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Authorized CIPY Epoxy Applicator | Pidilite Industries

Warehouse Epoxy Flooring
Forklift-Ready. Dust-Free. CIPY Certified.

CIPY-certified forklift-resistant, dust-free, safety-marked warehouse floors by Pidilite Authorized Applicator • Free Site Survey Available

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Why Warehouses Need Epoxy Flooring

The Critical Role of Flooring in Modern Warehouse & Logistics Operations

India's warehousing and logistics sector is experiencing unprecedented growth, driven by the expansion of e-commerce, the shift to organised retail, the formalisation of supply chains under GST, and massive infrastructure investment in logistics parks and distribution hubs. The floor of a modern warehouse is no longer an afterthought — it is a critical operational asset that directly influences productivity, safety, maintenance costs, and regulatory compliance.

Consider the mechanical demands placed on a typical distribution warehouse floor: counterbalance forklifts and reach trucks operating continuously across multi-shift operations, carrying loads of 3–8 tonnes per trip, executing tight turns in narrow aisles that generate extreme lateral tyre scuffing forces. Reach truck operations in narrow-aisle configurations impose even higher point loads and wear stresses on the floor. Loaded pallet trucks, powered rollers, dock levellers, and loading bay ramps all contribute additional stress cycles to the concrete substrate and its coating system.

The consequences of floor failure in a warehouse are immediate and costly. Cracking and spalling create tripping hazards for pedestrians and destabilise forklift operations. Dust generation from deteriorating concrete contaminates stored goods — a particular problem for FMCG, pharmaceutical, and food warehouses. Faded or damaged safety line marking creates confusion and safety hazards in busy traffic environments. Floor irregularities cause forklift stability issues that increase accident risk. In pallet racking configurations, uneven floors can create rack misalignment that compromises structural integrity and load-bearing capacity.

Beyond mechanical demands, modern warehouse floors must also support operational efficiency. Automated guided vehicles (AGVs) increasingly used in e-commerce and 3PL operations require highly flat, smooth floor surfaces that bare or deteriorating concrete cannot provide. Inventory accuracy in RFID and barcode-tracked facilities is improved by clean floor surfaces that don't scatter or contaminate products during floor-level storage. Fire safety systems — including sprinkler drains and containment channels — need to be integrated into floor systems in compliance with warehouse fire safety regulations.

CIPY warehouse epoxy flooring systems from Pidilite Industries, installed by Sri Sai Technologies as an Authorized Applicator, address all these challenges within a single, integrated floor system. Our CIPY warehouse floors eliminate dust, withstand the most demanding forklift traffic, carry comprehensive safety marking systems, and maintain flatness tolerances required for modern automated material handling — all backed by Pidilite's manufacturer warranty and Sri Sai Technologies' 15+ year track record of successful warehouse project delivery across India.

CIPY Warehouse Flooring Systems

Floor Systems We Install for Warehouses & Logistics Facilities

■ High-Build Epoxy Coating (2–3mm)

Best for: Standard warehouses with counterbalance and reach truck traffic, FMCG storage, general distribution centers.

CIPY high-build epoxy provides an excellent balance of durability, dust control, and cost-effectiveness for the majority of warehouse applications. The 2–3mm system handles standard forklift loads, eliminates concrete dust, provides excellent chemical resistance to pallet truck oils, and integrates comprehensive safety line marking.

■ Epoxy Mortar System (4–6mm)

Best for: Heavy logistics hubs, port-side warehouses, heavy engineering stores, facilities with 8–10 ton forklifts or frequent loaded container handling.

CIPY epoxy mortar provides maximum load-bearing capacity for the most demanding logistics environments. The aggregate-reinforced system handles the concentrated point loads from very heavy forklift operations and provides exceptional impact resistance for pallet drop zones and loading bay areas.

■ Dustproof Epoxy Sealer

Best for: Budget-constrained refurbishment of light-traffic warehouse areas, dry goods storage with pedestrian access only, mezzanine floors.

CIPY epoxy sealer provides effective dust elimination and light chemical resistance at a lower cost than full coating systems. Ideal for non-traffic storage areas, mezzanine floors, and budget-priority refurbishment projects where the operational demands are light.

