Austin Industrial Warehouse Transformation
Heavy-duty industrial coatings for Round Rock distribution center
Project Overview
A major e-commerce distribution center in Round Rock required comprehensive industrial coating to protect high-traffic floor areas, warehouse walls, and loading dock zones. The 120,000 square foot facility operates 24/7, processing thousands of shipments daily with heavy forklift traffic and frequent temperature fluctuations.
Our team implemented a phased coating schedule to maintain continuous operations, working in coordination with warehouse management to coat different zones during low-traffic periods. We installed chemical-resistant epoxy floor coatings, high-durability wall systems, and specialized loading dock protection designed for Austin's climate extremes.
Industrial Coating Systems
- • Heavy-duty epoxy floor coating
- • Forklift traffic zones
- • Loading dock protection
- • Warehouse wall systems
- • Chemical-resistant coatings
- • Impact-resistant surfaces
- • Safety line striping
- • High-reflectivity finish
Technical Specifications
- Floor System: 3-coat 100% solids epoxy system rated for 80,000 PSI compressive strength
- Preparation: Diamond grinding and shot blasting to achieve CSP-3 profile
- Traffic Resistance: Certified for Class 8 forklift traffic (35,000+ lbs)
- Cure Time: Fast-cure system allowing 24-hour return to service
- Light Reflectance: 85% LRV high-gloss finish to reduce lighting costs
Challenge & Solution
Challenge: The facility could not shut down for coating installation. All work had to be completed in phases while maintaining 75% operational capacity, with each zone returning to service within 36 hours.
Solution: We divided the warehouse into 8 zones and implemented a rotating schedule. Using fast-cure epoxy systems and working night shifts, we completed each 15,000 sq ft zone in 32 hours from prep to full cure, allowing the facility to maintain operations throughout the project.
Results
- ✓ Zero downtime for warehouse operations
- ✓ Floor coating withstands 1,200+ daily forklift trips
- ✓ 15% reduction in lighting costs from high-reflectivity coating
- ✓ Extended floor lifespan from 5 years to 15+ years
- ✓ Improved safety with clearly marked traffic lanes and zones
Client Testimonial
"Moorhouse Coating completed our massive warehouse floor coating without disrupting our 24/7 operations. Their industrial coating expertise and project management were exceptional. The floor looks incredible and is holding up perfectly under extreme daily use."
— Operations Director, Round Rock Distribution Center