CIPY-Certified forklift-resistant, chemical-proof, seamless factory floors by Pidilite Authorized Applicator • 500+ Projects Delivered
Manufacturing plants and factories present some of the most demanding flooring challenges in the built environment. Unlike commercial or office spaces, a factory floor must simultaneously endure extreme mechanical stress, chemical exposure, temperature variation, high-frequency traffic from heavy equipment, and — critically — must do all this while supporting hygiene requirements, safety standards, and operational continuity. For India's rapidly expanding manufacturing sector, the right factory floor is not a cosmetic choice; it is an operational and financial imperative.
Consider the daily reality of a typical Indian manufacturing plant floor: loaded forklifts carrying 3–10 tonnes pass dozens of times per hour, their solid rubber wheels generating concentrated point loads and lateral shear stresses that would crack or debond inadequately specified flooring within months. Steel-framed racking systems with leg loads of 2–5 tonnes per support create ongoing point load stress. Pallet trucks and dollies drag and scrape across the surface continuously. Heavy machinery mounts — injection moulding machines, CNC centres, stamping presses — transmit both static and dynamic loads through their footpads.
Simultaneously, the factory floor must resist chemical attack. Engine oils, hydraulic fluids, cutting fluids, cleaning solvents, battery acid, paint thinners, and industrial degreasers are the routine chemical environment of most manufacturing facilities. Ordinary concrete left unprotected will absorb these chemicals, leading to progressive degradation of the substrate, slippery surfaces, and contamination that compromises both safety and product quality standards. In food, pharmaceutical, and electronics manufacturing, chemical contamination of the floor can have regulatory consequences — product recalls, audit failures, and facility shutdowns.
The third major challenge is dust. Bare or lightly sealed concrete floors generate concrete dust continuously — fine silica particulate that infiltrates machinery, contaminates sensitive components and products, creates respiratory health hazards for workers, and violates clean manufacturing standards. A properly sealed CIPY epoxy floor eliminates concrete dust at source, protecting people, processes, and products alike.
Finally, factory floors must support safety. Poor floor condition — cracking, spalling, oil-contaminated surfaces — is a primary cause of workplace accidents in Indian manufacturing. Falls on slippery surfaces, forklift incidents caused by surface irregularities, and tripping hazards from cracked concrete all represent legal, financial, and human costs that effective floor systems prevent. CIPY factory epoxy floors from Sri Sai Technologies address all these challenges simultaneously: mechanical strength, chemical resistance, dust elimination, and safety — in a single, durable, warranty-backed system applied by India's experienced Authorized CIPY Applicator.
Best for: General manufacturing, automotive, heavy engineering, stamping & pressing areas with forklift and heavy machinery traffic.
The 4–6mm CIPY epoxy mortar system is the gold standard for factory flooring. Quartz aggregate incorporation provides exceptional compressive strength (>70 N/mm²) and impact resistance. Handles 10-ton forklifts, loaded pallet transfers, and heavy machinery mounts without deformation or cracking.
Best for: Assembly areas, quality control labs, electronics assembly rooms, cleanroom production spaces, and light-to-medium traffic factory zones.
CIPY self-levelling systems produce an exceptionally flat, smooth surface ideal for precision assembly environments. The 2–3mm system is dust-free, easy to clean, and maintains precise floor flatness tolerances required for AGVs (Automated Guided Vehicles) and robotic assembly systems.
Best for: Electronics manufacturing, PCB assembly, semiconductor handling, SMT production lines, and any area where electrostatic discharge damages components.
CIPY ESD flooring systems incorporate conductive carbon-based or metallic matrices to provide controlled static dissipation meeting IEC 61340 requirements. Copper tape earthing grids are installed beneath the floor system for reliable, permanent static control.
Learn More →Best for: Chemical processing areas, battery rooms, plating lines, acid storage bays, surface treatment facilities, and any area with aggressive chemical exposure.
CIPY novolac epoxy systems provide superior resistance to concentrated acids, alkalis, and solvents that would rapidly degrade standard epoxy. Combined with CIPY-specified cove skirting and drainage channels, these systems create a fully contained, chemically impervious floor zone.
Learn More →Best for: Food processing areas, steam-cleaned production zones, and any factory environment subject to frequent high-temperature cleaning or thermal cycling.