■ Anti-Slip Epoxy System

Best for: Dock leveller areas, loading bays, outdoor-connected zones, refrigerated warehouses with condensation risk, washdown areas.

CIPY anti-slip systems incorporate graded aggregate into the topcoat for controlled slip resistance (Pendulum Test Value >40 in wet conditions). Critical for loading bay areas where water ingress from trucks is common, and for refrigerated warehouses where condensation creates slip risk.

■ Integrated Line Marking System

Best for: All warehouses requiring safety compliance, traffic management, aisle identification, and hazard zone delineation.

Comprehensive safety line marking applied as an integral coloured CIPY epoxy feature — not paint applied over a base coat. Colour-coded systems for pedestrian walkways, forklift lanes, hazard zones, fire equipment, emergency routes, and racking foot positions. Substantially more durable than conventional floor paint marking.

■ CIPY PU Flooring for Cold Storage

Best for: Cold storage warehouses, controlled atmosphere stores, refrigerated dispatch areas with temperature cycling.

CIPY polyurethane flooring systems offer superior flexibility and thermal shock resistance for cold storage environments. PU systems maintain performance from -20°C through ambient temperatures without debonding or cracking from thermal cycling — a performance limitation of standard epoxy in cold store applications.

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Key Benefits

Benefits of CIPY Warehouse Epoxy Flooring by Sri Sai Technologies

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Zero Concrete Dust

CIPY epoxy seals concrete completely, eliminating dust generation that contaminates stored goods, reduces air quality, and creates product liability risks in food, pharma, and FMCG warehouses.

✔
Heavy Forklift Resistance

CIPY systems handle standard counterbalance and reach trucks to very heavy logistics vehicles — protecting the floor and the underlying slab from progressive damage.

✔
Comprehensive Safety Marking

Durable coloured epoxy line marking for all safety zones — significantly more durable than paint and compliant with Factories Act and IS safety marking requirements.

✔
Easy Maintenance

Smooth, non-porous CIPY surfaces are ideal for auto-scrubber cleaning — reducing cleaning time by up to 40% compared to bare or poorly sealed concrete.

✔
Light Reflection

High-gloss or satin CIPY epoxy surfaces improve ambient light reflection, reducing lighting energy consumption — measurable savings in large warehouse facilities.

✔
Chemical & Oil Resistance

Resists hydraulic oils, forklift battery acid, fuel spills, and cleaning chemicals — protecting the slab from contamination and maintaining safe, clean warehouse surfaces.

✔
Supports AGV Operations

CIPY self-levelling systems provide the floor flatness tolerances (FM2 equivalent) required for Automated Guided Vehicles increasingly deployed in e-commerce and 3PL warehouses.

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Phased Installation — No Shutdown

Our phased installation approach keeps your warehouse operational throughout the project. We work in racking bay sections, completing and opening each before starting the next.

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Long Service Life 10–20 Years

Properly maintained CIPY warehouse floors deliver decade-long service life — dramatically superior to paint or basic sealers that need replacement every 2–4 years.

✔
Pidilite Manufacturer Warranty

Applied by Sri Sai Technologies as an Authorized CIPY Applicator, your warehouse floor is backed by Pidilite's product warranty — comprehensive protection on India's most specified flooring brand.

Safety Line Marking

Comprehensive Warehouse Safety Marking Systems

Safety line marking is not an optional add-on — it is a legal requirement under India's Factories Act and a critical component of effective warehouse traffic management. Sri Sai Technologies applies all safety marking as integral coloured CIPY epoxy features, not paint, for maximum durability.

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Yellow — Pedestrian Walkways

100–150mm yellow CIPY epoxy lines delineate safe pedestrian routes through warehouse aisles, separating foot traffic from forklift operating zones. Cross-hatched pedestrian priority zones at aisle intersections.

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White — Forklift Lanes & Aisles

White aisle boundary lines define forklift operating zones, turning circles, and travel lanes. Width markings ensure compliance with minimum aisle width requirements for the specific forklift type operating.

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Red — Fire Safety Equipment

Red hatching marks fire extinguisher positions, hose reel stations, and fire hydrant access zones. Ensures fire fighting equipment can always be located quickly and access is maintained clear.

