Sealwell INC – Epoxy Mortar & Coating Flooring for Advance AB Warehouse

Advance AB, a logistics and distribution company, operates a large warehouse facility where materials of various kinds are stored and handled. Over time, the Advance AB facility developed inconsistent floor surfaces—some zones were plain concrete, others had old coatings, some had wear, cracking, and patching—that led to safety, maintenance, and operational inefficiencies.

Advance AB engaged Sealwell INC to deliver a uniform, robust, seamless flooring solution across the diverse floor zones. The goal: turn disparate substrates into a consistent, high-performance surface with long-term durability and ease of maintenance.

 Client’s Requirements

Advance AB’s key requirements included:

• A single, continuous floor surface across multiple zones (loading docks, storage, packing, transit pathways), irrespective of the prior floor types
• Resistance to heavy traffic (forklifts, pallet jacks, trucks), impact loads, and abrasion
• Chemical, spill, and stain resistivity (oils, cleaning chemicals, lubricants)
• Low maintenance and easy cleaning
• Minimal downtime during installation (warehouse operations needed to continue as much as possible)
• Good aesthetics and a clean finished look to reflect their brand professionalism
• Long-term durability and repairability

 Challenges

Implementing a uniform overlay in a working warehouse environment posed several challenges:

• Heterogeneous substrates: The existing floors varied in material (bare concrete, older coatings, patched areas), age, and condition. Achieving adhesion and compatibility across all these was nontrivial.
• Surface defects: Cracks, spalls, pits, and unevenness needed remediation. Some areas had moisture issues or delamination from prior coatings.
• Operational constraints: The warehouse could not be entirely shut down for long. Phased work and coordination with operations were imperative.
• Load demands: Heavy equipment traffic, including forklifts and occasional trucks, required the floor to resist high compressive and shear stresses.
• Chemical exposure: Oils, lubricants, cleaning acids/alkalis would be used over time, so the coating system needed chemical resistance.
• Thermal / humidity variations: The warehouse sees temperature and humidity fluctuations, potentially affecting curing and adhesion.

 Our Objectives & Solution

Objectives

• Create a continuous, seamless, and durable floor surface across the facility
• Restore and level deficient floor zones before applying the top system
• Apply a system with high mechanical strength and chemical resistance
• Minimize operational disruption
• Ensure longevity and ease of maintenance

Proposed Solution

Sealwell INC proposed a two-layer system:

1. Epoxy Mortar (cementitious epoxy mortar / trowel-grade epoxy mortar)
   • This was used for leveling, filling voids, and restoring uniform substrate thickness.
   • It bonds well to concrete and provides a strong base for the topcoat.
2. Epoxy Coating / Topcoat
   • After the mortar layer cured, a pigmented epoxy coating (high-build, high-durability) was applied to serve as the wear surface.
   • The coating offers abrasion resistance, chemical resistance, and a smooth, easy-clean surface.

This combined system gives both structural strength (from the mortar) and surface protection (from the coating).

 Implementation Process

The project was executed in the following phases:

To manage work without halting operations, Sealwell worked in zones, scheduling each zone during off-peak hours or weekends. The crews coordinated with Advance AB’s operations team to reroute forklift paths temporarily.

Quality control checks (moisture, adhesion, thickness, hardness) were undertaken at each step to ensure system integrity.

Results

The project achieved the following outcomes:

• Uniform seamless surface: All warehouse zones now share a consistent, high-quality floor surface without transitions between patch types.
• Enhanced durability: The new floor withstands heavy forklift and truck traffic with minimal wear or damage.
• Chemical resistance: The floor resists oils, lubricants, spills, and cleaning agents, reducing staining and deterioration.
• Ease of maintenance: The smooth epoxy surface is easy to clean, dust mop, or wash.
• Minimized downtime: By phasing work and coordinating with operations, the warehouse remained functional during most of the project.
• Extended service life: The combined mortar + epoxy coating system is projected to last many years with routine maintenance.
• Improved aesthetics & branding: The clean, uniform finish projects a professional look and instills confidence in clients and visitors.

Client Feedback

Sealwell’s team transformed our mismatched, worn-out warehouse floor into a seamless, premium surface. The coordination was excellent—they worked around our operations, and the final result is both durable and easy to maintain.”
“Since installation, we’ve observed significantly fewer maintenance issues. The floor still looks new despite continuous heavy traffic and occasional spills.

Operations Manager, Advance AB