Client Overview:
One of DC Flooring’s long-standing clients, with whom we regularly deliver specialist industrial flooring solutions, including resin flooring systems and polished concrete finishes. Having built a strong working relationship over numerous successful projects, our client once again entrusted our team to restore an existing warehouse floor to a consistent, high-quality finish.
The warehouse contained multiple flooring systems installed over time, resulting in an inconsistent appearance and varying surface conditions. The client’s objective was to create a seamless, uniform finish across the warehouse while ensuring the existing concrete slab was preserved and prepared for a new high-gloss coating.
Challenge:
Although the overall condition of the existing floor was good, the survey identified levelness and flatness issues across multiple areas of the floor as well as problems the steel construction joints.
An initial hardness inspection also returned results below the requirements specified by the robotic automation company.
The project was further complicated by a very tight programme, with the client requiring both the initial survey and subsequent remediation to be completed within a demanding timeframe.
To maximise productivity, the client allowed multiple working shifts, and provided a clean and clear destocked area, allowing our surveying and remediation teams unrestricted access to the floor. This allowed the team to work efficiently whilst maintaining the accuracy required for the project.
Solution:
We began with a comprehensive initial survey assessing multiple characteristics of the slab, including flatness, levelness, gloss, surface hardness, slip resistance and resistivity. This provided a detailed understanding of the floor condition and identified the areas requiring remediation.
The floor was then precision ground to specification in the areas identified as out of tolerance. Because the floor was destined for robotic automation, the remediation process required continuous monitoring and surveying/with our precision remediation process rather than simply grinding to a visual finish.
The team repeatedly surveyed the floor throughout the works to verify progress and ensure the required tolerances were being achieved.
To address the hardness requirements, DC Flooring applied a proprietary densification and polishing system, increasing the hardness of the floor while also improving the finished surface. Initial hardness testing showed results of 4 and below on the MOHs scale. After our DCF Express System was installed, we achieved results of 7 and above.
This combination of continual surveying, precision grinding, densification, and polishing provided a complete solution specifically tailored to the requirements of the robotic automation specifications.
Outcome:
The project was a significant success, with all the required tolerances achieved across the warehouse floor.
Following the application of DC Flooring’s proprietary densification system and polishing process, the hardness of the floor was increased by up-to 75%, bringing the slab in line with the requirements set by the robotic automation company.
Despite the tight programme, we successfully completed both the surveying and remediation works within the client’s required timeline.
Both the 3PL client and robotics automation supplier were extremely happy with the results, and the success of the project has already led to the release of Phase Two, with DC Flooring appointed to carry out the initial survey and remediation works.
The success of this project has also opened the door to further opportunities, from the robotics automation company enquiring about DC Flooring’s specialist surveying and remediation services across Europe and the UK.
Conclusion:
The success of this project was built around the right team, the right equipment and a commitment to achieving extremely demanding tolerances. From the initial survey through to the final remediation, DC Flooring maintained close communication with both the client and the robotics automation supplier, providing regular updates on progress and floor performance.
The project demonstrated the importance of combining accurate surveying with precision remediation and continual verification when preparing floors for robotic automation. Meeting the demanding programme while achieving the required technical specifications reinforced our ability to deliver specialist flooring solutions in complex, high-performance logistics environment.
Most importantly, the successful completion of the project has strengthened our relationship with both the client and automation supplier, creating opportunities for further projects across the UK and Europe.