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Black & Yellow — Hazard Zones

Black and yellow striped hazard marking for loading dock edges, overhead obstruction zones, machinery swing radii, and any area requiring heightened operator attention.

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Green — Emergency Exits & First Aid

Green marking for emergency exit routes, assembly point approach paths, first aid station positions, and eye wash / safety shower locations. Compliant with IS 9457 safety colour coding requirements.

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Grey / White — Racking Positions

Racking leg position markers and bay identification markers ensure accurate rack installation and ongoing rack alignment verification. Pallet storage bay boundaries in floor-level bulk storage areas.

Technical Specifications

CIPY Warehouse Epoxy Flooring — Technical Data

ParameterCIPY Dustproof SealerCIPY High-Build Epoxy (2–3mm)CIPY Epoxy Mortar (4–6mm)
System Thickness0.1 – 0.3 mm2 – 3 mm4 – 6 mm
Compressive Strength≥ 35 N/mm²≥ 60 N/mm²≥ 70 N/mm²
Pull-off Adhesion≥ 1.0 N/mm²≥ 1.8 N/mm²≥ 2.0 N/mm²
Maximum Forklift LoadPedestrian / pallet trucks3–5 ton counterbalance8–10+ ton heavy forklifts
Abrasion ResistanceModerateGood (≤60 mg CS10)Excellent (≤40 mg CS10)
Chemical ResistanceMild oil/water resistanceOils, mild acids/alkalisOils, acids, mild solvents
Anti-Slip (with aggregate)Not applicablePTV ≥ 40 (wet)PTV ≥ 40 (wet)
Temperature Range0°C to +40°C-10°C to +55°C-10°C to +60°C
Full Forklift Service2–3 days5–7 days7 days
Expected Service Life3–5 years10–15 years15–20 years
Warehouse Types We Floor

CIPY Epoxy Flooring Solutions for Every Warehouse Type

🏠

3PL / Distribution Centers

Multi-client third-party logistics facilities with mixed goods handling. CIPY high-build epoxy with comprehensive safety marking, anti-slip dock areas, and zoned floor treatments for different storage/handling areas.

❄

Cold Storage Warehouses

Temperature-controlled facilities from +4°C to -25°C. CIPY polyurethane flooring for thermal flexibility, anti-slip systems for condensation-prone areas, and specialist primers for cold substrate application.

📱

E-Commerce Fulfillment

High-velocity picking and packing operations with AGV integration. CIPY self-levelling epoxy for exceptional floor flatness, comprehensive aisle marking, and clean surface maintenance to support automated systems.

🛍

FMCG Warehouses

Fast-moving consumer goods with hygiene requirements. CIPY dust-free epoxy systems for clean storage, seamless surfaces that support hygiene audits, and anti-slip dock areas for year-round safety.

🏭

Manufacturing Stores & Bonded Warehouses

In-plant stores and bonded warehouse facilities with controlled access, specific storage zone requirements, and often concurrent factory-floor connections requiring seamless floor system integration.

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Import/Export Cargo Facilities

High-traffic port-side and ICD warehouse facilities with very heavy forklift operations, container handling equipment, and 24/7 operations. CIPY heavy-duty mortar systems with maximum durability specification.

Application Process

How Sri Sai Technologies Installs Warehouse Epoxy Floors

01

Warehouse Floor Survey

Comprehensive pre-project assessment of the warehouse floor — concrete strength testing, surface profile measurement, moisture content verification, contamination identification, crack mapping, and floor flatness measurement (FF/FL numbers or TR34 equivalent). We also review the racking layout, traffic patterns, and dock configurations to optimise the CIPY system specification and installation phasing plan.

02

Phasing Plan & Racking Coordination

For occupied warehouses, we develop a detailed phasing plan that works around racking bays and operational zones. This typically involves clearing one racking bay at a time, completing the full installation cycle (preparation through topcoat), and opening it to traffic before moving to the next bay. We coordinate with warehouse management and racking contractors to minimize disruption.

03

Mechanical Surface Preparation

Large warehouse floors are most efficiently prepared using ride-on shot blasting equipment, which rapidly achieves the required surface profile (CSP 3–4) while removing laitance and surface contamination. Diamond grinding addresses areas adjacent to walls, columns, and dock equipment. Oil-contaminated areas receive chemical degreasing treatment before mechanical preparation begins.

