Warehouse, Manufacturing and Plant Floors
Industrial Concrete Coatings in Dallas and Fort Worth
Short answer
Industrial concrete coatings are engineered floor systems chosen for a specific problem: thermal shock, chemical attack, static, impact, or a floor that has to be washed down and returned to. Densify and seal, or polish runs $1.50 to $6 per square foot installed in Dallas-Fort Worth. Same-day service is available.
The floor is not the cost. The shutdown is the cost.
Overview
Industrial concrete coatings are engineered floor systems chosen for a specific problem: thermal shock, chemical attack, static, impact, or a floor that has to be washed down and returned to service on a shift schedule. This is not the same category as a decorative garage floor, and the specification process is not the same either. It starts with what happens on your floor and works backward to the product.
Professional Garage Concepts has done commercial and industrial work in Dallas and Fort Worth since 2001. Our commercial client list includes Herzog and Coca-Cola. We hold 532 Google reviews at a 4.8 star average, an A+ rating with the BBB, and we are licensed, bonded and insured. We also keep a current W-9, certificate of insurance and safety documentation ready to send the same day you ask, so your purchasing process does not sit waiting on a vendor packet.
The number that matters on an industrial floor is not dollars per square foot. It is hours of lost production. A cheaper system that puts your line down an extra two days costs more than the premium system that did not. We schedule around that, and every scope we write states the return-to-service time for foot traffic and for equipment separately.
Urethane cement and urethane mortar
Urethane cement, also called urethane mortar, is the system for wet processing, thermal shock and heavy impact. It is a trowel-applied floor typically laid at a quarter inch, built from a urethane binder with cement and graded aggregate. Two properties make it the specification of record in food and beverage plants and in any area that gets hot washed.
First, its thermal expansion rate is very close to that of concrete, which means when boiling water or steam hits the floor, the coating and the slab move together instead of the coating shearing off. Epoxy does not do this. An epoxy floor in a steam cleaning area will delaminate, and it is only a question of when. Second, it tolerates moisture in the slab far better than epoxy does, so it can be installed on slabs that would fail a moisture test for a conventional coating.
Urethane cement is also installed with an integral cove base up the wall, so there is no seam at the wall to fail and nothing for bacteria to sit in. Floors get sloped to drain where the process requires it. This is a heavy, textured, functional floor and it is not trying to look pretty. It is trying to still be there in ten years.
- Withstands steam cleaning, boiling water and hot washdown without delaminating
- Thermal expansion matched to concrete, which is why it survives thermal shock
- Installs over slabs with higher moisture content than epoxy will tolerate
- Integral cove base and slope to drain for sanitary areas
- Typical uses: food and beverage processing, breweries, commercial kitchens, cold storage, wet manufacturing, chemical mixing rooms
- Textured by design for traction under wet conditions
Chemical-resistant novolac epoxy
Novolac epoxy is what you specify when the floor sees concentrated acids or aggressive solvents. Standard bisphenol-A epoxy holds up to mild chemicals, oils and detergents perfectly well. Push it to sulfuric acid, hydrochloric acid, or high-concentration solvents and it softens, blisters and lifts. Novolac resin has a higher crosslink density, which gives it a much broader chemical resistance range and better performance at higher temperatures.
The practical use cases in DFW are battery charging areas in distribution centers, plating and finishing lines, chemical storage and mixing rooms, laboratories, wastewater areas and any secondary containment that holds something aggressive. Novolac is usually built at a higher film thickness than a standard epoxy, often with a broadcast aggregate for traction, and it can be run up walls and curbs as part of a containment system.
Specifying this correctly requires knowing what is actually on your floor. Bring us the safety data sheets. Chemical resistance charts are specific to concentration and to temperature, and a product that handles 10 percent of something will not necessarily handle 70 percent of it. We will not guess at this.
ESD and static-dissipative flooring
Static-dissipative flooring gives static a controlled path to ground instead of letting it build on people and equipment. It matters in electronics assembly and repair, in server and data rooms, in cleanrooms, in ordnance and munitions handling, and anywhere solvents or fine combustible dust make a spark a safety issue rather than an annoyance.
These systems are built as an assembly, not a single product. A conductive primer or carbon-loaded grid is laid over the prepared slab, tied into copper grounding strips, and connected to the building ground. The topcoat is a static-dissipative epoxy or urethane formulated to hold surface resistance in a target range, generally between 10 to the sixth and 10 to the ninth ohms depending on what your standard requires. The floor is then tested and readings are documented.
