin and hardener in the correct proportion. Then, using a combination of squeegees and rollers, we evenly spread the epoxy across the entire floor surface. We carefully monitored the thickness of the coating to ensure optimal performance and longevity.

Given the client's concern for safety, we mixed a non-slip epoxy additive into the final layer. This provided a lightly textured surface, increasing the grip and reducing the risk of slips and falls.

After the epoxy application, we allowed ample time for curing. During this period, we maintained optimal temperature and humidity levels in the warehouse to ensure the epoxy hardened properly, transforming into a seamless, high-gloss finish.

With the curing complete, we conducted a final walk-through to inspect the quality and evenness of the application, ensuring the floor met the client's expectations and our quality standards.

The Outcome:

The transformation of the warehouse floor was remarkable. The new high-solid epoxy flooring not only addressed all the issues that the client was facing but also surpassed their expectations. With before-and-after photos, the client could see the dramatic enhancement in the aesthetics of the warehouse.


The client reported significantly improved efficiency in warehouse operations, owing to the durability and ease of maintenance the new flooring provided. They also noted an enhancement in workplace safety due to the non-slip texture. They were delighted with the aesthetic upgrade, stating that the glossy finish gave the industrial warehouse a professional and polished appearance.


before image of factory floor that has lots of damage
after photo with high gloss epoxy finish and anti slip finish

Final Thoughts:


This project underscores Crystal Clear Epoxy's expertise in delivering customized epoxy flooring solutions that meet unique industrial needs. Whether the objective is to improve functionality, enhance safety, or upgrade aesthetics, we're committed to providing high-quality, durable, and visually pleasing flooring solutions that stand the test of time.

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