04

Crack & Joint Treatment

All cracks are mapped, categorised (active vs dormant, structural vs non-structural), and treated appropriately. Structural cracks receive chase-and-fill treatment with CIPY repair mortar. Non-structural surface cracks are filled. Working joints are honoured through the system with CIPY flexible epoxy joint sealant. High spots are ground to flatness tolerance.

05

CIPY Primer Application

CIPY epoxy primer at specified coverage rate is applied by roller, penetrating the prepared concrete for maximum mechanical bond. Primer selection accounts for substrate moisture level — dry substrate primers vs. DPU (damp-substrate primer) formulations for warehouses with residual construction moisture or water table influence.

06

Build Coat Application

CIPY high-build epoxy or mortar applied to specified thickness using notched squeegee (high-build) or trowel/screed (mortar). For self-levelling specifications, material is poured and spread, then spike-rolled for bubble release and level distribution. Wet film thickness checked throughout application. Anti-slip aggregate broadcast during wet phase in dock and loading bay areas.

07

CIPY Topcoat & Line Marking

Final CIPY topcoat applied in the specified base colour. Safety line marking applied using masking tape and contrasting CIPY epoxy colours — pedestrian walkways, forklift lanes, hazard zones, fire equipment positions, emergency exits, and racking positions as per approved safety marking layout plan. QC inspection, adhesion testing, and handover documentation.

Project Case Studies

Warehouse Epoxy Flooring Projects by Sri Sai Technologies

3PL Distribution Center

Major 3PL Operator — 120,000 sq.ft. Distribution Center, Bhiwandi, Maharashtra

Challenge: New-build distribution centre with 6-ton reach trucks, narrow-aisle operation, AGV integration in picking zone, and strict handover deadline for a major FMCG client contract start date.

Solution: CIPY self-levelling epoxy (3mm) throughout for AGV-compatible floor flatness, with CIPY heavy-duty mortar (5mm) in dock and loading bay areas. Comprehensive safety marking system with 8 zone colour types. CIPY anti-slip system in all dock area connections. Project managed across three concurrent work fronts.

Outcome: 120,000 sq.ft. completed in 14 working days, handed over on schedule. AGV flatness testing (TR34 FM2 equivalent) passed first time. FMCG client contract commenced on planned date. Zero safety incidents during installation. Client has since awarded two further distribution centre floors to Sri Sai Technologies.

Cold Storage Warehouse

Cold Chain Logistics Provider — 40,000 sq.ft. Cold Store, Chennai, Tamil Nadu

Challenge: -18°C cold store facility requiring a floor system that would maintain adhesion and performance through daily thermal cycling, resist the condensation that forms on warmer access routes, and provide anti-slip safety for workers in cold protective clothing.

Solution: CIPY polyurethane (PU) flooring system throughout with cold-rated primer for application at +8°C substrate temperature. High-aggregate anti-slip PU topcoat in pedestrian and dock transition zones. CIPY waterproof membrane system to access ramp for water ingress control.

Outcome: Project completed as planned. Floor has now undergone 3+ years of -18°C cold storage operation with daily loading/unloading cycles. Zero adhesion failures or cracking incidents. Client slip-and-fall incident rate dropped significantly post-installation due to anti-slip surface.

E-Commerce Fulfillment

Leading E-Commerce Platform — Fulfillment Center, Hyderabad, Telangana

Challenge: 200,000 sq.ft. e-commerce fulfilment centre with 24/7 operations, conveyor system integration, AGV deployment, and extremely tight installation windows due to peak season operational constraints.

Solution: CIPY high-build epoxy (2mm) in general storage zones, CIPY self-levelling epoxy (3mm) in AGV and conveyor areas for flatness tolerance, and CIPY mortar (5mm) in inbound and outbound dock zones. Night-shift and weekend installation programme to avoid operational disruption. Eight installation teams deployed simultaneously.

Outcome: 200,000 sq.ft. completed in 22 working days without disrupting operations. All safety marking and conveyor integration features completed to client specification. AGV system commissioned successfully on CIPY floor without flatness adjustment. Project cited as a benchmark by the client's pan-India facility management team.