Two practical notes. Your target resistance range comes from your own standard or your insurer, so tell us the number rather than asking us to pick one. And ESD floors need maintenance with the correct cleaner, because ordinary floor finish will insulate the surface and take the floor out of spec without anyone noticing until it is tested.
Industries and areas we coat across DFW
The DFW logistics and manufacturing corridor runs from Alliance down through Grand Prairie and Arlington to south Dallas, and we work across all of it. Different buildings need very different floors.
- Warehousing and distribution. Racked warehouse floors, cross-dock areas, staging and pick lanes, battery charging rooms and cold storage. Usually densify and polish or a mid-build epoxy, with joint fill under lift traffic and full aisle and safety striping.
- Manufacturing. Machine shops, fabrication bays, assembly lines, paint and finishing areas. Specified around point loading from equipment, dropped tools, coolant and hydraulic fluid, and forklift traffic.
- Food and beverage. Processing floors, packaging halls, walk-in coolers, commercial kitchens and breweries. This is urethane cement territory: hot washdown, integral cove base, slope to drain and a floor with no seams for bacteria to occupy.
- Automotive service. Dealership service departments, fleet shops, quick lube bays and truck maintenance facilities. Needs oil and brake fluid resistance, hot tire resistance in the DFW summer, and a surface that reads clean to a customer walking past the bay.
- Aviation and hangars. Hangar floors and MRO shops, where fuel and hydraulic fluid resistance plus a bright reflective surface are both part of the spec.
- Laboratories and clean areas. Chemical resistance, cleanability, a jointless installation and controlled static where the process requires it.
Line striping, safety marking and secondary containment
A coated floor is also a communication surface, and this is the part of the scope that most often gets left out and then added later at higher cost. We lay out and stripe aisles, pedestrian walkways, forklift traffic lanes, equipment footprints, staging and inventory zones, exit paths, fire extinguisher and eyewash locations, electrical panel clearances and dock positions.
Striping goes down in the same coating system as the floor, not in tape and not in traffic paint. That distinction matters. Tape peels under a pallet jack. Traffic paint wears off in the lane where it is needed most. A striping line laid in the coating and topcoated over it lasts as long as the floor does. We follow standard color conventions for aisle, hazard and equipment marking, and we lay everything out with your safety manager before a line goes down, because the layout is a plant decision and not a coating decision.
Secondary containment is a related and separate scope. Containment areas around tanks, drums, transformers and chemical storage need a chemically compatible coating carried continuously across the floor, up the curb or dike wall, and into any coved corner, with no seam a liquid could find. We build these in novolac or a chemically appropriate system based on what is stored, and we coat the full inside of the containment rather than just the floor of it.
- Aisle, walkway and forklift lane striping laid in the coating system, not taped or painted on
- Hazard marking, equipment footprints, exit paths and panel clearance zones
- Dock position numbering and staging zone layout
- Anti-slip aggregate broadcast into ramps, wet areas and pedestrian crossings
- Secondary containment coated floor, curb, dike wall and cove as a single continuous system
- Trench drains, pits and equipment pads coated to match the surrounding floor
Working around your production schedule
This is where most industrial coating projects actually succeed or fail. Every coating system has a cure schedule, and cure time is the constraint on your building, not application time. A standard epoxy buildup can need 24 to 72 hours before equipment rolls on it. A polyaspartic topcoat can be back in service in a fraction of that. Choosing between them is often a schedule decision more than a performance decision, and we put both options in front of you with the return-to-service hours next to each price.
We work nights and weekends as standard practice, not as an exception. Most DFW plant and warehouse floors we coat are done in phases, with a section walled off, prepped, coated and handed back before the next section opens. That takes longer in total calendar time and it keeps you shipping, which is nearly always the cheaper trade. For a full shutdown, we plan backward from your restart time and staff it accordingly.
Dust and containment matter in an occupied building. Shot blasting and diamond grinding are done with vacuum recovery, work areas are sealed in plastic with negative air where required, and we coordinate with your EHS group on access, lockout, hot work and anything else your site requires before the first machine comes off the trailer.
