How to Fix Uneven Floors & Cracks in an Industrial Warehouse
The Problem: Sunken, Cracked Concrete in a 2 Million Sq. Ft. Facility
A concrete refinishing company, Floorworx, faced a major challenge in their 2 million sq. ft. warehouse. A 5,000 sq. ft. section (30 feet wide x 80 feet long) was sunken and cracked, creating a dangerous 3-inch difference between the center and the perimeter. The facility manager needed an industrial-grade epoxy cement repair strong enough to handle forklifts, heavy-duty trucks, and constant traffic; without tearing out the concrete.
Exploring Epoxy & Self-Leveling Solutions
Our customer service team evaluated multiple concrete floor repair products:
- TREFLITE™ - epoxy mortar patch/resurfacer, ideal for patching and resurfacing.
- GARONCLAD™ – flowable epoxy mortar for smoother applications.
- POUR N WALK™ – a self-leveling, ultra-smooth epoxy coating.
- For concerns about lip edges, which are slight raised ridges in concrete, GARONGUARD™ and TIGERSHIELD™ were recommended to lock in edges and prevent future breakage.
Key Considerations for Industrial Floor Repair
The facility required a high-abrasion, impact-resistant industrial floor coating capable of withstanding the rigors of a demanding environment, including frequent dropped tools, heavy machinery traffic, and exposure to harsh chemicals and cleaning agents. To ensure long-term durability and workplace safety, the chosen flooring system needed to offer superior chemical resistance, a smooth, level surface for optimal traction, and seamless application to prevent cracks or uneven wear.
Ideal for manufacturing plants, warehouses, and industrial workshops, this type of heavy-duty epoxy or polyurethane floor coating not only protects the substrate from physical and chemical damage but also contributes to operational efficiency by reducing maintenance downtime and improving safety compliance. By investing in a durable, high-performance industrial floor coating solution, the facility can maintain peak functionality even under the most punishing conditions.
The Winner: GARONGUARD™ Epoxy Floor Coating
GARONGUARD™ was chosen for its 93% solids, high-build, self-priming formula five times thicker than standard paint. It bonds directly to concrete, cures for light traffic in just 16–24 hours, and provides exceptional resistance to cracking, chipping, dusting, and abrasion. Perfect for warehouses, manufacturing plants, and heavy-duty workspaces, it delivers strength, beauty, and long-lasting protection in one solution.
Conclusion: A Durable, Seamless Solution with Colored Epoxy for Industrial Concrete Repair
In solving the significant challenge of sunken, cracked concrete in a 2 million sq. ft. facility, Floorworx found success with GARONGUARD™, a high-performance epoxy floor coating designed for industrial strength and safety. With its superior bonding, fast cure time, and high-abrasion resistance, GARONGUARD™ provided a seamless repair solution without the need for costly concrete removal.
Not only did this self-priming, high-build epoxy restore structural integrity, but it also enhanced the facility's appearance with a colored epoxy finish—offering both functionality and visual appeal. Whether you're addressing warehouse floor damage, heavy machinery zones, or areas prone to chemical exposure, colored epoxy coatings like GARONGUARD™ ensure long-lasting performance while transforming dull, damaged concrete into smooth, level, and vibrant surfaces.
For industrial environments demanding durability, aesthetics, and safety, colored epoxy floor systems are the smart, future-proof choice.
Contact our team today for questions about your concrete repair project.
