Warehouse Floor Coating Options

Every warehouse has different flooring needs, but there are a few concrete coating options that work for the vast majority of warehouses. The right choice for your warehouse floor depends on traffic levels, moisture, and usage. Balancing installation downtime with a coating that is durable enough for your operation is always the first topic of discussion. We will outline the floor coating options chosen by most warehouses and why they choose them to help guide you to the right choice for your commercial floors.

Quartz Epoxy

Quartz epoxy is one of the most durable options for warehouse environments. It bonds exceptionally well to concrete and withstands daily machinery traffic. This system provides superior slip resistance and helps cover up ugly concrete.

Benefits of a Quartz Epoxy Coating for Warehouses

Quartz epoxy is going to be a great choice for a heavily used warehouse floor where you are looking for a nicer aesthetic than plain concrete, but also want the durability benefits of a strong concrete coating. The quartz aggregate embedded in the epoxy creates a textured, impact-resistant surface. This texture improves traction while maintaining easy cleanability. The combination of epoxy resin and quartz granules delivers unmatched durability for industrial settings.

The reasons warehouses choose quartz epoxy: 

Aesthetic: A quartz epoxy floor eliminates ugly concrete and gives you an entirely new flooring system. 

Slip-Prevention: The rough texture of the quartz granules makes this epoxy system an anti-skid coating which equals less slip and falls in your warehouse. 

Resistance to Wear: The embedded quartz particles protect the underlying epoxy from wear. Heavy equipment causes minimal damage to properly installed systems.

Longevity: A properly installed epoxy floor should last 15-20 years if properly maintained. 

However, many large warehouses that do not get outside visitors or customers do not typically elect a quartz epoxy because of the price tag. Professional quartz epoxy applications will run between $10-$15/square foot. 

Polyaspartic Coatings

Polyaspartic coatings are frequently used in warehouse floors because they cure quickly compared to epoxy coatings. This is attractive for operations that do not want much downtime. 

However, when applied as a base layer, these coatings do not bond as well to concrete as epoxy. The molecular structure of polyaspartic resins lacks the penetrating characteristics of epoxy. Direct application to concrete creates a mechanical bond only. This bond is insufficient for heavy industrial traffic. This can lead to premature failure and shorter life span. 

Polyaspartic Coating as a Topcoat

We recommend polyaspartic coatings as a topcoat once an epoxy base has been established. 

As a topcoat, polyaspartic provides excellent abrasion resistance. The fast cure time minimizes operational downtime. Most polyaspartic topcoats are ready for traffic within 24-48 hours.

The combination of epoxy base and polyaspartic topcoat delivers superior results. Epoxy provides structural integrity and adhesion. Polyaspartic adds surface hardness and maintains appearance over time.

Consider a hybrid approach if considering polyaspartic coatings for your warehouse. 

Grind and Seal for Warehouse Floors

Grind and seal is a more affordable option compared to epoxy and polyaspartic coatings and will be the ideal choice for the majority of warehouse needs. The process removes surface imperfections and stains with a water-based urethane topcoat seal.

Diamond grinding exposes fresh, dense concrete underneath. This creates a smooth, level surface ready for sealing. The urethane topcoat penetrates slightly and forms a protective barrier.

When Grind and Seal Makes Sense for Warehouses

This option works best for busy warehouses where the current concrete is in decent shape, but the concrete needs to be polished and sealed. Maintenance is also minimal, with many warehouses not needing to do any resealing if they go with a water-based urethane sealer. 

Storage facilities, distribution centers, and most warehouses benefit from this approach. The system works well when existing concrete is in pretty good condition. Budget-conscious operations appreciate the lower upfront investment since grind and seal typically runs between $2-$6/square foot. 

Downside of Grind and Seal

The only real downside of choosing grind and seal for your warehouse is that it will not cover up where cracks have been repaired and oil and chemical stains in your current concrete. If you are looking for a new floor look, then grind and seal is not the best choice, and an epoxy coating would be better. 

Importance of Proper Concrete Prep

Properly preparing your concrete before applying a coating is equally, if not more important than the actual coating itself. Here are just a few of the important steps and reasons to take those steps to ensure your concrete is ready to be sealed. 

Grinding off the top layer of concrete to remove stains and visible imperfections in the existing concrete. Using a diamond-tooled grinder is the best and recommended method for prep work. 

Once the initial grind is completed, it is imperative to clean the surface of dust and particles. Our preferred approach is using a shot blasting machine. 

Once the floors are cleaned you can begin repairing cracks in the concrete with epoxy mortar or gels. 

Having all of the above steps done properly and thoroughly will ensure that the base layer of epoxy adheres strongly to the concrete. 

Professional Warehouse Floor Coating

At Elite Floor Coatings, we have been coating commercial floors for years, and have sealed hundreds of thousands of square feet of concrete across Pennsylvania and Maryland. If your warehouse or commercial floors are in need of an upgrade, we will be happy to evaluate your use-case to recommend the best coating option for your needs. Request a quote from our team and will get your warehouse floors looking better and performing better in no time!