- Night, weekend and holiday shifts at no drama and quoted up front
- Phased sectional work so only part of the floor is out of service at a time
- Written return-to-service hours for foot traffic and for equipment, quoted per system
- Fast-return polyaspartic topcoats where the schedule is the binding constraint
- Vacuum-recovery shot blasting and grinding, containment, and negative air where needed
- Coordination with your EHS and maintenance teams on access, lockout and site rules
- 24/7 emergency availability for a floor failure that is stopping production
Vendor documents: what your purchasing department needs from us
General contractors and plant purchasing groups cannot issue a PO to a vendor who is not set up, and this is where industrial flooring projects lose a week for no good reason. We keep the packet current and send it the same day you ask for it. No back and forth, no waiting on an insurance agent.
If your process needs something not on this list, ask. We would rather fill out your form on day one than find out about it when the PO is stuck.
- Completed W-9 for vendor setup
- Certificate of insurance, with your entity named as additional insured and the endorsement attached when your contract requires it
- Proof of general liability, auto and workers compensation coverage
- Safety data sheets for every product going into your building, sent before mobilization
- Product technical data sheets so your engineer can review the specification
- Written scope of work with system buildup, film thickness and return-to-service times
- Site-specific safety plan and job hazard analysis for the work area
- License, bonding and BBB documentation, and references from DFW commercial work
- Lien waivers on the schedule your contract specifies
How it works
How an industrial floor coating project runs
- STEP 01
Site walk and exposure survey
We walk the floor with your maintenance or EHS lead and document what actually happens on it: chemicals and concentrations, temperatures, washdown method, wheel loads, drainage and existing damage. We ask for safety data sheets on anything that hits the floor. This survey is what selects the system.
- STEP 02
Moisture and bond testing
We test the slab for moisture vapor emission and relative humidity and pull bond tests where the existing surface is questionable. On older DFW slabs poured without a vapor barrier, this test is what decides between a conventional epoxy, a moisture-tolerant primer, or urethane cement, which handles wetter slabs than epoxy will.
- STEP 03
Written specification and schedule
You get a written system buildup, film thickness, striping layout, containment scope and per-system return-to-service hours, with the shutdown plan attached. Vendor documents go over at this stage so purchasing can move in parallel rather than after the fact.
- STEP 04
Containment and mobilization
The work area is walled off in plastic, negative air is set up where required, and adjacent equipment, racking and product are protected. We coordinate access, lockout and any site-specific requirements with your team before equipment comes off the trailer.
- STEP 05
Mechanical surface preparation
Shot blasting or diamond grinding with vacuum recovery opens the slab to the profile the manufacturer specifies for that system. Old coatings come off, laitance comes off, and oil-contaminated concrete gets treated or removed. Nothing bonds to a floor that was not prepared, and prep is where cheap bids get cheap.
- STEP 06
Repair, joints and detail work
Spalls, gouges, joints and cracks are repaired with materials compatible with the coating going over them. Drains, pits, equipment pads, curbs and containment walls get their detail work and cove base. This stage is slow, it is unglamorous, and it is where floors are won or lost.
- STEP 07
System application
Primer, body coat and topcoat go on to the specified thickness, with aggregate broadcast where traction is required and cove base troweled in on sanitary floors. Urethane cement is trowel applied at its specified depth. We measure wet film thickness as we go rather than estimating from gallons used.
- STEP 08
Striping, testing and handback
Aisle and safety striping is laid out with your safety manager and installed in the coating system, then topcoated. ESD floors are resistance tested and the readings documented. We walk the floor with you, confirm the return-to-service times in writing, and hand over maintenance instructions and product data.
Straight pricing
Industrial floor coating pricing in DFW
These are installed DFW ranges and not a quote. Industrial pricing depends on the system, the condition of the slab, how much of the cost is preparation, and whether the work runs on nights, weekends or a phased shutdown. Off-hours work carries a premium that is almost always smaller than the production you would lose otherwise.