Polyurethane flooring systems by CIPY provide superior thermal shock resistance compared to standard epoxy — maintaining performance through repeated steam cleaning, hot water washdowns, and temperature fluctuations. PU systems are preferred in food and beverage manufacturing areas.
Learn More →Best for: Factories with moderate traffic loads, existing concrete in good condition, budget-conscious refurbishment of light-to-medium-duty production areas.
CIPY high-build epoxy coatings at 1–2mm provide an effective solution for moderately trafficked factory areas. Significantly better than floor paint in durability, chemical resistance, and lifespan — at a lower cost than full mortar systems. Ideal for phased factory floor upgrades.
CIPY mortar systems handle 10+ ton forklifts and loaded pallet transfers without deformation — the highest mechanical demand in factory environments.
Seals and hardens the concrete surface, eliminating silica dust generation — improving air quality, protecting machinery, and meeting clean manufacturing standards.
Resists engine oils, hydraulic fluids, cutting fluids, cleaning solvents, and mild to strong acids/alkalis depending on CIPY system specification.
No joints to trap contamination. Smooth CIPY surfaces are easily cleaned with auto-scrubbers — reducing cleaning time and labor costs significantly.
Walkways, forklift lanes, hazard zones, fire equipment positions, and emergency exits marked in durable CIPY epoxy colours — not paint that wears off quickly.
Anti-slip aggregate can be incorporated into CIPY topcoats for oil-wet or water-wet factory areas, reducing slip-fall accidents and improving safety compliance.
High-gloss or satin CIPY epoxy surfaces reflect ambient light, improving factory illumination levels and reducing lighting energy consumption.
Factory concrete slabs cost ₹500–₹2000+ per sq.ft. to replace. CIPY epoxy flooring protects this investment for decades at a fraction of replacement cost.
Applied by Sri Sai Technologies as an Authorized CIPY Applicator, your factory floor carries Pidilite's manufacturer product warranty — protecting your investment.
CIPY factory floors allow foot traffic within 24 hours and full forklift service within 5–7 days, minimizing production downtime during installation.
| Parameter | CIPY Epoxy Mortar (4–6mm) | CIPY Self-Levelling (2–3mm) | CIPY High-Build (1–2mm) |
|---|---|---|---|
| System Thickness | 4 – 6 mm | 2 – 3 mm | 1 – 2 mm |
| Compressive Strength | ≥ 70 N/mm² | ≥ 60 N/mm² | ≥ 50 N/mm² |
| Pull-off Adhesion | ≥ 2.0 N/mm² | ≥ 1.8 N/mm² | ≥ 1.5 N/mm² |
| Impact Resistance | Excellent (>10 Nm) | Good (>5 Nm) | Moderate (>3 Nm) |
| Forklift Load Capacity | 10+ ton forklifts | 3–5 ton light vehicles | Pallet trucks, pedestrian |
| Chemical Resistance | Oils, solvents, mild acids | Oils, mild acids/alkalis | Oils, mild chemicals |
| Operating Temperature | -10°C to +60°C | -10°C to +55°C | -5°C to +50°C |
| Shore D Hardness | ≥ 85 | ≥ 80 | ≥ 75 |
| Full Traffic Cure Time | 7 days | 5–7 days | 3–5 days |
| Expected Service Life | 15–20 years | 10–15 years | 7–10 years |
Assembly lines, body shops, paint shops, and engine test areas. Heavy-duty CIPY epoxy mortar for drive lanes, self-levelling for precision assembly areas, chemical-resistant for paint preparation and solvent areas.
PCB assembly, SMT lines, semiconductor handling, final test areas. CIPY ESD flooring with copper grid earthing for static-dissipative protection, clean self-levelling systems for clean production areas.
Weaving halls, dyeing & finishing areas, packing and dispatch. CIPY self-levelling for clean production areas, chemical-resistant for dyeing and chemical treatment zones, heavy-duty for loading dock areas.
Reactor bays, drum storage, blending areas, laboratory floors. CIPY novolac epoxy for maximum chemical resistance with containment bunding, acid-resistant cove skirting, and integral drainage channels.
