Stonhard Delivers Level Flooring to Support Major Wholesale Distributor's Automated Material Handling System

Project Overview

A major wholesale distributor and supply chain company in Ontario, Canada, sought a flooring solution that would support an automated material handling system (AMHS) in their Concord branch. To ensure the AMHS -- designed to boost storage capacity and accelerate order processing -- functioned effectively, it would be essential for the floor, spanning approximately 5,400 sq. ft., to be level. The company selected Stonhard to provide the durable flooring solution, formulated and installed to meet exact specifications.

Stonkote GS4 delivered exceptional durability, precision leveling, and long-term operational reliability.

Precision floor leveling and seamless epoxy installation helped prepare this warehouse and distribution facility for advanced automated material handling equipment.

Challenges & Requirements

The project came with several challenges. The existing floor, which was not suitable for the new system, would need to be completely removed, followed by careful preparation. Surveys showed that the floor had deep depressions, some as deep as 1.25 inches, which would need to be filled to make the surface level. The floor had to meet strict flatness and levelness standards to properly support the automated system, requiring precise surveying and levelling throughout the process.

Stonkote GS4 provided the durability required to support automated material handling equipment at this leading warehouse and distribution facility.

Precision-level flooring preparation enabled reliable performance and smooth operation of automated material handling equipment within the warehouse distribution system.

Solution

The Stonhard team removed the old floor, exposing the footprint for the equipment pad. Preparation required a combination of surface grinding to remove any remaining contamination, followed by mechanical preparation to achieve a concrete surface profile of SPS-A to ensure that the new floor would be well bonded.

To address the significant floor depressions, Stonhard’s technical team, in conjunction with the installation crew, marked a grid pattern and set levelling pegs using surveying equipment. Stonset TG5, a fast-setting, epoxy-based grout, was applied to fill the depressions, offering a durable base for anchoring equipment.

Next, a layer of Stonclad epoxy mortar was power trowelled over the entire area to create a smooth, impact-resistant base layer. To further enhance the surface, a liquid-rich flood coat was applied, followed by a topcoat of Stonkote GS4 epoxy coating, which ensures an abrasion resistant and durable finish. The project was completed on time and budget, with final verification of a level floor provided by the equipment manufacturer. Working with Stonhard allowed the company to stay on plan for the installation of their automated material handling system.

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