Densify and seal, or polish
$1.50 to $6per sq ft
Warehouse, distribution and dry manufacturing floors that need dust control, abrasion resistance and light reflectance with no film
- Lithium silicate densifier to stop concrete dusting
- Penetrating sealer, or a full mechanical polish to a specified gloss level
- Semi-rigid joint fill under lift traffic from $2.50 per linear ft
- No film, so no delamination risk on a slab with unknown moisture
- Fastest return to service of any system we install
Epoxy and polyaspartic systems
$5 to $12per sq ft
Machine shops, service bays, hangars, assembly areas and general plant floors needing chemical resistance and a cleanable surface
- Shot blast or diamond grind preparation with vacuum recovery
- Primer, body coat and topcoat at specified film thickness
- Anti-slip aggregate broadcast where traction is required
- Fast-return polyaspartic topcoat option when schedule is the constraint
- Written return-to-service hours for foot traffic and equipment
Urethane cement and novolac
Quoted by systemper sq ft
Food and beverage, wet processing, hot washdown areas, chemical rooms and secondary containment
- Trowel-applied urethane mortar, typically at a quarter inch
- Integral cove base and slope to drain
- Novolac epoxy where concentrated acids or solvents are present
- Installs on slabs too wet for a conventional epoxy
- Priced from your safety data sheets and process temperatures, not from a chart
ESD, striping and containment
Quoted with scopeper sq ft
Electronics, data centers, ordnance handling, and any facility needing safety marking or spill containment
- Conductive grid, copper grounding and static-dissipative topcoat, resistance tested and documented
- Aisle, walkway and hazard striping installed in the coating system and topcoated
- Secondary containment coated continuously across floor, cove and dike wall
- Layout approved with your safety manager before installation
- W-9, certificate of insurance and safety documentation provided on request
Answers
Frequently asked questions
Still stuck? Call (817) 381-6173 and talk to someone who does this every day.
What is the best floor coating for a warehouse in Dallas?
For most Dallas warehouse floors, densify and polish or a mid-build epoxy is the right answer. Densifying stops concrete dusting under forklift traffic, costs $1.50 to $6 per square foot, has no film to delaminate, and returns to service fastest. Epoxy at $5 to $12 per square foot suits floors needing chemical resistance.
Semi-rigid joint fill under lift traffic matters more than the coating choice on a racked floor.
Why does a food plant floor need urethane cement instead of epoxy?
Urethane cement expands and contracts at nearly the same rate as concrete, so it survives steam cleaning and boiling water washdown that would shear an epoxy floor off the slab. It also installs over slabs with higher moisture content than epoxy tolerates, and it is laid with an integral cove base.
An epoxy floor in a hot washdown area will delaminate. It is a question of when, not whether.
How long will my DFW warehouse or plant be down for a floor coating?
Most industrial coating work in DFW is phased so the building never fully shuts down. A section is walled off, prepped, coated and handed back before the next opens. Where a full shutdown is required, expect 24 to 72 hours of cure before equipment traffic on a standard epoxy system, and considerably less with a polyaspartic topcoat.
We work nights and weekends as standard, and every quote states return-to-service hours.
Can you coat a floor while our Fort Worth plant is running?
Yes. We wall work areas off in plastic, run negative air where required, and use vacuum recovery on all shot blasting and grinding so dust stays contained. Work is scheduled on nights, weekends or phased sections around your production plan, and we coordinate access, lockout and site rules with your EHS group first.
Most of our Dallas and Fort Worth industrial work happens in occupied, operating buildings.
Do you provide a W-9, certificate of insurance and safety documentation?
Yes, and we send them the same day you ask. That packet includes a completed W-9, a certificate of insurance naming your entity as additional insured with the endorsement when your contract requires it, proof of general liability, auto and workers compensation coverage, safety data sheets for every product entering your building, and a site-specific safety plan.
We are licensed, bonded, insured and BBB A+ rated, working in DFW since 2001.
What is ESD flooring and does my facility need it?
ESD or static-dissipative flooring gives static electricity a controlled path to ground, through a conductive grid tied to building ground and a topcoat that holds surface resistance in a target range. You need it in electronics assembly, data and server rooms, cleanrooms, ordnance handling and areas with combustible dust.
Typical targets run between 10 to the sixth and 10 to the ninth ohms. Your required range comes from your own standard, so tell us the number.
How much do industrial concrete coatings cost per square foot in DFW?
Industrial floor systems in DFW generally run $5 to $12 per square foot for epoxy and polyaspartic buildups, and $1.50 to $6 for densify and seal or polish. Urethane cement, novolac epoxy and ESD systems are quoted by specification because the material cost varies with thickness and chemistry.
Surface preparation is often the largest single line item, and off-hours scheduling carries a premium worth paying against lost production.
Can you stripe aisles and safety markings as part of the coating job?
Yes, and it costs far less done with the floor than added afterward. We lay striping into the coating system and topcoat over it, so it does not peel like tape or wear off like traffic paint. That covers aisles, pedestrian walkways, forklift lanes, equipment footprints, exit paths, panel clearances and dock positions.
Layout is approved with your safety manager before any line goes down.
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Learn moreReady to get industrial coatings handled?
Call (817) 381-6173 or send the form. We answer quote requests the same business day, and we have been doing this across DFW since 2001.