Production halls, packaging, cold stores, CIP rooms. CIPY PU systems for thermal shock resistance, anti-slip for wet processing areas, non-porous for hygienic compliance, and FDA-compatible formulations.
Learn More →API production, formulation areas, sterile filling, QC labs. CIPY self-levelling epoxy for GMP compliance, cove skirtings for seamless wall-floor junctions, ESD in specific areas, chemical-resistant for lab zones.
Learn More →Our technical team conducts on-site assessment of the factory floor — measuring concrete strength (Schmidt hammer/core test), checking surface moisture (MVER), identifying contamination (oil, grease, paint), mapping cracks and damage areas, and measuring existing floor levels for self-levelling specification. This data drives the CIPY system specification.
We work with your production planning team to design an installation sequence that minimizes disruption to factory operations. Phased installation — completing and curing one production zone before moving to the next — is standard practice. Temporary access routes and protective covers for active machinery are planned and documented.
Shot blasting is the preferred preparation method for large factory floors — it efficiently achieves the CSP 4–5 surface profile required for epoxy mortar adhesion while removing surface laitance, contamination, and weak concrete. Diamond grinding addresses localized areas. All oil contamination receives chemical degreasing treatment before mechanical preparation.
All active and dormant cracks are cut, cleaned, and filled with appropriate CIPY repair mortars. Spalled areas and hollow spots are repaired to restore a sound substrate. Machine mounts and anchor holes are addressed. High spots are diamond-ground. This phase is critical to preventing floor system failures in high-stress factory environments.
Factory-grade CIPY epoxy primer is applied at the specified coverage rate, penetrating and sealing the prepared concrete surface. Primer viscosity and formulation are selected based on substrate porosity and moisture content. Full primer cure is achieved before proceeding — critical for adhesion integrity in heavy-traffic environments.
CIPY three-component epoxy mortar is mechanically mixed to specification, applied by trowel or screed, and compacted to the specified thickness (typically 4–6mm for heavy-duty factory zones). Mortar broadcasts of graded quartz aggregate may be applied during the wet phase for additional surface texture and strength. Surface flatness is verified using long-board screeds and laser levels.
CIPY epoxy or PU topcoat is applied in the specified colour(s) with anti-slip aggregate where required. Factory floor line marking — walkways, forklift lanes, no-pedestrian zones, fire equipment positions, emergency routes — is applied as an integral coloured epoxy feature, not as painted-on lines that wear quickly. Final QC inspection, documentation, and client handover.
Challenge: 80,000 sq.ft. stamping and assembly plant floor with severe oil contamination, heavy forklift traffic (5–8 ton capacity), and significant concrete cracking from machinery vibration.
Solution: CIPY epoxy mortar system (6mm) with oil-degreased substrate preparation, crack injection repair, CIPY epoxy primer, mortar build coat, and CIPY PU topcoat with anti-slip aggregate in forklift lanes. Complete factory floor line marking in company colour scheme.
Outcome: Project completed in 18 working days with phased shutdown of only one production zone at a time. Zero production days lost. Floor has performed without maintenance issues for 5 years and counting. Client has since awarded three additional facility floors to Sri Sai Technologies.
Challenge: 25,000 sq.ft. electronics manufacturing facility requiring ESD flooring throughout PCB assembly and SMT areas, with cleanroom-quality self-levelling epoxy for final assembly, and heavy-duty mortar for loading and dispatch zones.
Solution: CIPY ESD flooring system with copper tape earthing grid in assembly areas (measuring <10⁸ Ω body resistance compliance). CIPY self-levelling epoxy (2mm) for final assembly cleanroom. CIPY epoxy mortar (4mm) for logistics and dispatch zones. Complete grounding point installation and IEC 61340 compliance verification.
Outcome: All three floor zones installed concurrently with phased work permits. Complete project in 10 working days. ESD compliance verified by independent testing lab. Client reported immediate reduction in ESD-related component damage incidents.
Challenge: 12,000 sq.ft. chemical production facility with exposure to concentrated sulfuric acid (up to 80%), sodium hydroxide, and various organic solvents. Previous standard epoxy floor had failed within 18 months due to incorrect chemical resistance specification.
