Is Your Old Concrete Floor Actually a Safety Hazard?

Posted on Sunday, January 31, 2016

Reconditioning an older facility is a wonderful way to repurpose a space, giving it a new lease on life. The key is to make sure that all the necessary updates are made, both for aesthetic reasons as well as to ensure that the environment is safe and ready for use.

We were recently called to Salem, NH, to address multiple flooring issues found in an older facility that is being given a second life as a storage warehouse.

As you can see in the first two photos above, this floor was scarred by multicolored, deeply-saturated stains (they were actually over a decade old!). On top of that, sections of the concrete were raised, creating a tripping hazard. Our goal was to restore a smooth, level, and safe surface.

Shotblasting - What Is the Process, and What Can It Do for Your Facility’s Concrete?

The advantage of shot blasting is found in its ability to restore a level profile. In addition, it simultaneously cleans and creates a slightly roughened finish that is perfect for coating.

How does it work?

Shotblasters are essentially enclosed blast chambers, inside of which steel balls are shot out of paddles onto the concrete. The steel shot is recycled as the machine runs, while the stirred up dust, dirt, and particles of old coating are sucked into an additional chamber. A flooring professional will guide the shot blasting unit along the floor, controlling the impact (and effect) that the process has. Depending on the speed at which the unit moves and the size/velocity of the shot, the result can range from light etching to a complete removal of the surface and its coatings.

We also used a deep-fill epoxy mortar to help level the deeper cracks and damaged sections of the floor.

Restoring a Warehouse Floor with an Epoxy Top Coat

After making repairs and shot blasting to level the surface, we installed a coating of high-quality, water-reducible epoxy from Protective Industrial Polymers. This is a product that we believe in, and know will serve the facility well.

Here are just a few benefits of this particular epoxy system:

  • Allows moisture transmission without risk of coating failure
  • Seals the surface, protecting against liquid damage and spills
  • Low-VOC - This is a low-odor product, complying with VOC regulations for industrial maintenance coatings
  • Long-lasting
  • Dust-proof

Two Pieces of Good News

First, we were able to mobilize within a week, accommodating our client’s busy construction schedule. We wanted to do all we could to get this repurposed facility up and running quickly.

Also, remember those ten-year-old stains? The shot blasting process removed the blemishes, creating a clean, like-new surface. What could be better?

It was a pleasure to offer our industrial flooring services to this Salem client, and we wish them all the best with their reconditioned space.

Kaloutas is New England's premier contractor for commercial & industrial painting, flooring, and related services. Established in 1987, Kaloutas has become a trusted resource for general contractors, facilities managers, and building owners from Connecticut to Maine. Our team prides itself on high quality workmanship, jobs done on time & budget, and tackling complex projects that other contractors don't have the experience or resources to handle. Contact us today for a painting or flooring estimate, or give us a call at 978-532-1414 to learn more.

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