Maintenance Guide

Maintaining Your CIPY Warehouse Epoxy Floor for Maximum Life

📅 Daily

  • Mechanized sweeping to remove grit (acts as abrasive under forklift tyres)
  • Mop up oil, fuel, and chemical spills immediately
  • Check dock area anti-slip surfaces for debris accumulation
  • Inspect high-traffic forklift turning zones for surface wear

📅 Weekly

  • Auto-scrubber cleaning with pH-neutral industrial floor cleaner
  • Check and clear floor drainage channels
  • Inspect safety line marking for visibility and legibility
  • Report any crack development or surface delamination for prompt repair

📅 Annual

  • Professional floor inspection including adhesion pull-off testing
  • Forklift aisle topcoat recoating when wear depth reaches build coat
  • Safety line marking refresh — more frequent for very high-traffic lanes
  • Dock edge anti-slip zone inspection and recoating if required

Cost-saving tip: Targeted topcoat recoating of forklift turning zones (typically the highest-wear areas) every 5–8 years extends overall floor life to 20+ years at a fraction of full replacement cost. Our maintenance inspection service identifies the right time to recoat — before wear penetrates to the build coat.

FAQ

Frequently Asked Questions — Warehouse Epoxy Flooring

For most warehouses, CIPY high-build epoxy (2–3mm) is the optimal balance of performance and cost. Very heavy forklift operations (>5 ton) benefit from CIPY epoxy mortar (4–6mm). E-commerce and AGV facilities require CIPY self-levelling epoxy for flatness. Cold stores need CIPY PU systems. Sri Sai Technologies assesses your specific operations and recommends the right CIPY system for each zone.

Yes, through phased installation. We work bay-by-bay, completing and curing one racking bay section before moving to the next. This keeps the majority of your warehouse operational throughout the installation programme. Our project managers have extensive experience coordinating with warehouse operations teams for zero-disruption installation programmes.

We apply comprehensive safety marking as part of every warehouse installation: pedestrian walkways (yellow), forklift lanes (white), hazard zones (black/yellow stripes), fire equipment positions (red), emergency exits (green), and racking/storage bay positions. All marking is applied as integral coloured CIPY epoxy — significantly more durable than conventional paint marking.

Yes. CIPY self-levelling epoxy systems installed to TR34 FM2 (or equivalent) floor flatness tolerance provide the surface quality required for AGV navigation in e-commerce and 3PL facilities. AGV manufacturers typically specify minimum floor flatness requirements — our team works to your specific AGV system requirements during the CIPY system design phase.

With CIPY standard systems, foot traffic is possible after 24 hours. Pallet truck traffic is typically allowed after 48–72 hours. Counterbalance forklift operations resume after 5–7 days of full cure. For CIPY epoxy mortar systems, full heavy traffic service is after 7 days. We provide a formal floor opening certificate confirming when each zone is ready for service.

CIPY warehouse epoxy flooring by Sri Sai Technologies ranges from ₹80–₹130/sq.ft. for dustproof sealers, ₹120–₹180/sq.ft. for standard 2–3mm high-build epoxy, and ₹180–₹280/sq.ft. for heavy-duty mortar systems. Large warehouse projects benefit from economies of scale. Contact us for a free site survey and area-specific quotation.

Yes, with appropriate system selection. CIPY polyurethane (PU) flooring systems are the preferred specification for cold stores operating at temperatures down to -25°C. PU systems provide superior thermal flexibility and resistance to debonding from thermal cycling that can affect standard epoxy in cold store environments. Our team specifies the correct CIPY system for your temperature range.

Crack assessment, mapping, and repair is a standard part of every Sri Sai Technologies installation. Minor cracks are filled with CIPY repair mortar. Structural cracks are routed and filled. Severely spalled areas are rebuilt with CIPY repair mortar to restore substrate integrity before the main coating system is applied. We address existing damage comprehensively — it is always more cost-effective to repair properly before coating than to coat over defects and face premature failure.

Get a Free Warehouse Floor Survey & CIPY Flooring Quote

Tell us about your warehouse flooring project. Our team will assess your facility, traffic loads, and operational requirements — and recommend the optimal CIPY system with a transparent, detailed quotation.

Request Free Warehouse Floor Survey

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