Solution: CIPY novolac epoxy system (6mm) with acid-resistant cove skirting to 150mm height, integral floor drainage channels with chemical-resistant CIPY sealant, and secondary containment bunding around reactor bays. CIPY chemical-resistant primer and novolac topcoat system throughout.
Outcome: Floor installed to full specification with zero production delays. Now in its 4th year of service with zero failure incidents despite daily exposure to the full range of specified chemicals. Client has subsequently specified CIPY through Sri Sai Technologies for two additional plant expansions.
Factory-specific CIPY primers with oil-tolerant or DPU (damp-substrate primer) formulations for factory concrete that often carries historic oil contamination. Ensures maximum adhesion even in challenging substrate conditions common to older manufacturing facilities.
Three-component quartz-filled epoxy mortar for the highest mechanical performance. Available in multiple gradations optimized for 4mm, 5mm, or 6mm application. The definitive CIPY product for heavy industrial factory flooring in India.
Wearing surface in CIPY standard epoxy or polyurethane formulation, with anti-slip aggregate for high-traction zones. Available in multiple RAL colours for zone identification and line marking systems. PU topcoat recommended for areas with UV exposure or steam cleaning.
Maximum chemical resistance formulation for factory areas with aggressive acid or alkali exposure. Uses novolac resin chemistry for resistance beyond the capability of standard epoxy. The CIPY choice for chemical plant floors, battery rooms, and plating lines.
For most manufacturing factories with forklift traffic, CIPY epoxy mortar systems (4–6mm) are the recommended specification. For lighter assembly areas, CIPY self-levelling epoxy (2–3mm) is appropriate. Electronics factories require CIPY ESD systems. Chemical factories need CIPY novolac epoxy. Sri Sai Technologies specifies the right CIPY system for each zone of your factory based on detailed operational assessment.
Yes. CIPY epoxy mortar systems achieve compressive strengths exceeding 70 N/mm², which comfortably handles forklifts up to 10+ ton capacity. The mortar system distributes point loads across a wider concrete area, protecting both the coating and the underlying slab. We have successfully floored facilities with 8–10 ton forklifts operating daily on CIPY systems for 10+ years.
A 10,000 sq.ft. factory floor installation using CIPY epoxy mortar typically takes 7–12 working days including all stages from substrate preparation to final topcoat and line marking. We offer phased installation to maintain production continuity — completing and opening individual zones sequentially rather than shutting down the entire factory.
In most cases, yes — through phased installation planning. We divide the factory floor into sections, complete each section's full installation and cure cycle, then move to the next while operations resume in completed areas. This requires careful coordination with your production planning team, which our project managers are experienced in managing.
Yes. CIPY epoxy flooring systems are specified and successfully used in food processing and pharmaceutical manufacturing facilities across India. For food contact areas, appropriate CIPY systems with food-safe or FDA-compatible formulations are specified. For pharmaceutical facilities, GMP-compliant self-levelling systems with seamless cove skirtings are standard. See our dedicated pharma and food flooring pages for details.
Oil contamination is one of the most common challenges in factory floor refurbishment. Our team uses a combination of chemical degreasing agents applied and thoroughly cleaned before mechanical preparation, followed by shot blasting to physically remove contaminated concrete surface. CIPY oil-tolerant primer formulations provide additional adhesion security over historically contaminated concrete. Our 15+ years of factory refurbishment experience means we have well-developed protocols for this challenge.
CIPY factory epoxy flooring costs range from approximately ₹100–₹180/sq.ft. for standard 2–3mm systems to ₹180–₹300/sq.ft. for heavy-duty 4–6mm mortar systems. Chemical-resistant or ESD systems range ₹200–₹400/sq.ft. The actual cost depends on area, substrate condition, system specification, and location. Contact us for a free site survey and detailed quotation.
Yes. Factory floor line marking — pedestrian walkways, forklift lanes, no-entry zones, loading bay delineation, fire equipment positions, first aid points, emergency exit routes, and racking foot positions — is applied as an integral part of our CIPY topcoat installation using durable coloured epoxy systems. Epoxy line marking substantially outlasts conventional floor paint marking.
Tell us about your factory flooring project. Our technical team will visit your site, assess substrate conditions and operational demands, and recommend the optimal CIPY system — with a detailed quotation.